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cylinders. Rivets attach a special rubber sealing strip to the top of the baffle. The rubber sealing strip
makes a seal between the baffle and the inside of the top cowling. The air goes down between the
cylinders and around the outside of the cylinders. The used air goes out from the bottom rear of the
engine bay.
These items pass through rubber grommets in the cooling baffle:
) The propeller control cable.
) The mixture control cable.
) The fuel flow divider drain.
The cables for the top spark plugs of No’s 1 & 3 cylinders, go through a cable feed-thru in the rear of
the baffle, on the right side. The cables for the top spark plugs of No’s 2 & 4 cylinder pass through
holes in the left side of the baffle, at the top.
Screws attach the baffle to the cylinder head and tie-bars hold the baffle in position around the bottom
of the cylinders.
AIRCRAFT
Cooling DA 40 Series
AMM
Page 2
20 Sep 2007 75-00-00 Doc # 6.02.01
Rev. 5
Lower Intake Baffle
Upper Intake Baffle
Left Rear Baffle
Right Rear Baffle
Right
Front
Baffle
Rubber Seal
Seal Retaining
Plate
Pop Rivet
Washer
Baffle
Rear Baffle
Front Baffle
Mixture Control
Cable
Propeller
Control Cable
TYPICAL ATTACHMENT
Figure 1: Cooling Air Baffle
AIRCRAFT
DA 40 Series
AMM
Cooling
Doc # 6.02.01
Rev. 5 75-00-00 Page 201
20 Sep 2007
Maintenance Practices
1. General
These maintenance practices tell you how to remove/install the cooling air baffle. See Figure 1 for
location data.
Refer to the Lycoming Maintenance Manual for data on the inter-cylinder baffles.
2. Remove/Install the Cooling Air Baffle
A. Remove the Cooling Air Baffle
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY
WORK ON THE BAFFLES. IF THE ENGINE IS TURNED, THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S The ignition switch is set to OFF.
S The throttle is set to IDLE.
S The mixture control is set to LEAN CUT-OFF.
(2) Remove the engine cowlings. Refer to Section 71-10.
(3) Disconnect the battery. Refer to Section 24-31.
(4) Disconnect the cables from the top spark plugs
% on No’s 2 & 4 cylinders. Move the spark plug
cables clear of the baffle.
(5) Disconnect the cables from the top spark plugs
on No’s 1 & 3 cylinders.
(6) Remove the nuts and bolts which attach the
spark plug cable feed-thru to the rear of the
baffle.
(7) Move the spark plug cables aft through the hole
in the baffle.
(8) Disconnect the mixture cable from the fuel
injector. Move the cable aft, through the rubber
grommets in the baffle.
Refer to Section 76-00.
AIRCRAFT
Cooling DA 40 Series
AMM
Page 202
20 Sep 2007 75-00-00 Doc # 6.02.01
Rev. 5
Detail Steps/Work Items Key Items/References
(9) Disconnect the propeller governor control cable.
Move it aft through the rubber grommets in the
baffle.
Refer to Section 61-20.
(10) Disconnect the drain tube from the fuel flow
divider. Move it aft through the rubber grommet in
the baffle.
Refer to Section 71-70.
(11) Release the tie-bars from the bottom of the baffle
on the left side and on the right side.
(12) Remove the four screws which attach the cooling
baffle to No’s 2 & 4 cylinder heads.
Note the location of the P-clamps which
hold the spark plug cables and which
hold the manifold pressure pipe.
(13) Remove the four screws which attach the cooling
baffle to No’s 1 & 3 cylinder heads.
Note the location of the P-clamps which
hold the spark plug cables.
(14) Remove the cooling air baffle.
B. Install the Cooling Air Baffle
Detail Steps/Work Items Key Items/References
(1) Make sure that :
S The cooling baffle is clean.
S The cooling baffle is not damaged.
S That the rubber sealing strip is correctly
attached and not damaged.
(2) Move the cooling baffle into position around the
cylinders.
(3) Install the four screws which attach the baffle to
No’s 1 & 3 cylinder heads.
Make sure that the P-clamps holding
the spark plug cables are in the correct
position.
(4) Install the four screws which attach the baffle to
No’s 2 & 4 cylinder heads.
Make sure that the P-clamps holding
the spark-plug-cables and the manifold
pressure hose are in the correct
position.
AIRCRAFT
DA 40 Series
AMM
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