Casualties unknown

Engine Seizure During Takeoff Climb Following Mismatched Cylinder Installation (N2366W)

Schaumburg, IL, US

On April 5, 1991, a Piper PA-28-161 (registration N2366W) operated by Northwest Flyers Inc was involved in an aviation accident near Schaumburg, IL. Investigators recorded the probable cause as: THE MECHANIC'S NOT UNDERSTANDING THE IDENTIFYING MARKS ON THE REPLACEMENT PART. A FACTOR IN THE ACCIDENT WAS THAT THE MECHANIC WAS PROVIDED WITH AN IMPROPER PART. This summary draws on records from the U.S. National Transportation Safety Board (NTSB) historical archive; 4 related events involving the same aircraft type or operator are linked below.

Sourcesthe U.S. National Transportation Safety Board (NTSB) historical archivePrimary reportUpdated 2026-07-04Data APIEditorial standards

An airplane's engine seized at 70 feet during takeoff climb, forcing a landing. Investigation revealed a recently replaced cylinder was chrome-plated to standard bore, while the other three cylinders and all pistons were 0.010 oversize. The mechanic was unaware of color mark significance and did not measure part compatibility.

Incident Overview

During the takeoff climb, at approximately 70 feet above ground level, the airplane's engine seized. The pilot subsequently conducted a forced landing. No further details on the outcome or injuries are available in the source material.

Engine Maintenance History

The engine had recently undergone maintenance involving the replacement of the number 1 cylinder. No other components were replaced during this maintenance action. The replacement cylinder bore paint marks indicating it had been chrome plated to standard bore dimensions. In contrast, the three remaining cylinders and all pistons were marked as 0.010 oversize.

Maintenance Procedure

The operator's director of maintenance obtained the replacement cylinder and provided it to the mechanic. The mechanic later stated that he was unaware of the significance of the color marks on the cylinders. Additionally, the mechanic did not measure the matching parts (cylinders and pistons) during the replacement process to ensure compatibility.

Findings

The mismatch between the standard bore replacement cylinder and the oversize remaining cylinders and pistons likely led to improper fit. The mechanic's lack of knowledge regarding cylinder identification markings and failure to verify part compatibility contributed to the improper installation. The engine seizure occurred during the subsequent takeoff climb.

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Frequently asked questions

What happened in the 5 Apr 1991 Piper PA-28-161 accident near Schaumburg, IL?

An airplane's engine seized at 70 feet during takeoff climb, forcing a landing. Investigation revealed a recently replaced cylinder was chrome-plated to standard bore, while the other three cylinders and all pistons were 0.010 oversize. The mechanic was unaware of color mark significance and did not measure part…

What aircraft was involved and where did it happen?

The accident on 5 Apr 1991 involved a Piper PA-28-161, registration N2366W, operated by Northwest Flyers Inc, at Schaumburg, IL.

What was the probable cause of the accident?

THE MECHANIC'S NOT UNDERSTANDING THE IDENTIFYING MARKS ON THE REPLACEMENT PART. A FACTOR IN THE ACCIDENT WAS THAT THE MECHANIC WAS PROVIDED WITH AN IMPROPER PART.

Investigation report by the U.S. National Transportation Safety Board (NTSB) historical archive. Original record: https://carol.ntsb.gov/event/20001212X16753. This page is a structured re-presentation; facts and quotes are in the National Transportation Safety Board (NTSB), United States.