7 Common Causes of Engine Failure in Aircrafts and How to Avoid Them

You're flying along when suddenly the engine goes quiet. Your heart races as you scan the instrument panel. This is every pilot's nightmare, but here's something that might surprise you: according to recent data, engine failure happens in only about 0.00004% of flight hours for modern commercial aircraft. 

While airplane engine failures are rare, understanding why they occur can help pilots and aircraft owners keep their planes in top condition. Knowing what causes engines to quit and how to stop these problems before they start can make all the difference between a routine flight and an emergency landing.

Key Takeaways

Airplane engines fail due to seven main causes: fuel problems, contamination, mechanical wear, design flaws, icing conditions, improper maintenance, and human error. Most failures can be prevented through regular inspections, proper pre-flight checks, using clean fuel, following maintenance schedules, and staying alert to warning signs. Multi-engine planes can fly safely on one engine, while single-engine pilots train extensively for emergency landings.

How Often Do Airplane Engines Fail?

The good news is that aviation has become incredibly safe over the years. Modern airplane engine technology works better than ever before. Commercial jets have failure rates so low that most pilots never experience an engine problem during their entire career.

Let's look at some real numbers:

• Turbine engines in commercial jets fail about once every 375,000 flight hours
• General aviation piston engines fail more often—roughly once every 10,000 to 20,000 hours
• Twin-engine planes reduce risk because they can fly safely on just one engine
• Most engine problems happen during takeoff or landing, not while cruising

The type of engine matters a lot. Jet engines are super reliable because they have fewer moving parts. Piston engines in smaller planes need more care and attention. They work harder and have more pieces that can wear out.

Here's what affects how often engines fail:

• Age of the aircraft and engine
• How well the owner maintains the plane
• Where the plane flies (hot, cold, or humid climates)
• How many hours the engine has been running
• Quality of fuel and oil used

The FAA keeps close track of all engine failures. They study every incident to find patterns and make flying safer. This careful watching has helped cut failure rates by more than half over the past 30 years.

Most engine failures don't happen suddenly. Engines usually give warning signs first—unusual sounds, vibrations, or gauge readings. Pilots who pay attention to these clues can often land safely before a real problem starts.

What Happens If an Engine Stops Working?

When an engine quits, the plane doesn't just drop from the sky like a rock. This is probably the biggest myth about flying. Aircraft are designed to glide even without engine power. Pilots train for this situation over and over again.

Here's what actually happens:

For Multi-Engine Aircraft:

• The plane keeps flying on the remaining engine or engines
• The pilot adjusts power and trim to balance the aircraft
• The flight might need to land sooner than planned, but it stays controlled
• Commercial jets can fly hundreds of miles on one engine

For Single-Engine Aircraft:

• The plane becomes a glider and starts descending gradually
• The pilot looks for the best place to land—an airport, field, or road
• Most single-engine planes glide about 1.5 miles for every 1,000 feet of altitude
• Training prepares pilots to handle this calmly and safely

The ignition system shuts down, but the plane's control surfaces still work perfectly. The wings keep producing lift as long as the plane keeps moving forward. Think of it like coasting downhill on a bicycle—you're still rolling even though you stopped pedaling.

Pilots follow specific emergency procedures:

• Check if the engine can be restarted
• Find the best landing spot
• Declare an emergency with air traffic control
• Set up for a controlled landing
• Keep passengers calm and informed

Modern aircraft have backup systems for almost everything. Even if the engine stops, pilots still have instruments, radios, and flight controls. The magneto system in many planes provides spark even without battery power.

The key is that pilots practice engine-out scenarios regularly during training. This practice turns a scary situation into a manageable procedure. It's similar to how fire drills prepare you to exit a building calmly—you know exactly what to do because you've done it before.

Why Do Airplane Engines Fail in the First Place?

Airplane engines are complex machines with hundreds of parts working together. When you understand how engines work, it's easier to see why problems happen. Let's break down the basic reasons engines quit.

Fuel-Related Problems:

Fuel exhaustion means running out of fuel—it sounds simple, but it causes about 40% of all engine failures in general aviation. Pilots need to check fuel tank levels carefully before every flight. Sometimes fuel gauges stick or give wrong readings.

Contamination in fuel lines can clog filters and starve the engine. Water gets into fuel tanks through condensation or bad fuel at the pump. Dirt, rust, or even insect nests in fuel vents can block flow. This is why draining fuel sumps during pre-flight checks matters so much.

Mechanical Wear and Breakage:

Engine parts wear out over time. Pistons slide up and down thousands of times per minute. Valves open and close constantly. Bearings spin at high speeds. Eventually, metal fatigues and breaks.

Critical components that can fail include:

• Crankshafts that transfer power from pistons to the propeller
• Camshafts that control valve timing
• Connecting rods that link pistons to the crankshaft
• Cylinder heads where combustion happens

Regular inspections prove aircraft airworthiness and catch wear before parts break. The FAA requires specific maintenance intervals based on flight hours and calendar time.

Environmental Factors:

Icing conditions affect carbureted engines in particular. When moisture in the air freezes inside the carburetor, it blocks airflow and chokes the engine. This can happen even when outside temperatures seem too warm for ice—carburetor ice forms between 20°F and 70°F with humidity.

Temperature extremes stress engines too. Very hot days reduce engine power because hot air is less dense. Cold weather makes oil thick and hard to pump. These conditions push engines closer to their limits.

Understanding these basic causes helps explain the seven specific problems we'll explore in detail next. Each cause connects to one or more of these fundamental issues with fuel, mechanical systems, or operating conditions.

7 Common Causes of Aircraft Engine Failure (and How to Prevent Them)

1. Fuel Starvation and Exhaustion

Fuel starvation happens when fuel exists in the tanks but can't reach the engine. This differs from exhaustion, which means actually running out of fuel completely. Both are leading common causes of engine failure and both are completely preventable.

Why It Happens:

• Fuel selector valve set to an empty tank while full tanks sit unused
• Blocked fuel lines or clogged fuel filters
• Fuel pump failure that stops fuel flow from tank to engine
• Ice crystals forming in fuel lines during cold weather
• Vapor lock in fuel lines during very hot conditions

The scary part? You might have plenty of fuel aboard but the engine still quits. Many pilots have crashed with full fuel tanks simply because the fuel system wasn't delivering it to the engine.

Prevention Steps:

• Switch between fuel tanks during flight to use fuel evenly
• Know your plane's fuel system completely
• Check fuel selectors are on the fullest tank before takeoff
• Install and maintain fuel filters properly
• Drain fuel sumps before every flight to check for water
• Calculate fuel needs with generous reserves (plan for 45-60 minutes extra)
• Monitor fuel gauges throughout the flight
• Never trust fuel gauges alone—do a visual fuel check

One student pilot learned this lesson the hard way during training. His single engine piston plane had fuel in the right tank but he'd left the selector on the left (empty) tank. The engine quit on short final approach. Luckily, his instructor caught the mistake and switched tanks. The engine roared back to life just 200 feet from the ground.

2. Contaminated Fuel

Fuel contamination causes roughly 20-25% of general aviation engine problems. Something in the fuel that shouldn't be there—water, dirt, rust, or wrong fuel type—can shut down an engine faster than almost anything else.

Common Contaminants:

• Water from condensation in partially full fuel tanks
• Water from contaminated fuel truck deliveries
• Dirt and sediment from old airport underground fuel storage
• Rust particles from corroded fuel tanks
• Biological growth (algae and bacteria) in stored fuel
• Jet fuel accidentally pumped into piston aircraft

Water is the biggest culprit. It's heavier than gasoline, so it sinks to the bottom of fuel tanks. When you drain the sumps during pre-flight, you're checking for water droplets. Just a small amount of water can stop an engine cold.

Prevention Strategies:

• Drain all fuel sumps thoroughly before every single flight
• Keep fuel tanks full overnight to minimize condensation
• Use fuel from busy airports where fuel turns over quickly
• Watch the fuel truck operator pump fuel into your plane
• Add fuel from the truck immediately after the truck refuels (never sit on the tarmac for hours)
• Install and replace fuel filters on schedule
• Use fuel testing kits that detect water
• Know the color of correct fuel for your engine type (blue for 100LL avgas)

The National Transportation Safety Board investigates hundreds of fuel contamination accidents each year. Many victims report they drained their sumps but didn't see any water—they didn't drain enough. You need to drain until you see pure, clean fuel with no bubbles or discoloration.

3. Mechanical Component Failures

Despite excellent manufacturing, mechanical parts eventually wear out. This represents a common cause of engine failure that affects every type of aircraft engine—from tiny piston engines to massive turbine engines.

Critical Components That Fail:

• Crankshafts crack from repeated stress cycles
• Connecting rods break when metal fatigues
• Cylinder heads crack from extreme heat
• Valves stick or break during combustion
• Bearings seize from lack of lubrication
• Camshafts wear down and lose proper timing
• Engine parts like pushrods bend or snap

Mechanical failure doesn't always mean catastrophic destruction. Sometimes an engine just loses power gradually. The RPM drops. Oil temperature rises. The engine runs rough. These warning signs give pilots time to find a place to land.

Prevention Through Maintenance:

• Follow manufacturer's maintenance schedule exactly
• Track flight hours and calendar time for all inspections
• Use certified mechanics with engine experience
• Replace parts at recommended intervals even if they look fine
• Monitor oil pressure and oil temperature every flight
• Send oil samples for laboratory analysis
• Listen for unusual engine sounds or vibrations
• Keep detailed maintenance logs

Here's something important: aircraft piston engines work much harder than car engines. Your car engine loafs along at 2,000-3,000 RPM. A plane engine runs at 2,400-2,700 RPM constantly. This means wear happens faster. Parts that would last 200,000 miles in a car might need replacement after just 2,000 hours in a plane.

The FAA issues Airworthiness Directives (ADs) when they discover problems with specific engine models. Ignoring an AD is illegal and dangerous. Always check for new ADs that apply to your aircraft.

4. Design and Manufacturing Defects

Sometimes engines fail because of problems built into them from the start. Engine design flaws are rare but serious. Manufacturing defects happen when a part isn't made correctly at the factory.

Types of Design Issues:

• Blade failure in turbine engines from resonance frequencies
• Weak mounting points that crack under vibration
• Inadequate cooling systems that let engines overheat
• Engine case designs that don't contain failures properly
• Compressor blade angles that cause surge and stall
• Fuel system designs prone to vapor lock

One famous example involved a specific Boeing engine model where fan blades could fracture mid-flight. After investigation, the probable cause of engine failure was a design flaw in how blades attached to the hub. The manufacturer issued a fix that required inspecting or replacing thousands of engines.

How the Industry Responds:

• Manufacturers test engines for thousands of hours before certification
• Aircraft certification requires proving engines can handle abuse
• When problems appear, mandatory inspections or modifications follow
• Service bulletins alert operators to potential issues
• AD compliance becomes mandatory for affected engines
• Continuous monitoring of in-flight performance data

For aircraft owners, this means:

• Stay current on all service bulletins for your engine
• Join type clubs for your aircraft model to learn about known issues
• Comply with all ADs immediately—they're issued for good reasons
• Consider upgraded parts that fix known weaknesses
• Research engine history before buying a used airplane

Engine failures are rare in modern certified aircraft because testing is so thorough. But when design problems do appear, acting quickly on manufacturer fixes prevents failures.

5. Carburetor Icing and Induction System Problems

Even on a beautiful spring day, ice can form inside your engine and shut it down. Carburetor ice is a sneaky problem that surprises many pilots because it forms in temperatures up to 70°F.

How Carburetor Ice Forms:

• Air flowing through the carburetor expands and cools
• This cooling can drop temperatures by 40-70 degrees
• Moisture in the air freezes onto carburetor walls
• Ice blocks airflow into the engine
• Engine loses power or quits completely

You might notice:

• Gradual loss of engine power
• Rough engine operation
• RPM dropping steadily
• Engine running unevenly

The Fix: Pull on carb heat before power loss becomes critical. Carb heat routes hot air from around the exhaust into the carburetor, melting any ice. When you apply carb heat, the engine might run rougher briefly—that's the ice melting and passing through as water. Keep the heat on until the engine smooths out.

Prevention Best Practices:

• Use carb heat during any descent with reduced power
• Apply carb heat if you notice any power loss
• Use carb heat during prolonged flight at reduced power settings
• Check carb heat is working during runup
• Consider switching to fuel injection (which doesn't ice)
• Monitor carburetor temperature gauges if installed

Fuel-injected engines largely avoid carburetor icing. The fuel system in injected engines sprays fuel directly into cylinders, skipping the carburetor entirely. Many newer aircraft use fuel injection for this reason.

Other induction system problems include:

• Air filters clogged with dirt or debris
• Induction hoses cracking and leaking air
• Alternate air doors sticking closed
• Ice forming on air intakes in visible moisture

These issues starve the engine of air it needs for combustion. Checking your induction system during pre-flight catches many potential problems.

6. Improper Maintenance and Neglect

Poor maintenance causes more aircraft accidents than most people realize. Skipping inspections, using wrong parts, or ignoring small problems leads to big failures.

Common Maintenance Mistakes:

• Skipping required inspections to save money
• Using unapproved parts instead of certified components
• Letting oil changes go past due dates
• Ignoring small oil leaks that get worse
• Not torquing bolts to proper specifications
• Failing to safety-wire critical fasteners
• Using wrong types of lubricants

The FAA requires annual inspections for most aircraft plus 100-hour inspections for planes used for hire. These aren't optional. Certificated mechanics trained on your engine type should do the work.

What Proper Maintenance Includes:

• Regular oil changes (typically every 50 hours or 4 months)
• Spark plug inspection and cleaning
• Magneto timing checks and adjustment
• Compression tests on cylinders
• Valve clearance adjustments
• Fuel system cleaning and filter replacement
• Inspection of all hoses and lines for cracks
• Checking engine case for cracks or oil seeps

Understanding aircraft ownership responsibilities means knowing that maintenance isn't optional. Your signature in the logbook means you've ensured the plane is airworthy.

Many pilots who buy flight school Cessna 172s discover maintenance was deferred to keep operating costs low. Before buying any used aircraft, review maintenance logs carefully. Missing entries, pencil-whipped inspections, or large gaps in records are red flags.

Cost of Poor Maintenance: Beyond aviation safety risks, neglected engines cost more money. Small problems become expensive repairs. An overheated engine might need a complete overhaul. Corroded parts can damage other components. Insurance companies can deny claims if maintenance records show negligence.

Think of it this way: your engine is basically running at full power for hours at a time. It needs care like a professional race car engine, not like the engine in your daily driver.

7. Pilot Error and Operational Mistakes

Humans make mistakes. Even experienced pilots can do things that cause engine failure. Recognizing common errors helps everyone avoid them.

Frequent Pilot Mistakes:

• Forgetting to switch fuel tanks and starving one engine while another tank stays full
• Running the mixture too lean at low altitude, causing overheating
• Advancing throttle too quickly when cold, damaging cold components
• Failing to use carb heat when conditions require it
• Ignoring pre-flight checklist items
• Missing warning signs from gauges
• Not monitoring fuel consumption during flight
• Attempting takeoff without proper run-up checks

During takeoff, engines work hardest. That's when errors show up most dramatically. A pilot who forgot to switch magnetos to "both" might make it off the ground but have engine problems. Missing the step to set mixture correctly reduces power when you need it most.

Event of an engine failure, proper pilot response makes the difference between a successful emergency landing and a crash. Pilots train for:

• Recognizing engine failure occurs immediately
• Establishing best glide speed
• Finding suitable landing areas
• Completing emergency checklist items
• Declaring emergency with air traffic control
• Making controlled landing

For multi-engine aircraft, losing one engine inoperative means the pilot must quickly identify which engine failed, verify it, feather the propeller on the dead engine, and maintain directional control. This complex procedure requires practice. Many plane crashes happen when pilots react incorrectly to losing one engine.

Training Helps Prevent Errors:

• Regular recurrency training keeps skills sharp
• Practice emergency procedures with instructors
• Chair fly procedures at home
• Study POH (Pilot's Operating Handbook) emergency sections
• Fly with safety pilots to get outside observations
• Use simulator time to practice emergencies
• Join safety seminars and online courses

Before you fly, ask yourself: "Am I really ready for this flight?" If you're tired, stressed, or distracted, you're more likely to make mistakes. The flight crew on commercial planes uses checklists for everything—even with thousands of hours of experience. If professional pilots need checklists, general aviation pilots definitely do.

Many single engine aircraft accidents happen because pilots weren't prepared for what to do if the engine is running rough or quits. Practice makes these procedures automatic so you react correctly under stress.

Simple Ways the Aviation Industry Prevents Engine Failure

The aviation industry doesn't just wait for engines to fail and then fix them. Manufacturers, airlines, mechanics, and regulators work together to prevent problems before they happen.

Advanced Monitoring Systems:

Modern jet engines come with dozens of sensors that track everything happening inside. These systems monitor:

• Temperature at multiple points
• Oil pressure and oil quality
• Vibration levels and patterns
• Fuel flow and pressure
• RPM and power output
• Compressor efficiency

Data downloads after each flight let maintenance crews spot problems early. If a sensor shows temperatures creeping up slowly over weeks, mechanics can fix the issue before catastrophic engine damage occurs.

Regular Inspection Programs:

Airlines don't wait for engines to break. They follow strict inspection schedules:

• Daily walk-around checks by flight crew
• Frequent oil analysis to detect metal particles
• Regular borescope inspections to look inside engines without taking them apart
• Scheduled component replacements based on flight hours
• Complete teardown and rebuild at specific intervals

For general aviation, owners should adopt similar practices at smaller scale. Send oil samples to labs. Track engine performance trends. Don't skip inspections.

Improved Manufacturing:

Today's aviation engines use better materials than engines from 30 years ago:

• Stronger alloys that resist cracking
• Better coatings that prevent corrosion
• Precision manufacturing that ensures parts fit exactly right
• Computer modeling that predicts stress points
• Engine design that accounts for worst-case scenarios

Turbine engine technology keeps improving. The latest engines run hotter and more efficiently while being more reliable. Percent of engine failures keeps dropping as materials and designs improve.

Redundancy and Safety Margins:

Every airplane certified for passenger service must prove it can handle engine problems:

• Multi-engine planes must fly safely on fewer engines
• Systems have backups—dual magnetos, backup fuel pumps
• Engine nacelle designs contain failures and prevent fire spread
• Aircraft to fly certification requires demonstrating one engine operation
• Safety margins built into engine power ratings mean engines rarely run at true maximum output

When a catastrophic engine failure happens in flight—like a turbine blade breaking—the engine is designed to contain fragments. The engine case and cowling are engineered to keep metal pieces from flying into the fuselage or other engines.

Continuous Safety Programs:

• The National Transportation Safety Board investigates every aircraft crash and serious incident
• Data from investigations leads to design improvements
• Aviation safety organizations share information about problems
• Industry groups publish best practices
• Training programs incorporate lessons from past accidents

Airlines track their engines so carefully that they can predict when problems might occur. If in-flight data shows early signs of trouble, they might shut down an engine preventatively and land before a real failure happens.

Pre-Flight Preparations:

Smart pilots prevent most problems on the ground:

• Complete thorough pre-flight inspections
• Check for oil leaks around the engine
• Look for loose or damaged parts
• Verify fluid levels
• Test magneto function during run-up
• Check that everything moves freely

When you find possible causes of future problems during pre-flight, you can fix them before they become a serious safety of flight issue. That oil drip you ignore today might become an oil pump failure tomorrow.

Better Pilot Training:

Modern flight training emphasizes engine operation understanding:

• Students learn what makes engines work
• Training covers what causes engines to fail
• Practice handling engine fault scenarios
• Emphasis on using checklists religiously
• Focus on recognizing warning signs early

For Cessna 172 autopilot basics and common mistakes, pilots learn that autopilot can help reduce workload—but they still must monitor the engine constantly.

Fuel Quality Control:

Airports work hard to deliver clean fuel:

• Underground storage tanks get inspected regularly
• Fuel trucks have multiple filters
• Fuel samples get tested before delivery
• Water detectors in storage systems
• Regular maintenance of fuel farm equipment

However, pilots still need to verify fuel quality themselves. Never assume fuel from the pump is perfect.

Emergency Response Planning:

If prevention fails, good planning saves lives:

• Pilots practice emergency procedures regularly
• Airports have emergency response teams
• Air traffic control prioritizes aircraft with engine problems
• Pilots know where suitable landing areas exist
• Runway foam can be prepared for emergency landings

The combination of all these efforts means that percent of engine failure accidents relative to total flights is incredibly low. When caused by engine problems, most incidents end with safe landings rather than crashes.

The aviation industry learned these lessons the hard way through decades of experience. Each aircraft piston engines improvement came from studying failures. Each new safety procedure came from analyzing what went wrong. The result is that flying today is safer than ever before—and it keeps getting better.

Prevention works. Following procedures works. Proper maintenance works. Paying attention works. Pilots and owners who take these steps seriously almost never experience actual engine failures. And when problems do occur, trained pilots who follow procedures typically land safely.

Remember: engines don't just quit randomly. There's always a reason. Understanding those reasons and taking steps to prevent them keeps every airplane flying safely.

Conclusion

Engine failure in aircraft may sound scary, but now you understand it's largely preventable. The seven common causes of engine failure in aircrafts we covered—fuel problems, contamination, mechanical wear, design issues, icing, poor maintenance, and pilot error—all have solutions. By following proper procedures, maintaining your aircraft diligently, and staying alert during flight, you significantly reduce risk.

Modern engines are remarkably reliable when properly cared for. Commercial aviation's incredible safety record proves this. For general aviation pilots and aircraft owners, the message is clear: take maintenance seriously, never skip pre-flight checks, monitor your engine constantly, and stay current with training.

Flying safely isn't about luck. It's about knowledge, preparation, and consistent good practices. Whether you're considering aircraft ownership, currently fly, or just curious about aviation, understanding what causes engines to fail—and how to prevent it—helps you make informed decisions. Keep learning, stay safe in the skies, and remember that resources like Flying411 offer valuable guidance for all your aviation needs.

Frequently Asked Questions

How long can a plane glide without engine power?

Most single-engine aircraft can glide approximately 1.5 to 2 miles forward for every 1,000 feet of altitude they lose. A plane at 10,000 feet could potentially glide 15-20 miles to find a suitable landing spot. Glide distance depends on aircraft weight, configuration, and how well the pilot maintains optimal glide speed. Jets glide less efficiently but still travel significant distances—a commercial airliner at cruising altitude could glide over 100 miles.

Can turbulence cause engine failure?

Turbulence itself almost never causes engine failure. Engines are built to withstand severe turbulence and violent maneuvers far beyond what passengers would experience. However, extreme turbulence could potentially damage engine mounts or accessories if severe enough. The real concern is that turbulence might distract pilots from monitoring engine instruments or performing proper procedures. Engines can handle turbulence better than passengers can, so if the ride gets bumpy, your engine isn't in danger.

What's the difference between engine failure and engine malfunction?

Engine failure means the engine has completely stopped producing power—it's dead. An engine malfunction means the engine still runs but isn't working correctly. Malfunctions include rough running, loss of partial power, overheating, unusual vibrations, or abnormal gauge readings. Many malfunctions give pilots time to diagnose the problem and land safely before complete failure occurs. Catching malfunctions early through careful monitoring often prevents them from becoming failures.

Are older aircraft engines more likely to fail?

Age alone doesn't determine engine reliability—maintenance history matters more. A well-maintained 40-year-old engine that followed all inspection schedules and part replacement intervals can be extremely reliable. Conversely, a newer engine that missed inspections or used improper parts becomes risky. However, older engines often accumulate more total flight hours and operate with older technology, which can increase failure risk if not properly maintained. Always review complete maintenance records before flying or buying older aircraft.

What should passengers do if they hear the engine quit?

Passengers should remain calm and follow crew instructions. In multi-engine aircraft, one engine failing rarely creates immediate danger—the plane continues flying normally. Listen for announcements from the flight crew about what's happening. Keep your seatbelt fastened and don't panic, as your fear could distract others. Flight attendants are trained to manage emergencies and will guide passengers through proper procedures if needed. Remember that pilots train extensively for these situations and know exactly what to do.