DA 40 Series AMM
DA 40 F
Intentionally left blank
DA 40 F
Maintenance Practices
1. General
The maintenance practices for the exhaust system tell you how to remove/install the components of the exhaust system. They also tell you how to do an inspection of the muffler.
WARNING: MAKE SURE THAT THE EXHAUST SYSTEM IS COOL BEFORE YOU TOUCH IT. THE EXHAUST SYSTEM CAN BE VERY HOT, THIS CAN CAUSE INJURY TO PERSONS.
2. Remove/Install the Exhaust Muffler
A. Remove the Exhaust Muffler
Detail Steps/Work Items Key Items/References
WARNING: MAKE THE ENGINE IS SAFE BEFORE YOU DO ANY WORK ON THE EXHAUST SYSTEM. IF THE ENGINE STARTS 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 ALT/BAT 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 71-12.
(3) Release the worm drive clamp that holds the flexible hose to the front stub-pipe of the muffler. Move the flexible hose clear of the muffler.
(4) Release the worm drive clamp that holds the flexible hose to the rear stub-pipe of the muffler. Move the flexible hose clear of the muffler.
DA 40 Series AMM
DA 40 F
Detail Steps/Work Items Key Items/References
(5) Remove the lower of the two expansion-joints: S Remove the four nuts, washers and bolts which hold the expansion-joint-halves. S Move the expansion joint halves clear of the airplane. Do this step for each of the cylinders. Hold the muffler!
(6) If necessary , remove the second expansion-joint. For easier maintenance .
(7) Lower the exhaust muffler clear of the airplane.
B. Install the Exhaust Muffler
Detail Steps/Work Items Key Items/References
(1) Examine the muffler. Make sure that: S The muffler is not cracked. S The shroud is located correctly. S The muffler is clean.
(2) While holding the muffler in the correct position: S Move the expansion joint halves into position. S Install a washer on the bolt. S Push the bolt through the joint halves. S Install a second washer on the joint. S Install the nut. Use a second person. Do these steps for each down-pipe.
(3) Make sure that all the expansion joints are located correctly. Tighten the attachment bolts.
(4) Install the rear flexible hose into position over the rear stub-pipe of the shroud and install the worm drive clamp.
DA 40 Series AMM
DA 40 F
Detail Steps/Work Items Key Items/References
(5) Install the front flexible hose over the front stub-pipe of the shroud and install the worm drive clamp.
(6) Install the engine cowlings. Refer to Section 71-12.
(7) Do an engine run-up. Listen for sounds of exhaust gas leakage. Refer to the DA 40 F Airplane Flight Manual.
(8) Examine the inside of the engine cowlings for signs of exhaust gas leakage.
DA 40 Series AMM
DA 40 F
3. Remove/Install an Exhaust Down-Pipe
A. Expendable Items
Item Quantity Part Number
Nut. 8 IPC
Gasket. 4 IPC
B. Remove an Exhaust Down-Pipe C. Install an Exhaust Down-Pipe
Detail Steps/Work Items Key Items/References
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