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2. Remove/Install the Coolant Radiator
Refer to Figure 2.
A. Remove the Coolant Radiator
Detail Steps/Work Items Key Items/References
(1) Make sure that the engine is safe for
maintenance:
S Remove the key from the key switch.
(2) Remove the engine cowlings. Refer to Section 71-11.
WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT
TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
CAN FORCE HOT COOLANT TO COME OUT AND BURN YOU.
(3) Remove the pressure cap from the coolant tank:
S Turn the cap counter-clockwise a small
distance to release the pressure.
S When the pressure has fully released, turn
the cap fully counter-clockwise.
(4) Drain the coolant:
S Remove the drain plug from the left side of
the coolant radiator near the bottom.
S Open the drain plug on the engine RH lower
side above the turbo-charger.
Use a suitable container to catch the
coolant.
You need not remove this drain plug.
Use a suitable duct to guide the coolant
into the container.
(5) Disconnect the hose between the coolant tank
and the bypass pipe.
At the coolant tank.
(6) Disconnect the hose between the thermostat
valve and the pipe to the coolant radiator.
At the thermostat valve.
AIRCRAFT
Cooling DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 202
20 Sep 2007 75-01-00 Doc # 6.02.01
Rev. 5
(7) Disconnect the hose between the coolant radiator
outlet and the bypass pipe.
At the coolant radiator.
(8) Disconnect the overflow line. At the coolant tank near the pressure
cap.
(9) Remove the 3 nuts and washers from the coolant
radiator mounting points.
The front outboard nut also attaches a
bonding cable.
(10) Disconnect the electric wires from the coolant
level sensor.
(11) Lift the coolant radiator together with the coolant
tank clear of the airplane.
(12) Disconnect the hose between the coolant tank
and the coolant radiator.
(13) Remove the nuts and bolts from the coolant tank
support bracket that attaches to the coolant
radiator.
(14) Remove the pipe and the hose from the coolant
radiator inlet port.
(15) Put caps on the open end pipes and connections.
(16) Close the coolant drain-plug above the turbocharger.
(17) Install the drain plug to the coolant radiator. Use a new copper gasket.
AIRCRAFT
DA 40 Series
AMM
Cooling
Doc # 6.02.01
Rev. 5 75-01-00 Page 203
20 Sep 2007
B. Install the Coolant Radiator
Detail Steps/Work Items Key Items/References
(1) Install the pipe and the hose to the coolant
radiator inlet port.
(2) Attach the coolant tank to the coolant radiator
with nuts and bolts.
(3) Install the hose between the coolant tank and
the coolant radiator.
(4) Put the coolant radiator together with the
coolant tank in position on the engine mount.
Engage the hoses on the related
connections as you move the coolant
radiator into position.
(5) Connect the electric wires to the coolant level
sensor.
(6) Install the nuts and washers attaching the
coolant radiator to the engine mount.
The front outboard nut also attaches a
bonding cable.
(7) Connect the overflow line. At the coolant tank near the pressure
cap.
(8) Connect the hose between the coolant radiator
outlet and the bypass pipe.
At the coolant radiator.
(9) Connect the hose between the thermostat
valve and the pipe to the coolant radiator.
At the thermostat valve.
(10) Connect the hose between the bypass pipe and
the coolant tank.
At the coolant tank.
(11) Fill and bleed the cooling system. Refer to Paragraph 5 of this Section.
(12) Install the engine cowlings. Refer to Section 71-11.
AIRCRAFT
Cooling DA 40 Series
AMM
Page 204
20 Sep 2007 75-01-00 Doc # 6.02.01
Rev. 5
3. Remove/Install the Coolant Tank
A. Remove the Coolant Tank
Detail Steps/Work Items Key Items/References
(1) Make sure that the engine is safe for
maintenance:
S Remove the key from the key switch.
(2) Remove the engine cowlings. Refer to Section 71-11.
WARNING: DO NOT REMOVE THE PRESSURE CAP FROM THE COOLANT
TANK IF THE ENGINE IS HOT. THE PRESSURE IN THE SYSTEM
CAN FORCE HOT COOLANT TO COME OUT AND BURN YOU.
(3) Remove the pressure cap from the coolant tank:
S Turn the cap counter-clockwise a small
distance to release the pressure.
S When the pressure has fully released, turn
the cap fully counter-clockwise.
(4) Drain the coolant:
S Remove the drain plug from the left side of
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