B. Install the Engine Air Filter
Detail Steps/Work Items  Key Items/References 
(1)  Make sure that the worm drive clamp is in position on the air filter. 
(2)  Put the air filter in position on the air filter housing. 
(3)  Tighten the worm drive clamp which holds the air filter. 
(4)  Connect the spark plug leads to the spark plugs.  Torque: 12.4 - 13.6 Nm (110 - 120 in.lb). 
(5)  Connect the airplane battery.  Refer to Section 24-31. 
(6)  Install the engine cowlings.  Refer to Section 71-10. 
(7)  Do an engine run-up.  Refer to the Airplane Flight Manual. 

3. Remove/Install the Fuel Injector
A. Remove the Fuel Injector
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 to IDLE. S Set the mixture control lever to LEAN CUT-OFF. 
(2)  Remove the engine cowlings.  Refer to Section 71-10. 
(3)  Disconnect the airplane battery.  Refer to Section 24-31. 
(4)  Disconnect the spark plug cables from the spark plugs. 

Doc # 6.02.01 Page 203
Rev. 4 09 Jan 2003

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AIRCRAFT AMM
To Fuel Distributor Fuel Pressure Sensor  Gasket  Mixture Control 
Fuel Supply From Pump 
Throttle Control  LH SIDE 
Idle Stop Screw  RH SIDE Idle Mixture Adjustment Figure 3: Fuel Injector Installation 

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Engine Fuel and Control
AMM

DA 40 Series

Detail Steps/Work Items  Key Items/References 
(5)  Remove the air filter and the alternate air assembly.  Refer to Section 71-60. 
(6)  Disconnect the throttle control: S Remove the nut and washer from the throttle lever. S Pull the eye-end from the lever. S Remove the second washer and bolt from the lever.  Refer to Figure 3. 
(7)  Disconnect the mixture control: S Remove the nut and washer from the mixture lever. S Pull the eye-end from the lever. S Remove the spacer and the bolt from the lever. 
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN INJURE PERSONS AND DAMAGE EQUIPMENT. 
(8)  Disconnect the fuel hose to the fuel distributor.  Put a container to catch the fuel. Put caps on the hose and the injector. 
(9)  Disconnect the fuel supply hose to the injector.  Put a container to catch the fuel. Put caps on the hose and the injector. 
(10)  Remove 4 nuts, serrated washers and plain washers that attach the fuel injector to the engine. 
(11)  Pull the injector forward off the studs and away from the engine.  Discard the gasket. Put caps on the injector and cover on the engine intake. 

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AMM

B. Install the Fuel Injector
DA 40 Series

Detail Steps/Work Items  Key Items/References 
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN INJURE PERSONS AND DAMAGE EQUIPMENT. 
(1)  Prepare the new injector: S Remove the caps from the inlet and outlet connections of the new injector. S Clean the inlet fuel strainer. S Flush the injector with clean fuel until clean fuel flows from the outlets.  Use a syringe. Do not use more than 1 bar (15 psi) pressure. 
(2)  Remove the cover from the engine air intake and the caps from the injector. 
　
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