N236CH

Part: BLADDER — COLLAPSED (LT EING FUEL) · airframe 28,748 hrs

PERFORMED THE INITIAL POWER REDUCTION, THE AIRCRAFT EXPERIENCED AN UNEXPECTED DECREASE IN ENGINE POWER AND ENGINE ROUGHNESS. PERFORMED THE "ENGINE FAILURE AFTER LIFTOFF" CHECKLIST ITEMS. AT THIS POINT THERE WAS NO IMPROVEMENT IN THE ENGINE PERFORMANCE. DECLARED AN EMERGENCY WITH ATC AND PERFORMED THE "MAXIMUM GLIDE " CHECKLIST ITEMS. CLOSER TO THE AIRPORT, CLEARED TO LAND. WHEN IN A POSITION TO LAND AND SINCE THE ENGINE WAS NOT PRODUCING APPRECIABLE POWER, CLOSED THE MIXTURE AND EXECUTED A POWER-OFF LANDING. CAME TO A STOP ON THE RUNWAY AND REQUESTED TO BE TOWED TO THE FBO. CONTACTED FLIGHT OPERATIONS AND ADVISED THEM OF THE SITUATION. THE MECHANIC ON SITE REMOVED THE AND CHECKED FOR FOULED PLUGS, NO FAULTS NOTED. CHECKED ENGINE COMPRESSIONS, NO FAULTS NOTED. PERFORMED A BORESCOPE OF THE NR 3 & 4 CYLINDERS, NO FAULTS NOTED. CHECKED BELLY AND FINGER SCREEN FOUND SLIGHT DEBRIS ON FINGER SCREEN. PULLED ALL SIX INJECTORS SONICALLY CLEANED AND FLOW CHECKED, FOUND TO BE IN PARAMETERS. RAN AIRCRAFT ENGINE THROUGH ALL RPM'S, CHECKED OPERATION OF BOOST PUMP AND MECHANICAL PUMP, OP'S AND LEAK CHECK SATISFACTORY. DURING THE AIRCRAFT’S NORMAL 100-HOUR INSPECTION, IT WAS DETERMINED THAT THE INBOARD VENT LINE WAS FLUSH WITH THE FUSELAGE AT THE WING FAIRING LOCATION. ADDITIONALLY, THERE WAS A CLOG IN THE VENT SYSTEM AS DETERMINED BY A BACKWARDS AIRFLOW TEST ON THE SYSTEM. AS A RESULT OF THESE ITEMS, THE LEFT WING PROBE PANELS WERE OPENED (FUEL SENDERS WERE REMOVED) AND IT WAS OBSERVED THAT THE FUEL TANK BLADDER WAS PARTIALLY COLLAPSED AS THE AFT OUTBOARD FUEL TANK BUTTON WAS DISLODGED ALLOWING THIS BLADDER MOVEMENT. AFTER SPEAKING WITH TWO OUTSIDE FUEL TANK VENDORS, A CLOGGED FUEL VENT CAN CAUSE THE TANK TO NOT PROPERLY PRESSURIZE RESULTING IN A PARTIAL VACUUM DISRUPTING FUEL FLOW OUT OF THE TANK. IT IS SUSPECTED THAT THESE ITEMS WERE CONTRIBUTORY TO THE ISSUE REPORTED BY THE PILOT AND RESULTED IN THE DECLARATION OF THE EMERGENCY WITH ATC. CLEARED THE CLOGGED FUEL VENT LIN

Part: FRAME SPLICE — CORRODED (FUSELAGE) · airframe 27,872 hrs

CORROSION FOUND ON UPPER FRAME SPLICE BEHIND HAT SHELF,FUSELAGE STATION 179.00. CORROSION FOUND ON 2 UPPER SKINS (LEFT & RIGHT) AFT OF HAT SHELF, FUSELAGE STATION 179.00-207.00.

Part: CIRCUIT BREAKER — FAILED (NAV LIGHT)

AS A RESULT OF AD 2008-13-17, THE NEW CB REPLACEMENTS ARE FAILING AT A REGULAR RATE, COMPARED TO THE ORIGINAL PN SWITCHES. THESE REPLACEMENT SWITCHES ARE OF POOR QUALITY & DO NOT LAST LONG. WE ARE HAVING A HIGH FAILURE RATE.

Part: PRESSURE SENSOR — INTERMITTENT (MANIFOLD)

MANIFOLD PRESURE SENSOR BECAME INTERMITTENT.

Part: WIRE — DISCONNECTED (BRUSH BLOCK)

ALTERNATOR FAILED IN FLIGHT. WIRES TO THE BRUSH BLOCK HAD BECOME DISCONNECTED INSIDE THE ALTERNATOR.

Part: CYLINDER — CRACKED (ENGINE)

CYLINDER HEAD CRACKED IN THE EXHAUST PORT AREA. (K)

Part: CYLINDER — CRACKED (ENGINE)

CYLINDER HEAD CRACKED IN THE EXHAUST PORT AREA. (K)

Part: CYLINDER — CRACKED (ENGINE)

CYLINDER HEAD CRACKED IN THE EXHAUST PORT AREA. (K)

Part: CYLINDER — CRACKED (ENGINE)

FOUND CYLINDER HEAD CRACKED IN THE EXHAUST SIDE OF THE CYLINDER HEAD DURING 50 HR INSPECTION. THIS IS AN ON GOING PROBLEM WITH THE ECI CYLINDERS. (K)

Part: CYLINDER — CRACKED (ENGINE)

FOUND CYLINDER HEAD CRACKED IN THE EXHAUST SIDE OF THE CYLINDER HEAD DURING 50 HR INSPECTION. THIS IS AN ON GOING PROBLEM WITH THE CYLINDERS. (K)

Part: CYLINDER — CRACKED (ENGINE)

CYLINDER HEAD CRACKED IN THE EXHAUST PORT AREA. (K)

Part: CYLINDER HEAD — DEPARTED (CYLINDER)

CYLINDER HEAD DEPARTED CYLINDER BARREL, WHILE AIRCRAFT WAS IN FLIGHT. AIRCRAFT LANDED WITHOUT INCIDENT.

Part: FIELD WIRE — BROKEN (ALTERNATOR)

INSPECTION OF THE AIRCRAFT'S ELECTRICAL SYSTEM FOUND A BROKEN FIELD WIRE AT THE TERMINAL END ATTACHMENT TO THE ALTERNATOR. THIS CAUSED A LOSS OF ELECTRICAL POWER AND DEAD BATTERY. PILOT PUT THE GEAR DOWN, GEAR ONLY WENT DOWN EST. 80 PERCENT, HOWEVER, LANDING WAS ATTEMPTED. THE PILOT TOOK OFF AGAIN WHEN HE HEARD A NOISE OF THE GEAR DOORS CONTACTING THE GROUND. THE A/C TOOK OFF AND RETURNED TO HOME BASE. UPON LANDING AND AT ROLL-OUT, THE RT LANDING GEAR COLLAPSED.