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INJURY TO PERSONS.
WARNING: YOU MUST MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU
TURN THE PROPELLER. DISCONNECT THE BATTERY.
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 ENGINE OIL, GEAR OIL OR COOLANT ON YOU. THESE
LIQUIDS 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.
2. Remove/Install the Engine (without the Engine Mount)
% Note: If you remove an engine with a serial number which is not higher than
% 02-01-0309-SL01-004-0100, and replace it with an engine with serial number
% 02-01-0309-SL01-004-0101 or higher, then you must carry out Service Bulletin No.
% OSBD4-026 before you install the new engine.
AIRCRAFT
Power Plant DA 40 Series
AMM
Page 202
20 Sep 2007 71-01-00 Doc # 6.02.01
Rev. 5
Manifold Pressure
Connection
Manifold Temperature
Sensor
Coolant Temperature
Sensor
Crankshaft 2 Sensor
Oil Pre-Separator Oil Radiator
Oil Separator
Oil Return Line
Oil Return from Oil Radiator
Oil Supply to Oil Radiator
Oil Temperature
Sensor
Oil Filler
Starter Motor
Intercooler
Alternator
Fuel Return
Oil Filter Housing
Overboard Vent
Breather Line
Oil Return from
Turbo-Charger
Combined
Oil Pump
A. Equipment
Item Quantity Part Number
Hoist. 1 Commercial.
Engine sling. 1 Commercial.
Engine stand. 1 Commercial.
Tail trestle. 1 Commercial.
% Figure 2: TAE 125 Diesel Engine Components, Engine S/N up to 02-01-0309-SL01-004-0100
AIRCRAFT
DA 40 Series
AMM
Power Plant
Doc # 6.02.01
Rev. 5 71-01-00 Page 203
20 Sep 2007
% Figure 3: TAE 125 Diesel Engine Components,
% Engine S/N 02-01-0309-SL01-004-0101 and higher
AIRCRAFT
Power Plant DA 40 Series
AMM
Page 204
20 Sep 2007 71-01-00 Doc # 6.02.01
Rev. 5
B. Remove the Engine
Detail Steps/Work Items Key Items/References
(1) Read the engine event log. Refer to Section 72-01.
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.
(2) Set the emergency fuel valve to OFF.
(3) Make sure that the engine is safe:
S Set all switches to OFF.
S Set the power lever to IDLE.
(4) Remove the engine cowlings. Refer to Section 71-11.
(5) Disconnect the airplane main battery. Refer to Section 24-34.
(6) Remove the propeller. Refer to Section 61-11.
(7) Drain the coolant system. Refer to Section 75-01.
(8) Drain the engine oil. Refer to Section 72-01.
(9) Remove the coolant radiator together with the
coolant tank.
Refer to Section 75-01.
(10) Disconnect the breather line. At the oil pre-separator.
(11) Disconnect the oil hoses between the oil radiator
and the engine at the oil filter housing.
Use a suitable container to catch the oil
in the tubes.
(12) Disconnect the electrical cables from the starter
motor.
S Disconnect the two control cables at the
solenoid.
S Disconnect the main supply cable at the
solenoid.
S Release all clips and ties holding the cables to
the engine.
Do not remove clips and ties on the
engine mount.
(13) Disconnect the electrical cables on the alternator.
S Release all clips and ties holding the cables to
the engine.
AIRCRAFT
DA 40 Series
AMM
Power Plant
Doc # 6.02.01
Rev. 5 71-01-00 Page 205
20 Sep 2007
Crankshaft 1 Sensor
Camshaft 2 Sensor Camshaft 1 Sensor
Fuel Rail
Pressure Sensor
Fuel
Injectors
Fuel
Injector
Fuel
Injector
Vacuum
Pump
% Figure 4: TAE 125 Diesel Engine Components
AIRCRAFT
Power Plant DA 40 Series
AMM
Page 206
20 Sep 2007 71-01-00 Doc # 6.02.01
Rev. 5
Detail Steps/Work Items Key Items/References
(14) Disconnect the engine wire harness and bonding
cables from these electrical sensors:
S Crankshaft 1.
S Crankshaft 2.
S Camshaft 1.
S Camshaft 2.
S Coolant temperature.
S Oil temperature.
S Oil pressure.
S Manifold air temperature.
　
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