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S Replace gasket.
S Install the oil suction screen to the oil sump.
X X X
AIRCRAFT
DA 40 Series
AMM
Time Limits and
Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items (Lycoming engine only) 50 100 200 1000 Time Initials
Doc # 6.02.01
Rev. 5 05-20-00 Page 9
20 Sep 2007
6. Install the drain plug.
S Tighten the drain plug. Torque: 18 Nm
(160 in.lb).
S Lock the drain plug with safety wire.
X X X X
7. Replace the oil filter. (Refer to Section 79-00). X X X X
8. Cut open the used oil filter. Look for particles of
metal. If the filter contains particles of metal, refer
to the Lycoming Maintenance Manual.
X X X X
CAUTION: YOU MUST USE ENGINE OILS THAT AGREE WITH THE
SPECIFICATION IN LYCOMING SERVICE INSTRUCTION NO. 1014.
9. Fill the engine with new oil. X X X X
Note: Drain the engine oil and fill with straight oil 25 hours after a new engine is
installed. Change to an ashless oil at the next 50 hour check. Refer to Lycoming
Service Instruction No. 1014 for details of acceptable oils.
10. Do a compression test with the engine warm and
the throttle open.
Do the compression test on the four cylinders.
Use 5.5 bar (80 psi). Maximum permitted
decrease 1.4 bar (20 psi).
Record the compression test results:
1 _______ 2 _______ 3 _______ 4 _______
X X X
11. Remove the spark plugs.
S Examine the spark plugs. Look specially for
damaged electrodes.
S Clean the spark plugs (refer to spark plug
manufacturer's instructions).
S Do a spark plug gap test (Refer to the
manufacturer's specified spark plug gap).
X X X
AIRCRAFT
Time Limits and
Maintenance Checks
DA 40 Series
AMM
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items (Lycoming engine only) 50 100 200 1000 Time Initials
Page 10
20 Sep 2007 05-20-00 Doc # 6.02.01
Rev. 5
12. Install the spark plugs. Use a thread lubricant
approved by the spark plug manufacturer:
S Install the spark plugs.
S Torque to 47 Nm (35 ft.lb).
S Refer to Lycoming Service Instruction
No. 1042 for approved spark plugs.
X X X
13. Examine the ignition harness and cables.
Examine the sleeve nut on each spark-plug
connector for cracks.
X X X X
14. Inspect the ignition system.
S If the LASAR system is installed, then do a
100 hr. / 500 hr. check of the LASAR system
and the magnetos. Refer to the Slick
Maintenance and Overhaul Manual L-1503
(latest issue).
S If the SlickSTART system is installed, then do
a 100 hr. / 500 hr. check of the SlickSTART
system and the magnetos. Refer to the
SlickSTART Installation, Operation,
Maintenance and Troubleshooting Manual
L-1492 (latest issue).
X 500
hrs.
15. Examine each cylinder. Look specially for broken
fins and heat damage.
X X X
16. Examine the rocker-box covers. Look specially for
signs of oil leaks.
X X X X
AIRCRAFT
DA 40 Series
AMM
Time Limits and
Maintenance Checks
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items (Lycoming engine only) 50 100 200 1000 Time Initials
Doc # 6.02.01
Rev. 5 05-20-00 Page 11
20 Sep 2007
17. Examine the valves and rockers:
S Remove the rocker covers.
S Look specially for abnormal wear and broken
parts in the areas of:
S Valve tips.
S Valve keepers.
S Springs.
S Spring seats.
S Install the rocker covers.
Refer to the Lycoming Maintenance Manual.
400
hrs.
18. Examine the inlet manifolds. X X X X
19. Examine the fuel injector. Remove and clean the
inlet finger filter.
X X X X
20. Examine the fuel flow-divider. X X X X
21. Remove and clean the fuel injector nozzles:
S Refer to Lycoming Service Instruction 1275
(latest issue).
S Refer to Lycoming Service Instruction 1414
(latest issue).
X X
22. Examine the fuel pump drain pipe. X X X
AIRCRAFT
Time Limits and
Maintenance Checks
DA 40 Series
AMM
100 hr items marked X* apply to US registered airplanes only Interval
Inspection Items (Lycoming engine only) 50 100 200 1000 Time Initials
Page 12
20 Sep 2007 05-20-00 Doc # 6.02.01
Rev. 5
WARNING: MAKE SURE THE EXHAUST SYSTEM IS COOL BEFORE YOU DO
MAINTENANCE ON THE EXHAUST SYSTEM. THE EXHAUST
SYSTEM CAN BE HOT. THIS CAN CAUSE INJURY TO PERSONS.
23. Examine the exhaust system. Look specially for
cracks and heat damage.
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