What happened
On 7 March 2015, a DA 40 D Diamond Star, registration G-CCHD, was performing a private flight near Shoreham Airport, West Sussex. The pilot was conducting a flight to build experience. During the initial climb, the aircraft appeared to be performing normally. However, as the aircraft reached approximately 1,000 ft, the pilot noticed a reduction in engine noise and a drop in RPM.
While attempting a wide turn to prepare for a potential return to the airfield, the engine lost power completely at an altitude of roughly 1,100 ft. Seeking a safe landing site away from built-up areas and power lines, the pilot selected a field containing sheep. During the landing, the aircraft struck three sheep, which were killed. The aircraft then crossed a boundary fence and struck a tree, causing the nosewheel to collapse and the rear fuselage to partially detach. The pilot, who sustained no injuries, exited the aircraft safely.
The investigation
Investigators examined the engine's FADEC data, which revealed multiple alerts for low fuel rail pressure prior to the failure. A physical inspection of the engine revealed that the No 2 cylinder injector, its support, and the securing screw were all missing. Additionally, the associated fuel pipe unions had loosened, and the copper injector seal was absent.
Records showed that the injector had been serviced on 24 February 2015 to fix a leak. While the maintenance staff were aware of a requirement to perform a specific thread repair after a certain number of injector changes, the engine logbook did not explicitly track the number of times an injector had been disturbed, only the completion of major tasks.
Findings
- The engine failure was caused by a total loss of fuel pressure resulting from a loose fuel injector.
- The loss of the injector, its support, and the securing screw prevented the maintenance of proper fuel pressure.
- The absence of the copper injector seal may have allowed high-temperature gases to escape, potentially compromising the self-locking mechanism of the screw.
- It could not be determined exactly how the components became detached, as the screw and support were not recovered from the site.