What happened
On 22 November 2020, a Beechcraft Bonanza F35, registration N5045B, was conducting a multi-sector leisure flight through Malaysia. After successfully completing initial legs between Seletar, Malacca, and Senai, the aircraft was cruising at 5,000 feet on its third sector from Senai back to Malacca. During this flight, the pilot heard a loud popping sound accompanied by a physical shudder in the airframe. Immediately following this, the engine suffered a significant loss of power and fuel pressure dropped.
Despite the pilot's attempts to restore power by switching fuel selectors and utilizing the electrical fuel pump—which briefly improved performance before the pump's toggle switch broke—the engine could not maintain sustained operation. The pilot opted to execute an emergency glide landing on the North-South (PLUS) Highway near Sedenak, Johor. The aircraft landed safely on the roadway without striking any structures or causing damage to the aircraft or surrounding property. The pilot and passenger were able to exit the aircraft and assist in directing highway traffic away from the scene until authorities arrived.
The investigation
AAIB Malaysia examined the aircraft's fuel management and mechanical state. The investigation looked into the sequence of fuel tank selections, including the use of the left main, auxiliary, and tip tanks. Investigators also reviewed the pilot's compliance with Malaysian flight permit requirements, noting a discrepancy between the approved flight permit route and the actual flight plan used during the incident.
Findings
- The engine power loss was preceded by a mechanical failure or malfunction within the fuel system, indicated by a popping sound and sudden loss of fuel pressure.
- The pilot's attempt to use the electrical fuel pump was hindered when the pump's toggle switch broke during the emergency.
- There was a discrepancy in regulatory compliance, as the flight permit approved by CAAM did not include the specific route to Senai Airport used by the pilot.
Safety action
- The investigation recommended that CAAM review the air traffic clearance process to ensure personnel verify flight permit approvals against submitted flight plans for foreign aircraft.
- A recommendation was made for the manufacturer, Hawker Beechcraft Corporation, to review the inspection intervals for the fuel sender unit, moving from an 'on condition' basis to a fixed inspection schedule.