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Attach the sling to the hoist.
There are lifting points at:
S Front right cylinder head.
S Front left of the reduction gear
housing.
S Rear left of the cylinder head near
coolant pump.
(2) Remove the support strut from the turbocharger.
(3) Remove the oil hose from the turbo-charger
cage tank to the oil return pump.
At the cage tank, front side.
(4) Remove the shipping stand from the engine.
(5) Carefully move the engine back into position in
the engine mount.
Make sure that the engine does not hit the
engine mount.
(6) Install the bolts, nuts and washer that attach the
engine shock-mounts to the engine mount.
Refer to Chapter 20 for torque values.
(7) Install the bonding cable at the engine near each
engine shock-mount.
(8) Install the turbo-charger support strut.
(9) Connect the oil hose from the turbo-charger
cage tank to the oil separator.
At the cage tank, rear side.
AIRCRAFT
Power Plant DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 210
20 Sep 2007 71-01-00 Doc # 6.02.01
Rev. 5
(10) Connect the oil hose from the turbo-charger
cage tank to the oil return pump.
At the cage tank, front side.
(11) Install the coolant bypass pipe.
(12) Connect the oil hoses between the oil radiator
and the engine.
At the oil filter housing.
(13) Connect the electrical cables to the starter
motor.
S Connect the two control cables at the
solenoid.
S Connect the main supply cable at the
solenoid.
S Attach all clips and ties holding the cables to
the engine.
(14) Connect the hose from the alternate air valve to
the turbo-charger inlet.
At the turbo-charger.
(15) Install the cabin heat heat-exchanger shroud:
S Move heat exchanger shroud in position at
the engine mount.
S Install bolts, nuts and washers on top
forward and bottom forward corners on the
shroud.
S Install bolt, nut and washer on the bracket at
the rear side together with the air filter
housing.
S Install worm-drive clamp to the hose
between the shroud and the heat valve.
At the heat valve.
(16) Install the cabin heat heat-exchanger. Refer to Section 75-01.
% (17) Install the intercooler. Refer to Section 81
% (18) Connect both manifold pressure connections. At the engine inlet manifold.
AIRCRAFT
DA 40 Series
AMM
Power Plant
Detail Steps/Work Items Key Items/References
Doc # 6.02.01
Rev. 5 71-01-00 Page 211
20 Sep 2007
% (19) Move the engine wire harness into position on
the engine. Connect the engine wire harness
and bonding cables to 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.
S Fuel rail pressure regulator.
S Fuel rail pressure sensor.
S Propeller governor.
S Gear temperature.
S Waste gate valve solenoid.
S Fuel injectors.
S Glow plugs.
S Waste gate control valve.
At the front right crank case.
At the front left crank case.
On inlet valve cover between cyl. 3 & 4.
On inlet valve cover between cyl. 1 & 2.
At the thermostat valve.
At the bottom of the oil case.
At the rear side of the oil filter housing.
% At the engine inlet manifold.
At the rear end of the fuel rail.
At the front side of the fuel rail.
At the right side of the reduction gear.
At top left of front bearing reduction gear.
At the lower crankshaft cover.
At each fuel injector.
At the lower crankshaft cover.
At the lower crankshaft cover.
% (20) Install clips and ties clamps holding the engine
wire harness to the engine.
% (21) Connect the fuel supply hose. At the low-pressure pump.
Install clamp at the front right hoist
bracket.
% (22) Connect the fuel return hose. Behind the rail pressure regulator.
AIRCRAFT
Power Plant DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 212
20 Sep 2007 71-01-00 Doc # 6.02.01
Rev. 5
% (23) Install the fuel return hose to the injector fuel
leak rail.
% (24) Connect the vacuum hose at the engine driven
vacuum pump.
Restrictor is installed in the inlet pipe of
the pump.
% (25) Install the coolant radiator together with the
coolant tank.
Refer to Section 75-01.
% (26) Install the oil filler tube:
S Put the oil filler tube in position on the
engine.
S Install the 4 attaching bolts.
Torque: 10 - 12 Nm (7.4 - 8.9 lb.ft)
　
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