What happened
A certificated private pilot and one passenger were conducting a cross-country personal flight under Title 14, CFR Part 91. Shortly after takeoff, while the Cessna (type not specified in source, but engine is IO-540) was approximately 200 feet above the ground, the engine began to run rough and lost power. The pilot attempted emergency procedures, but they failed to restore power. During the subsequent off-airport forced landing, the aircraft collided with a barbed wire fence. The impact resulted in substantial damage to the wings, fuselage, and empennage. There were no fatalities reported.
The investigation
The aircraft was equipped with a recently installed factory-remanufactured Textron Lycoming IO-540 engine. Investigators discovered a grayish, soft, rubbery material partially blocking the ports of the fuel flow divider's metering pin. No debris was found within the interior of the fuel injector servo or the fuel injector's inlet screen. A representative from Textron Lycoming noted that fuel system components on factory-remanufactured engines are shipped separately, and it is the responsibility of the maintenance technician to install these components and ensure no debris enters the fuel line or divider during installation.
Findings
A senior metallurgist for the Safety Board examined the gray foreign material but could not identify its specific source. The material consisted of agglomerations of smaller particles consistent with a Teflon-like substance. The investigation determined that the rubbery material was not consistent with the material used in the fuel supply line, and no other debris was located inside the fuel line or the fuel injector servo. The primary cause of the engine malfunction was foreign material contamination within the fuel flow divider.