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the bracket.
S Install the bottom adjustment nut to the
Bowden cable outer sheath.
(8) Install the eye end to the Bowden cable at the
engine:
S Install the lock-nut.
S Install the eye end.
S Tighten the lock-nut to the eye end.
Use a piece of lock-wire to make sure
that the eye end has been installed
correctly.
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Rev. 5
(9) Install the eye end to the mixture lever at the at
the fuel injector:
S Put the long bolt through the control lever.
S Put the spacer onto the long bolt.
S Put the eye end onto the long bolt.
S Put a washer onto the bolt.
S Attach the nut to the bolt.
Tighten the assembly.
From the injector side.
(10) Install the feed-thru to the engine side of the
firewall with firewall sealant:
S Put the 2 parts of the feed-thru round the
Bowden cable.
S Push the feed-thru in the firewall.
S Put the 2 shields in position over the feedthru.
S Install 2 pop-rivets to attach the shields to the
firewall.
Use PR 812 (MIL-S-38249 Type 1) Fire
Wall Sealant.
(11) Do a test for correct range, full and free
movement of the mixture control system.
Refer to the Mixture Control Range of
Movement Test in this Chapter.
(12) Do an inspection of the control connections which
you disconnected. If necessary, for your
airworthiness authority, do a second inspection of
the mixture control assembly.
(13) Do a check for loose items in the cockpit.
Specially in the area of the engine control
assembly.
(14) Do an engine controls freedom of movement
check.
AIRCRAFT
DA 40 Series
AMM
Engine Controls
Detail Steps/Work Items Key Items/References
Doc # 6.02.01
Rev. 5 76-00-00 Page 213
20 Sep 2007
(15) Connect the spark plug cables to the spark plugs. Torque to 12.4 - 13.6 Nm (110 - 120
in.lb).
(16) Connect the airplane battery. Refer to Section 24-31.
(17) Install the engine cowlings. Refer to Section 71-10.
(18) Do an engine run-up. Refer to the DA 40 Airplane Flight
Manual.
4. Throttle/Mixture Control Range of Movement Test
These procedures tell you how to do a throttle and mixture control range of movement test. They do
not tell you how to adjust the engine fuel control units. Refer to the Lycoming Maintenance Manual for
data on the engine fuel control units.
Do the throttle/mixture control range of movement test using two persons. You must make sure that
the throttle/mixture control levers hit the stops in the throttle/mixture valve before they hit their stops
in the engine control assembly. This will make sure that the throttle/mixture controls have the correct
range of movement. You should set the controls to 3 mm (0.125 in) clearance (bounce) at the engine
control assembly cover plate.
A. Throttle Control Range of Movement Test
Detail Steps/Work Items Key Items/References
WARNING: DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER
IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR
INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
DO WORK ON THE ENGINE CONTROLS. IF THE PROPELLER
TURNS IT CAN CAUSE INJURY TO PERSONS.
(1) Make sure that the engine is safe:
S Set the ignition switch to OFF.
S set the throttle to IDLE.
S Set the mixture control to LEAN CUT-OFF
(2) Remove the engine cowlings. Refer to Section 71-10.
(3) Disconnect the airplane battery. Refer to Section 24-31.
(4) Disconnect the spark plug cables from the spark
plugs.
AIRCRAFT
Engine Controls DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 214
20 Sep 2007 76-00-00 Doc # 6.02.01
Rev. 5
(5) Move the throttle control lever between IDLE and
FULL.
S Make sure the lever moves freely with no
restrictions.
(6) Set the throttle control lever to FULL and hold it in
position.
S Make sure that the throttle lever at the
injector hits the stop. If necessary, adjust the
Bowden cable outer sheath at the support
bracket at the bottom of the engine.
With the throttle lever on the stop at the
injector, there must be at least 3 mm
(0.125 in) clearance (bounce) between
the lever in the engine control assembly
and the cover plate.
(7) Set the throttle control lever to IDLE and hold it in
position:
S Make sure that the throttle lever at the
injector hits the IDLE stop. If necessary,
adjust the Bowden cable outer sheath at the
support bracket at the bottom of the engine.
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