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(20) Connect the spark plug cables to the spark plugs.
(21) Connect the battery. Refer to Section 24-31.
(22) Install the engine cowlings. Refer to Section 71-10.
(23) Write the compression test values in the airplane
records.
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Section 72-01
TAE 125 Diesel Engine
1. General
This Section gives you background data about the TAE 125 Diesel engine installed in the DA 40
airplane.
% Note: Only TAE authorized maintenance organizations may carry out maintenance and
inspection work on the TAE engine. Refer to TAE Service Bulletin No. 125-0003.
Any engine malfunction must be reported to TAE.
2. Description
The TAE 125 is a liquid-cooled, 4-cylinder, 4-stroke in-line turbocharged engine with double overhead
camshafts. The engine has a direct-injection fuel system controlled by computers. A reduction gearbox
with a ratio of 1.69:1 turns the propeller. The gearbox has an integral torsional vibration damper with
an overload clutch. The engine has an electric starter and a generator.
The TAE 125 engine operates on the Diesel cycle. The engine has a crankcase, crankshaft, cylinders,
pistons and valves like conventional piston aero-engines. However, there is no ignition system.
In the Diesel engine, air is drawn into the cylinders and compressed to a high pressure. A high
pressure pump injects a metered quantity of fuel into the cylinder. The air is hot enough to ignite the
fuel. The fuel burns and expands the air to force the piston down the cylinder. The air pumping cycle
and valve operation is the same as in a conventional piston aero-engine.
A Full Authority Digital Engine Control (FADEC) system controls the fuel system, propeller and turbocharger.
The FADEC has 2 Engine Control Units (ECU's) located in a sealed unit under the pilot's seat.
Sensors located on the engine measure the engine parameters for the system. An electrical harness
connects the system components.
The fuel injection pump supplies 4 injectors connected to a common high-pressure rail. The active
ECU controls the opening of each injector to inject the correct quantity of fuel for position of the cockpit
power lever.
The TAE 125 has a turbo-charger to increase the efficiency and power output. Exhaust gases go
through a turbine before flowing through a conventional exhaust to atmosphere. A ‘Waste Gate’
(bypass valve) in parallel with the turbine controls the volume of exhaust gas going through the turbine.
The turbine turns a centrifugal compressor. The compressor supplies air to the engine through an
intercooler.
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Engine DA 40 Series
AMM
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Engine Oil Filter Housing
Engine Oil Filler
Engine Oil Drain Plug
Gearbox Oil
Filler Plug
Gearbox Oil
Level Window
Gearbox Oil
Filter Cover
Gearbox Oil
Drain Plug
Figure 1: Oil System Maintenance Locations
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DA 40 Series
AMM
Engine
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3. Engine Oil System
The engine has the usual wet sump oil system. The sump has a maximum capacity of 6 liters (6.3 US
qts). Refer to the Airplane Flight Manual Chapter 2 for data about the oil types to use in the engine.
The oil pump supplies oil to all bearings and other components that require oil. Oil galleries inside the
engine crankcase and cylinder head supply oil to the internal components.
Figure 1 shows the location of the items that you can maintain on the engine oil system. The engine
has these maintenance locations:
) A full-flow oil filter located at the top left adjacent to the cylinder head. You must replace the filter
at the times given in Chapter 05.
) An engine oil drain plug at the rear left of the engine sump.
) An oil filler located at the left of the crankcase.
) A gearbox oil filler plug located at the top of the gearbox.
) A gearbox oil level window located at the front left of the gearbox. When the oil covers half of the
inspection window, the gearbox contains the correct quantity of oil.
) A gearbox oil drain plug located at the bottom of the gearbox.
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Engine DA 40 Series
AMM
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AMM
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Trouble-Shooting
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