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Refer to Figure 2.
Torque to 1.6 Nm (1.2 ft.lb).
AIRCRAFT
DA 40 Series
AMM
Engine Controls
Detail Steps/Work Items Key Items
Doc # 6.02.01
Rev. 5 76-00-00 Page 205
20 Sep 2007
(5) Install the engine control assembly:
S Do a check for loose articles.
S Move the engine control assembly into
position in the center console.
S Loosely attach the knob for the throttle
friction adjuster.
S Install the four cross head screws which
attach the lower-cover-plate to the center
console.
S Install the two hex-headed bolts which
attach the upper-cover-plate to the center
console.
Specially in the center console.
Make sure all the control cables take up
the correct position.
(6) Install the knob on the fuel selector valve:
S Move the cover plate into position over
the selector valve.
S Push the selector knob onto the valve
shaft.
S Install the cross-head screw which
attaches the knob to the shaft.
(7) Put the Bowden cable through the bracket at
the bottom of the engine:
S Install the two nuts which hold the
Bowden cable to the bracket.
(8) Install the eye end to the Bowden cable at the
engine
Use a piece of lock-wire to make sure
that the eye-end has been installed
correctly.
AIRCRAFT
Engine Controls DA 40 Series
AMM
Detail Steps/Work Items Key Items
Page 206
20 Sep 2007 76-00-00 Doc # 6.02.01
Rev. 5
(9) Install the eye end to the injector throttle
lever:
S Put the bolt through the throttle lever form
the injector side.
S Install a washer on the bolt.
S Put the eye end on the bolt.
S Install a second washer on the bolt.
S Attach the nut to the bolt.
Tighten the assembly.
Torque 1.6 Nm (1.2 ft.lb).
(10) 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
feed-thru.
S Install 2 pop-rivets to attach the shields to
the firewall.
Use PR 812 (MIL-S-38249 Type 1) Fire
Wall Sealant.
(11) Do a test for correct range, full and free
movement of the throttle control system.
Refer to the Throttle Control Range of
Movement Test in this Section.
(12) Do an inspection of the control connections
which you disconnected. If necessary, for
your airworthiness authority, do a second
inspection of the controls.
(13) Do a check for loose items in the cockpit. For example: Tools. Look specially in
the area of the engine control assembly.
(14) Test all the engine control levers for freedom
of movement.
AIRCRAFT
DA 40 Series
AMM
Engine Controls
Detail Steps/Work Items Key Items
Doc # 6.02.01
Rev. 5 76-00-00 Page 207
20 Sep 2007
(15) Connect the spark plug cables to the spark
plugs.
Torque to 12.4 - 13.6 Nm (110 - 120
in.lb).
(16) Connect the airplane battery. Refer to Section 24-31.
(17) Install the engine cowlings. Refer to Section 71-10.
(16) Do an engine run-up. Refer to the DA 40 Airplane Flight
Manual
3. Remove/Install the Mixture Bowden Cable
A. Remove the Mixture Bowden 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) Disconnect the eye-end at the engine mixture
control lever in the engine bay:
S Remove the nut and washer from the long
bolt at the mixture lever.
S Remove the mixture Bowden cable eye end.
S Remove the spacer and the long bolt.
Refer to Figure 3.
AIRCRAFT
Engine Controls DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 208
20 Sep 2007 76-00-00 Doc # 6.02.01
Rev. 5
(6) Remove the eye end from the Bowden cable:
S Release the lock-nut.
S Remove the eye end fitting and the lock-nut
from the cable.
(7) Remove the Bowden cable from the support
bracket at the bottom of the engine:
　
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