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filter to air filter housing.
(6) Pull the air filter forward and clear of the air filter
housing.
(7) Release the alternate air control Bowden cable
from the alternate air valve assembly:
S Loosen the swivel fitting at the alternate air
valve body.
S Pull the Bowden cable wire end clear of the
swivel fitting.
S Remove and keep the swivel fitting.
S Remove the retaining nut which holds the
Bowden cable outer sheath in the support
bracket at the alternate air valve spacer.
S Move the Bowden cable clear of the alternate
air valve.
(8) Remove the air filter housing and the alternate air
valve:
S Remove the 4 bolts which attach the air filter
housing to the alternate air valve assembly.
S Move the air filter housing and the alternate
air valve assembly clear of the airplane.
Support the air filter housing and the
alternate air valve assembly.
Remove and keep the spacers as you
remove the bolts.
AIRCRAFT
Power Plant DA 40 Series
AMM
Page 204
20 Sep 2007 71-60-00 Doc # 6.02.01
Rev. 5
B. Install the Alternate Air Valve
Detail Steps/Work Items Key Items/References
(1) Install the air filter housing onto the alternate air
valve:
S Install 4 new lock-washers onto the attaching
bolts.
S Install the 4 bolts into air filter housing.
S Install the spacers onto the 4 attaching bolts.
S Put the air filter assembly in position on the
alternate air valve.
Make sure that the spacer with the
support bracket for the Bowden cable is
correctly positioned
Make sure that the bolts pass through
the flange on the alternate air valve.
(2) Move the air filter housing and alternate air valve
assembly into position on the airplane so that the
attaching bolts align with the threaded holes in
the fuel injector.
(3) Tighten the 4 attaching bolts.
(4) Install the alternate air Bowden cable:
S Install the swivel onto the alternate air valve
body.
S Move the Bowden cable outer sheath into
position in the support bracket at the alternate
air valve.
S Install the retaining nut which holds the
Bowden cable outer sheath in the support
bracket.
S Push the Bowden cable wire end through the
swivel fitting.
S Tighten the swivel fitting.
AIRCRAFT
DA 40 Series
AMM
Power Plant
Detail Steps/Work Items Key Items/References
Doc # 6.02.01
Rev. 5 71-60-00 Page 205
20 Sep 2007
(5) Install the air filter:
S Put the worm-drive clamp into position on the
air filter.
S Put the air filter in position on the air filter
housing.
S Tighten the worm-drive clamp.
(6) Do a test for correct range, full and free
movement of the alternate air valve control
system.
Refer to the Alternate Air Valve Control
System Range of Movement Test in this
Section.
(7) Do an inspection of the control connections which
you disconnected. If necessary, for your
airworthiness authority, do a second inspection of
the controls.
(8) Connect the spark plug leads to the spark plugs. Torque to 12.4 to 13.6 Nm (110 - 120
in.lb).
(9) Connect the airplane battery. Refer to Section 24-31.
(10) Install the engine cowlings. Refer to Section 71-10.
(11) Do an engine run-up. Refer to the DA 40 Airplane Flight
Manual.
4. Remove/Install the Alternate Air Valve Control Cable
A. Remove the Alternate Air Control Cable
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.
AIRCRAFT
Power Plant DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 206
20 Sep 2007 71-60-00 Doc # 6.02.01
Rev. 5
(1) Make sure that the engine is safe:
S Set the ignition switch to OFF.
S Set the throttle control to IDLE.
S Set the mixture control lever to LEAN CUTOFF.
(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.
(5) Release the alternate air control Bowden cable
from the alternate air valve assembly:
S Loosen the swivel fitting at the alternate air
valve body.
S Pull the Bowden cable wire end clear of the
swivel fitting.
S Remove and keep the swivel fitting.
S Remove the retaining nut which holds the
　
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