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(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. 

76-00-00
Engine Controls
AMM

Detail Steps/Work Items  Key Items 
(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 CUT-OFF 
(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. 

Doc # 6.02.01 Page 207
Rev. 4 09 Jan 2003

76-00-00
AMM

DA 40 Series

Detail Steps/Work Items  Key Items/References 
(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: S Remove the bottom adjustment nut from the Bowden cable. S Move the Bowden cable clear of the bracket. S Remove the top adjustment nut from the Bowden cable.  Make a note of the cable adjustment! 
(8)  Pull the Bowden cable through the grommets in the front and back air baffles. 
(9)  Cut the cable binders which hold the cable to the engine mount. 
(10)  Remove the spiral wrap which protects the cable aft of the engine. 
(11)  Remove the feed-thru from the engine side of the firewall: S Remove the fire resistant sealant from where the cable goes through the firewall. S Remove the two rivets that attach the split shields to the firewall. S Remove the split-shields. S Move the two halves of the split-bush forward and clear of the cable. 
(12)  Remove the knob from the fuel selector valve: S Remove the cross-head screw from the center of the control-knob and pull the knob up and off the fuel selector valve. S Remove the mounting plate. 
　
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