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Heat Exchanger
Hot Air Outlet
from Heat-Exchanger
Heat-Exchanger Shroud
Look for Soot Marks
Exhaust Outlet
Exhaust
Muffler
Inspect These
Welded Joints
Downpipe
Gasket
Expansion Joints
Inliner (not shown)
Support Bracket
(not on all S/N)
Muffler brace
(not on all S/N)
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Figure 1: Exhaust Manifold and Muffler
AIRCRAFT
DA 40 Series
AMM
Exhaust
Doc # 6.02.01
Rev. 5 78-00-00 Page 101
20 Sep 2007
Trouble-Shooting
1. General
The table below lists the defects you could have with the exhaust system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given
in the Repair column.
Trouble Possible Cause Repair
Exhaust gas fumes in the
cabin.
Muffler cracked under the
shroud.
Replace the muffler.
More noise than usual. Exhaust muffler/pipe cracked.
Internal damage to muffler.
Look for signs of exhaust gas
leaks. Replace damaged
gaskets. Repair or replace
cracked pipes.
Replace muffler.
AIRCRAFT
Exhaust DA 40 Series
AMM
Page 102
20 Sep 2007 78-00-00 Doc # 6.02.01
Rev. 5
Intentionally left blank
AIRCRAFT
DA 40 Series
AMM
Exhaust
Doc # 6.02.01
Rev. 5 78-00-00 Page 201
20 Sep 2007
Maintenance Practices
1. General
The maintenance practices for the exhaust system tell you how to remove/install the components of
the exhaust system. They also tell you how to do an inspection of the muffler.
WARNING: MAKE SURE THAT THE EXHAUST SYSTEM IS COOL BEFORE YOU
TOUCH IT. THE EXHAUST SYSTEM CAN BE VERY HOT, THIS CAN
CAUSE INJURY TO PERSONS.
2. Remove/Install the Exhaust Muffler
A. Remove the Exhaust Muffler
Detail Steps/Work Items Key Items/References
% WARNING: MAKE SURE THE ENGINE IS SAFE BEFORE YOU DO ANY WORK
ON THE EXHAUST SYSTEM. IF THE ENGINE STARTS THE
PROPELLER CAN CAUSE INJURY OR DEATH.
(1) Make sure that the engine is safe:
S The ignition switch is set to OFF.
S The ALT/BAT switch is set to OFF.
S The throttle is set to IDLE.
S The mixture control is set to LEAN CUT-OFF.
(2) Remove the engine cowlings. Refer to Section 71-10.
(3) Release the worm drive clamp that holds the
flexible hose to the front stub-pipe of the muffler.
Move the flexible hose clear of the muffler.
(4) Release the worm drive clamp that holds the
flexible hose to the rear stub-pipe of the muffler.
Move the flexible hose clear of the muffler.
(5) If installed disconnect the muffler brace from the
% support bracket by removing the 2 AN4 bolts.
%
(6) Remove the lower of the two expansion-joints:
S Remove the four nuts, washers and bolts
which hold the expansion-joint-halves.
S Move the expansion joint halves clear of the
airplane.
Do this step for each of the cylinders.
Hold the muffler!
AIRCRAFT
Exhaust DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 202
20 Sep 2007 78-00-00 Doc # 6.02.01
Rev. 5
% (7) If necessary, remove the second expansion-joint. For easier maintenance.
% (8) Lower the exhaust muffler clear of the airplane.
B. Install the Exhaust Muffler
Detail Steps/Work Items Key Items/References
(1) Examine the muffler. Make sure that:
S The muffler is not cracked.
S The shroud is located correctly.
S The muffler is clean.
(2) While holding the muffler in the correct position:
S Move the expansion joint halves into position.
S Install a washer on the bolt.
S Push the bolt through the joint halves.
S Install a second washer on the joint.
S Install the nut.
Use a second person.
Do these steps for each down-pipe.
(3) Make sure that all the expansion joints are
located correctly. Tighten the attachment bolts.
(4) If furnished connect the muffler brace to the
% support bracket by installing the 2 AN4 bolts.
%
% (5) Install the rear flexible hose into position over the
rear stub-pipe of the shroud and install the worm
drive clamp.
(6) Install the front flexible hose over the front stubpipe
of the shroud and install the worm drive
clamp.
(7) Install the engine cowlings. Refer to Section 71-10.
(8) Do an engine run-up. Listen for sounds of
　
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