On August 17, 2021, a Diamond Aircraft Industries DA-42, registration N215BN, was involved in an accident near Bellefontaine, Ohio. The aircraft, being operated by Midwest Corporate Air Inc for instructional purposes, was performing a short-field takeoff from runway 7 when the right engine suffered a total loss of power. Shortly thereafter, the left engine experienced a partial loss of power, retaining approximately 30% of its available output. The flight instructor subsequently performed a forced landing into a grass field located near the departure end of the runway. The flight instructor and student pilot were not injured, though the aircraft sustained substantial damage to the landing gear and wing spar.
The investigation
Investigators examined the aircraft's maintenance history and engine data. On the day of the accident, the left and right engine fuel feed pumps (FFP) had been replaced as part of a 600-hour maintenance interval. Engine Control Unit (ECU) data showed numerous canceled engine start messages for both engines prior to the flight. For the right engine, the final recorded messages included low rail pressure alerts.
Post-accident inspection of the engines revealed that the exhaust pipes on both engines failed the testing protocol required by FAA Airworthiness Directive 2018-CE-002, which addresses uncommanded engine shutdowns caused by fractured pipes.
During subsequent maintenance testing, the right engine failed to operate normally until the fuel feed pump bolt was moved to a seated position. Maintenance personnel noted that the position of the right engine's FFP bolt was not changed during installation on the day of the accident. The engine manufacturer stated that if the FFP bolt is not fully seated, air can enter the system or fuel can escape, potentially causing insufficient fuel pressure to the high-pressure pump.