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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.
Refer to Figure 1.
(6) Remove the firewall feed-thru from the engine
side of the firewall:
S Remove the fire wall sealant from the feedthru.
S Drill out the two rivets which hold the shields
to the firewall.
S Remove the shields.
S Pull the 2 parts of the feed-thru clear of the
firewall.
AIRCRAFT
DA 40 Series
AMM
Power Plant
Detail Steps/Work Items Key Items/References
Doc # 6.02.01
Rev. 5 71-60-00 Page 207
20 Sep 2007
(7) Release the alternate air control Bowden cable
from the alternate air control lever in the cockpit:
S Release the screw in the swivel fitting and
pull the Bowden cable wire end out from the
swivel fitting.
S Remove the front adjusting nut from the
Bowden cable outer sheath at the control
lever bracket.
S Pull the Bowden cable clear from the control
lever bracket.
Refer to Figure 2.
(8) Pull the alternate air cable through the firewall
from the engine bay side and clear of the
airplane.
B. Install the Alternate Air Control Cable
Detail Steps/Work Items Key Items/References
(1) Put the alternate air cable through the firewall.
(2) Put the Bowden cable through the support
bracket at the alternate air valve assembly.
Refer to Figure 1.
(3) Install the retaining nut on the Bowden cable
outer sheath.
(4) Put the Bowden cable wire end through the
swivel fitting in the alternate air valve and tighten
the swivel fitting screw.
(5) Put the Bowden cable through the support
bracket at the alternate air control lever in the
cockpit.
Refer to Figure 2.
AIRCRAFT
Power Plant DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 208
20 Sep 2007 71-60-00 Doc # 6.02.01
Rev. 5
(6) Install the front adjusting nut to the Bowden cable
outer sheath.
(7) Put the Bowden cable wire end through the
swivel fitting on the lever and tighten the swivel
fitting screw.
(8) Install the feed-thru to the engine side of the
firewall with firewall sealant:
S Put the 2 parts of the feed-thru round the
bowden cable.
S Push the feed-thru in the firewall.
S Put the 2 shields in position over the feedthru.
S Install 2 pop-rivets to attach the shields to the
firewall.
Use PR 812 (MIL-S-38249 Type 1) Fire
Wall Sealant.
(9) Do a test for correct range, full and free
movement of the alternate air control system.
Refer to the Alternate Air Valve Control
Range of Movement Test in this Section.
(10) Do an inspection of the control connections which
you disconnected. If necessary, for your
airworthiness authority, do a second inspection of
the controls.
(11) Connect the spark plug cables to the spark plugs. Torque to 12.4 - 13.6 Nm (110 - 120
in.lb).
(12) Connect the airplane battery. Refer to Section 24-31.
(13) Install the engine cowlings. Refer to Section 71-10.
(14) Do an engine run-up. Refer to the DA 40 Airplane Flight
Manual.
AIRCRAFT
DA 40 Series
AMM
Power Plant
Doc # 6.02.01
Rev. 5 71-60-00 Page 209
20 Sep 2007
5. Test/Adjust 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.
(1) Make sure that the engine is safe:
S Set the ignition switch to OFF.
S Set the throttle control lever to IDLE.
S Set the mixture control lever to LEAN CUTOFF
(2) Remove the engine cowlings. Refer to Section 71-10.
(3) Disconnect the battery. Refer to Section 24-31.
(4) Disconnect the spark plug cables from the spark
plugs.
(5) Move the alternate air control lever from OFF to
ON:
S Make sure the lever moves freely with no
restrictions.
(6) Set the alternate air control lever in the cockpit to
OFF and hold it in position:
S Make sure that the alternate air valve is fully
closed and that the swivel fitting contacts the
end of the cut-out in the alternate air flanged
housing.
With the alternate air valve fully closed
there must be at least 3 mm (0.125 in)
clearance (bounce) between the
alternate air control lever and the stop
bush. Figure 2.
(7) Set the alternate air control lever in the cockpit to
　
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