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2. Change the Engine Oil and Replace the Engine Oil Filter . . . . . . 201
3. Change the Gearbox Oil and Replace the Gearbox Oil Filter . . . . 203
4. Read the Engine Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
AIRCRAFT
Engine DA 40 Series
AMM
Page 2
20 Sep 2007 72-CONTENTS Doc # 6.02.01
Rev. 5
Intentionally left blank
AIRCRAFT
DA 40 Series
AMM
Engine
Doc # 6.02.01
Rev. 5 72-00-00 Page 1
20 Sep 2007
CHAPTER 72
ENGINE
Section 72-00
Lycoming Engine
1. General
This Section tells you about the Lycoming IO-360-M1A engine installed in the DA 40. It tells you about
the engine for background only. The data given in this Section will not be amended and you must
always refer to the Lycoming manuals for data about the engine.
2. Description
A. Crankcase
The IO-360-M1A is a four cylinder, horizontally opposed, direct drive engine. The engine has an
aluminum alloy crankcase. The crankcase is in two halves, a left half and a right half. Bolts, studs
nuts and washers attach the left half to the right half.
The oil sump bolts to the bottom of the crankcase. The fuel injector is attaches to a pad at the front
of the sump with fours studs, washers and nuts. The first part of the induction manifold is integral
with the sump.
The crankcase has the bearings for the crankshaft and the camshaft. The top of the crankcase has
the mounting pads for the cylinders. The rear of the crankcase has the mounting for the
accessories and the accessory housing.
B. Crankshaft
The I0-360-M1A engine has a hollow crankshaft with four main bearings. The crankshaft has four
big-end bearings for the connecting rods. The front of the crankshaft has a drive flange for the
propeller and flywheel.
The drive flange has six bolt holes. The bolt holes have special bushes. The bushes have a screw
thread on the inside for the propeller bolts. Four of the bushes are long and two of the bushes are
shorter. One of the shorter bushes is marked with an “o”, this is the index bush.
C. Camshaft
The one-piece camshaft is mounted in the crankcase. The camshaft is driven by a gear on the rear
of the crankshaft. Another gear at the front of the camshaft drives the propeller governor gear-train.
The camshaft has eccentric lobes which operate the push-rods for the valve-operating-gear.
AIRCRAFT
Engine DA 40 Series
AMM
Page 2
20 Sep 2007 72-00-00 Doc # 6.02.01
Rev. 5
Oil Sump
Fuel Injector
Flywheel
Crankcase
Left Half
Crankcase
Right Half
Cylinder 1
Cylinder 3
Cylinder 4
Cylinder 2
Rocker Cover
Figure 1: Engine Assembly
AIRCRAFT
DA 40 Series
AMM
Engine
Doc # 6.02.01
Rev. 5 72-00-00 Page 3
20 Sep 2007
D. Connecting Rods
The engine has the usual connecting rods. The “big-end” of the connecting rod attaches to the
crankshaft journal and the “small-end” attaches to the piston.
Each rod has a split big-end bearing and it has a bearing cap. Two special bolts attach the bearingcap
to the connecting rod. The small-end has a plain bearing which is a sliding fit with the piston
gudgeon-pin.
E. Flywheel
The flywheel attaches to the front of the crankshaft. The drive bushes hold the flywheel in place and
a central spigot on the drive flange aligns the flywheel.
The flywheel has two Vee grooves machined in it. One Vee groove on the rear of flywheel moves
a flexible belt for the generator.
The outside of the flywheel has the starter-ring -gear attached. A pinion gear on the electric starter
turns the flywheel with the starter-ring-gear when the starter is operated.
F. Cylinder Assembly
The engine has four individual cylinders. The head of the cylinder is aluminum alloy and the barrel
of the cylinder is steel. The cylinder heads is screwed onto the cylinder during production and
cannot be removed.
The base of the cylinder has a flange which is used to attach the cylinder to the crankcase. A spigot
below the flange aligns the cylinder in the crankcase. Studs, nuts and washers attach the cylinder
to the crankcase. An O-ring seal makes an oil-tight seal between the base of the cylinder and the
crankcase.
The intake and exhaust flanges are machined into the lower side of the cylinder head. The cylinder
head has an upper and a lower hole for the spark plugs. The outboard end of the cylinder head has
the intake and exhaust valves. It also has a housing for the valve operating gear.
The valve housing (rocker box) is closed with a cover plate. The cover plate attaches to the cylinder
　
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