What happened
During the initial climb phase following takeoff, the pilot detected the smell of smoke inside the cockpit. In an attempt to return to the departure airport, the aircraft experienced a complete loss of engine power. The pilot performed an emergency forced landing in a field located near the airfield, where the aircraft type struck a metal pipe and a fence during the impact. Following the landing, all occupants were able to exit the aircraft safely. Shortly after the occupants egressed, a fire was observed originating from beneath the engine cowling.
Post-accident inspections identified fire damage affecting the roof, the forward section of the baggage compartment, and the engine accessory area situated between the aft air baffles and the firewall.
Findings
Investigation into the engine failure revealed that an engine exhaust crossover pipe assembly was improperly aligned at the slip joint. Although a manufacturer service bulletin had previously mandated inspections of exhaust joints, and a maintenance event occurred only 7.5 flight hours prior to the accident, the installation was flawed. The mechanic responsible for the recent maintenance failed to follow the prescribed reinstallation procedures for the crossover pipes. Furthermore, the inspector failed to monitor the installation process, instead performing a final check only after the components were obscured by protective heat shields.
This misaligned exhaust crossover pipe allowed hot gases to escape into the engine compartment. The escaping heat ignited a fire that damaged essential fuel and oil lines, ultimately causing the engine to lose all power.