EJ22 engine failure

[b.charlton]

Thought I'd let you guys know I had an engine failure today resulting in a forced landing, no damage to myself or the gyro. The engine has 330 hrs on it and is one of the RAF supplied engines. One of the engine timing chain idlers had overheated and lost its bearings. the other idler was replaced at 100hrs because it was leaking grease, should have replaced both but the other seemed ok. I inspected the timing chain at 300hr inspection and everything seemed ok. If you have an RAF supplied engine I would be seriously considering replacement of these bearings.

[Aussie_Paul]

Glad all worked out without damage.

It would seem that Raf put too much grease in one and not enough in the other idler!!!:eek: We know for a fact that Raf were prizing the seals out and repacking with grease instead of replacing the bearings. There are 3 idlers, two smooth ones and one with belt teeth on it. I had the one with belt teeth on it do the same. I had heard of the rumours of the Raf re greasing but do not take too much notice of rumours.

I was fortunate that the sister engine to the one in the machine I was flying had not been started. I rang the owner of the sister engine and he got a Subaru mechanic to pull it apart and they could see on the idlers where something sharp had been used to prise the seals off to repack grease into the bearings.

I was horrified as was the owner of the sister engine. These two engines were built for two Aussies who knew each other and they had arranged and paid for the two engines to be blue printed.:rolleyes:

I had bought the one that had been roughly assembled in the US. The other guy wanted to build his own. We were not happy campers.

Barry, I plan to be down your way around July, and would love to catch up.

Aussie Paul.:)

[KenSandyEggo]

I had grease all over my idler housing, finally looking at it thanks to Paul's righteous nagging. One flange on a pulley was bent down, as if whacked with a hammer. The tensioner, which should be full of silicone fluid was bone-dry. An engine stoppage waiting to happen. I would have an engine from RAF thoroughly inspected before I went airborne with it. Some have lasted as little as 30 hours before disintegrating. The water pump was also shot on mine and needed replacing. Sometimes "newly overhauled" means bead blasting and a can of silver spray paint.

[Harry_S.]

I don't have my log books with me, but, I think at my 75 hr. maint. I found grease all over the timing belt, bearings, etc.

I believe it cost about $340 for all new bearings and a new timing belt...plus a little somethin' for the mechanic.

No problems since.


Cheers :)

[rgraffeo]

I'm not sure how the idlers are designed. I visually check them every 25hrs.

The bearings for the idlers, do you replace them or do you replace the entire idler? Is the bearing pressed into the idler?

[Aussie_Paul]

I'm not sure how the idlers are designed. I visually check them every 25hrs.

The bearings for the idlers, do you replace them or do you replace the entire idler? Is the bearing pressed into the idler?

I think the only idler that does not have replaceable bearings is the one that the automatic tensioner pushes on.

Aussie Paul.:)

[rgraffeo]

Thanks Paul,
My 25hr inspection is due soon, I'll try to inspect them extra close this time.
Any tips on what to look far or how to do it?

[Canadian Rhino]

Does anyone have any pictures of this and does it apply to the 2.5 engine as well?

[mceagle]

When replacing the idler bearings take a measurement of the position of the centre sleeve in relation to the pulley so that they can be re-assembled the same. They have no "foolproof" stops.

[Aussie_Paul]

Thanks Tim, I did not know that.

Aussie Paul. :)

[b.charlton]

Looks like i'm destined to follow in your footsteps paul, it was the toothed pulley that faied with me also, grease must have leaked out and seized the bearing!

[Aussie_Paul]

Barry, did you get the Raf AD to check pretty well everything under the plastic covers every 25 hours?

Aussie Paul.:)

[Iron]

I have been rebuilding a raf through the help of this forum. I took the timeing belt cover off and found every thing to be spotless, belt looks brand new, and pulleys have no play in them. I removed the redrive sprockets and on the lower one the seal fell out of the bearing (china) the top bearings are japanese. Took a lot of looking to replace these with good bearings, still had to settle for ones from Japan. Roy engine has 37 hours

[Harry_S.]

Bearings from Japan and some Western European countries are among the best available. USE NOTHING FROM CHINA or most Mid-Eastern countries.

I think most US names of bearing mfg's. have outsourced their bearings. The last Fafrin bearing I bought was made in Japan.

I recently replaced the wheel axle bearings, The bearing store informed me that the size bearing I wanted was made only in China. So...I had to use 'em again. They don't hold up long at all.:(


CFWMDF
Cheers :)

[b.charlton]

I have decided after estimating bearing life to repace all the timing belt bearings vey 500hrs! Better than more forced landings!

[Harry_S.]

I have almost made that same decision, Barry.

I will replace 'em with genuine Subaru parts as well.;)


CFWMDF
Cheers :)