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head with six screws and a cork gasket makes an oil-tight seal.
AIRCRAFT
Engine DA 40 Series
AMM
Page 4
20 Sep 2007 72-00-00 Doc # 6.02.01
Rev. 5
G. Accessory Housing
The rear accessory housing attaches to the rear of the crankcase. The rear part of the crankcase
holds the gears which turn the accessories. The crankshaft has a gear on the rear end.
The crankshaft gear turns two idler gears. The left idler gear turns the camshaft gear and it turns
a gear which attaches to the left magneto. The right idler gear turns the right magneto.
The accessory housing closes the rear of the crankcase. Bolts attach the accessory housing to the
crankcase. The accessory housing has mounting pads for the magnetos.
The accessory housing holds the engine lubricating oil pump. The oil pump, is on the inside of the
housing and an internal oil gallery connects the inlet of the oil pump to the sump. A shaft from the
rear of the crankshaft turns the oil pump.
AIRCRAFT
DA 40 Series
AMM
Engine
Doc # 6.02.01
Rev. 5 72-00-00 Page 201
20 Sep 2007
Maintenance Practices
1. General
The maintenance practices given in this Section are limited to the compression testing of the cylinders.
For more data on the engine you must refer to the Lycoming Maintenance Manual and the Lycoming
Overhaul Manual.
2. Cylinder Compression Test
Do this test with the engine warm, but not hot.
A. Equipment
Item Quantity Part Number
Differential compression test kit. 1 Commercial.
Dry air pressure supply. Minimum pressure 5.5 bar (80
psi).
B. Compression Test
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
TURN THE PROPELLER. MAKE SURE THAT THE IGNITION SWITCH
IS SET TO “OFF” AND THAT THE SPARK-PLUG-CABLES ARE
DISCONNECTED FROM THE SPARK PLUGS. SET THE THROTTLE
TO “IDLE” AND THE MIXTURE CONTROL TO “LEAN CUT-OFF”.
(1) Set the fuel selector/shut-off valve to CLOSED.
(2) Make sure that the engine is safe:
S The ignition switch is set to OFF.
S The throttle is set to IDLE.
S The mixture control is set to LEAN CUT-OFF.
AIRCRAFT
Engine DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 202
20 Sep 2007 72-00-00 Doc # 6.02.01
Rev. 5
(3) Remove the engine cowlings. Refer to Section 71-10.
(4) Disconnect the battery. Refer to Section 24-31.
(5) Disconnect the spark plug cables from the spark
plugs.
(6) Remove one spark plug from each cylinder.
(7) Turn the propeller four complete turns by hand in
the usual direction the propeller turns.
(8) Connect the hose of the differential-pressuretester
(DPT) to the number 1 cylinder spark plug
hole.
(9) Turn the propeller by hand to set number 1
cylinder piston to top-dead-center (TDC) on the
compression stroke.
Feel the open end of the DPT hose.
The pressure in the hose will increase
to a maximum when the piston is at
TDC.
(10) Turn the DPT reducing valve fully counterclockwise
(closed).
(11) Connect the air supply to the DPT. Make sure that both gauges read zero.
WARNING: YOU MUST HOLD THE PROPELLER FIRMLY. WHEN YOU SUPPLY
AIR TO THE CYLINDER THE PROPELLER WILL WANT TO TURN. IF
THE PROPELLER TURNS IT CAN CAUSE INJURY TO PERSONS.
(12) Hold the propeller firmly. Use a second person.
(13) Connect the DPT to the tester hose (which is
connected to the cylinder to be tested).
(14) Turn the knob of the DPT reducing valve slowly
clock-wise until the input gauge reads 5.5 bar (80
psi).
The person holding the propeller must
be ready to resist the propeller turning.
If the force necessary to resist the
turning of the propeller is high then the
cylinder may not be at TDC. Gently rock
the propeller backwards and forwards
until the turning force is at a minimum.
Monitor the gauge readings.
(15) Read the DPT outlet gauge and make a note of
the value.
(16) Turn the knob of the DPT reducing valve fully
counter-clockwise (closed).
Make sure that both gauges read zero.
AIRCRAFT
DA 40 Series
AMM
Engine
Detail Steps/Work Items Key Items/References
Doc # 6.02.01
Rev. 5 72-00-00 Page 203
20 Sep 2007
(17) Disconnect the DPT from the tester hose and
remove the tester hose from the cylinder.
(18) Repeat items 8 to 17 for the other cylinders.
(19) Install the spark plugs. Torque 47 Nm (35 ft.lb).
　
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