Low EGT at idle in one cylinder...
The KitFox Vixen has now found a warm home in my hanger and doesn't want to leave. The aircraft with an early 912UL and 375hrs came to the shop with fuel flooding the float bowls of both carbs pouring out the vent tubes resulting in extreme rough idle/low rpm operation. In the past year, she has had a five year rubber replacement, a re-engineered fuel system because she didn't have a return line. Complete carb overhauls including all the floats, float needles, and associated hardware. A fuel pressure gauge was added. An engine monitoring system was added. I've performed every fuel system test recommended by Rotax and known to man. I am now looking elsewhere. The differential compression check is excellent with a range of 84 - 86 at 87 psi. Borescope inspection showed good crosshatch and good valves in each cylinder. The new fuel pressure gauge reads a steady 4psi. The new engine monitor does give a low EGT indication for #2 cylinder at idle. However, when the throttle is advanced to higher rpm 3800 or better all the EGTs line up. There is something going on in that #2 cylinder at low RPMs. Like I said the compression is good 85 @ 87psi. I have checked both plugs for gap and resistance, they are new by the way, both new spark plug connectors for resistance, and both cables from the coil. Everything is within limits. How do I go further and test the coils, DCDI boxes, and trigger coils/stators, etc.? How about the valve train for the #2 cylinder? Could there be a bent pushrod or weak or leaking lifter or weak valve springs? Could sticking valves in that cylinder cause the rough idle and not be a problem at higher RPMs? This engine doesn't fall in the serial number range of any of the recent service bulletins about these items. Still doesn't mean there can't be a problem there. What else could possibly be causing the low EGT, resulting in the extremely rough running at idle that smooths out at higher RPMs? My frustration level is thru the hanger roof and I have to remind myself that nothing I did during the rubber replacement or other work caused the problem. She came into the shop running like that. HELP...!!!
Jeffrey Fritts, USAF (ret.)
www.flywwlsa.com
"In aircraft maintenance, good enough is not good enough."