Maintenance Practices
1. General
These maintenance practices tell you how to remove/install the engine. These maintenance practices also tell you how to remove/install the engine and engine mount together.
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 TURN THE PROPELLER. MAKE SURE THAT THE IGNITION SWITCH IS SET TO “OFF” AND THAT THE SPARK-PLUG-CABLES ARE DISCONNECTED FROM THE SPARK PLUGS. SET THE THROTTLE TO “IDLE” AND THE MIXTURE CONTROL TO “LEAN CUT-OFF”.
WARNING: DO NOT GO BELOW THE ENGINE WHEN YOU LIFT THE ENGINE WITH THE HOIST. THE HOIST CAN FAIL. THIS CAN CAUSE DEATH OR INJURY TO PERSONS.
WARNING: DO NOT GET OIL ON YOU. OIL CAN CAUSE SKIN DISEASE.
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO NOT ALLOW FIRE OR SPARKS NEAR FUEL. FUEL BURNS AND BURNING FUEL CAN CAUSE INJURY TO PEOPLE AND DAMAGE TO EQUIPMENT.
CAUTION: YOU MUST ATTACH CAPS TO HOLES/PIPES WHEN YOU REMOVE THE ENGINE. IF YOU DO NOT DO THIS, CONTAMINATION CAN ENTER THE HOLES/PIPES. THIS CAN CAUSE BLOCKAGE TO THE AIRPLANE SYSTEMS.
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DA 40 Series AMM
Figure 2: Connections at the Rear of the Engine
DA 40 F
2. Remove/Install the Engine (without the Engine Mount)
A. Equipment
Item Quantity Part Number
Hoist. 1 Commercial.
Engine sling. 1 Commercial.
Engine stand. 1 Commercial.
Airplane jacks. 3 Commercial.
Nose trestle. 1 Commercial.
Wing trestles. 2 Commercial.
B. Remove the Engine
Detail Steps/Work Items Key Items/References
(1) Lift the airplane on jacks and make the airplane level. Refer to Section 07-10.
(2) Move the wing trestles into position. Refer to Section 07-10.
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY WORK ON THE PROPELLER. IF THE ENGINE IS TURNED, THE PROPELLER CAN CAUSE INJURY OR DEATH.
(3) Set the fuel selector/shut-off valve to CLOSED.
(4) 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.
(5) Remove the engine cowlings. Refer to Section 71-12.
(6) Remove the airplane battery. Refer to Section 24-31.
(7) Disconnect the spark plug cables from the spark plugs.
(8) Remove the spark plugs and put blanks in the spark plug holes in the cylinders. This will stop contamination going into the engine cylinders.
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DA 40 Series AMM
DA 40 F AIRCRAFT
Figure 3: Left Side of the Engine
DA 40 Series AMM
% % % %
DA 40 F
Detail Steps/Work Items Key Items/References
(9) Remove the cable ties that attach the top left-hand ignition cable to the propeller control cable. Remove the 2 nuts/washers/screws that hold the left-hand fairlead for the top ignition cables.
(10) Release the P-clamps holding the left ignition cables to the engine-cooling-baffles.
(11) Remove the 2 nuts/washers/screws that attach the right-hand fairlead for the top ignition cables.
(12) Remove the cable ties attaching the left-side ignition cables to the engine mount and move the cables to the rear of the engine. Note the position of the cable ties.
(13) Release the P-clamps holding the right ignition cables to the engine cooling baffles.
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