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March 25, 2022 · Diamond Aircraft Ind DA 40 NG · N471BL

Smithfield, NC

Overview

Report Status
Final with probable cause
Event Type
Accident
Date
March 25, 2022
Injury Outcomes
2 injuries (2 serious injuries)
Location
Smithfield, NC
Aircraft
Diamond Aircraft Ind DA 40 NG (2020)
Tail Number
N471BL
Operator
Blue Line Aviation
Injuries
Serious
Aircraft Damage
Substantial
NTSB Number
ERA22LA169

According to the flight instructor, shortly after takeoff, she heard a “weird” noise coming from the engine and noted a drop in engine rpm. The flight instructor directed the pilot receiving instruction to turn back toward the airport; however, the engine lost all power, and the airplane impacted trees about 1 mile from the departure end of the runway. The airplane sustained substantial damage to the wings, fuselage, and empennage. A postaccident examination of the engine revealed that the engine valvetrain was not timed correctly and that the misalignment resulted in a piston striking a valve. The valve head had separated and fallen into the cylinder, resulting in the total loss of engine power. Examination of the maintenance logbooks revealed that the cylinder head and exhaust camshaft had been replaced the day before the accident flight. Thus, it is likely that the engine’s timing was not set correctly after this maintenance.

NTSB Probable Cause

Maintenance personnel’s failure to set the correct engine timing after the replacement of a cylinder head and exhaust camshaft before the accident flight, which resulted in a total loss of engine power.

Full Narrative

On March 25, 2022, about 1613 eastern daylight time, a Diamond DA-40NG, N471BL, was substantially damaged when it was involved in an accident near Johnston Regional Airport (JNX), Smithfield, North Carolina. The flight instructor and pilot receiving instruction were seriously injured. The airplane was operated as a Title 14 Code of Federal Regulations Part 91 instructional flight. According to the flight instructor and pilot receiving instruction, they conducted a preflight inspection of the airplane, with no anomalies noted, before departing from runway 21 at JNX. Review of radar data revealed that the airplane climbed to an altitude of about 650 ft while turning left. The flight instructor stated that she “heard a weird noise come from the engine” and saw the rpm gauge drop. Shortly afterward, the flight instructor directed the pilot receiving instruction to turn back to the airport, and the engine lost total power while in the turn. The flight instructor attempted to restart the engine while the airplane descended but was unsuccessful. The airplane subsequently impacted trees about 1 mile from the departure end of the runway, resulting in substantial damage to the fuselage. In addition, both wings and the empennage were fractured from the impact. A postaccident examination of the engine revealed that engine valvetrain was not timed correctly and that the resulting misalignment resulted in the piston striking the valve. The valve head had subsequently separated and fallen into the cylinder. Examination of the maintenance logbooks revealed that the cylinder head and exhaust camshaft had been replaced the day before the accident flight.

Flight

Event TypeAccident
Event Time16:13 EDT
Nearest AirportJohnston Regional Airport (1nm SSE)
Aircraft FireNo
Aircraft ExplosionNo

Aircraft

AircraftDiamond Aircraft Ind DA 40 NG
Tail NumberN471BL
Aircraft CategoryAir
DamageSubstantial
OperatorBlue Line Aviation
Operating RulePart 91
Engines1
Engine TypeReciprocating
Engine DetailsAustro · E4-A · Reciprocating · 165
Seats4

People & Injuries

Injury Summary2 injuries (2 serious injuries)
Fatal0
Serious2
Minor0
Uninjured0
Total2
Crew 1Age 20 · First Class · Serious
Crew 2Age 26 · First Class · Serious

Conditions

ConditionsVMC
LightDaylight
Wind260° @ 8 kt, gusting 18 kt
Visibility10 sm
CeilingBroken clouds 10000 ft
Temperature / Dew Point68 F / 32 F
Altimeter29.70 inHg
Observation Time16:15
Weather SourceWFAC

Appendix: Source Data