No fatalities

Engine Fire Prompts Return and Evacuation After Takeoff (N604US)

Seattle, WA, US

On August 22, 1991, a Boeing 747-151 (registration N604US) operated by Northwest Airlines, Inc was involved in an aviation accident near Seattle, WA. No fatalities were reported. Investigators recorded the probable cause as: A FIRE IN THE NUMBER 4 ENGINE, RESULTING FROM A FUEL LEAK AT THE MAIN FUEL CONTROL UNIT, DUE TO IMPROPER MAINTENANCE BY UNKNOWN/UNDETERMINED PERSON. THE L5 EMERGENCY EXIT FAILED TO OPERATEE DUE TO A BROKEN PLASTIC PULLEY GUARD IN THE SLIDE RELEASE MECHANISM. This summary draws on records from the U.S. National Transportation Safety Board (NTSB) historical archive; 2 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
Aircraft registered N604US
Aircraft registered N604US. Photo: Eduard Marmet / CC BY-SA 3.0, via Wikimedia Commons

During climb after takeoff, the No. 4 engine caught fire. Crew activated fire extinguisher, dumped fuel, and returned for emergency landing. Airport fire crews extinguished engine and grass fire. Evacuation conducted via left side; L5 door and slide failed to deploy. Investigation revealed fuel leak from main fuel control unit.

Incident Description

Shortly after takeoff, while the aircraft was climbing, the No. 4 engine experienced a fire. The flight crew responded by activating the engine fire extinguisher system and initiating fuel dumping procedures. They then returned to the departure airport for an emergency landing.

Emergency Response

Upon landing, the aircraft stopped on the runway. Airport crash fire rescue (CFR) personnel arrived and extinguished both the No. 4 engine fire and a grass fire that had ignited in the runway touchdown zone. The crew then initiated an emergency evacuation, which was conducted from the left side of the aircraft.

Evacuation

During the evacuation, the L5 emergency door and its associated slide failed to deploy, hindering egress from that location. Despite this, the evacuation proceeded from the left side without further reported issues.

Examination

Post-incident examination of the No. 4 engine revealed evidence of a fuel leak originating from the main fuel control unit. The specific cause of the fire was not stated in the source.

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Frequently asked questions

What happened in the 22 Aug 1991 Boeing 747-151 accident near Seattle, WA?

During climb after takeoff, the No. 4 engine caught fire. Crew activated fire extinguisher, dumped fuel, and returned for emergency landing. Airport fire crews extinguished engine and grass fire. Evacuation conducted via left side; L5 door and slide failed to deploy. Investigation revealed fuel leak from main fuel…

Were there any fatalities in the 22 Aug 1991 Boeing 747-151 accident?

No fatalities were recorded in this accident.

What aircraft was involved and where did it happen?

The accident on 22 Aug 1991 involved a Boeing 747-151, registration N604US, operated by Northwest Airlines, Inc, at Seattle, WA.

What was the probable cause of the accident?

A FIRE IN THE NUMBER 4 ENGINE, RESULTING FROM A FUEL LEAK AT THE MAIN FUEL CONTROL UNIT, DUE TO IMPROPER MAINTENANCE BY UNKNOWN/UNDETERMINED PERSON. THE L5 EMERGENCY EXIT FAILED TO OPERATEE DUE TO A BROKEN PLASTIC PULLEY GUARD IN THE SLIDE RELEASE MECHANISM.

Investigation report by the U.S. National Transportation Safety Board (NTSB) historical archive. Original record: https://carol.ntsb.gov/event/20001212X17976. This page is a structured re-presentation; facts and quotes are in the National Transportation Safety Board (NTSB), United States.