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(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)  Install the rear flexible hose into position over the rear stub-pipe of the shroud and install the worm drive clamp. 
(5)  Install the front flexible hose over the front stub-pipe of the shroud and install the worm drive clamp. 
(6)  Install the engine cowlings.  Refer to Section 71-10. 
(7)  Do an engine run-up. Listen for sounds of exhaust gas leakage.  Refer to the DA 40 Airplane Flight Manual. 
(8)  Examine the inside of the engine cowlings for signs of exhaust gas leakage. 

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3. Remove/Install an Exhaust Down-Pipe
A. Expendable Items
Item  Quantity  Part Number 
Nut.  8  IPC 
Gasket.  4  IPC 

B. Remove an Exhaust Down-Pipe
Detail Steps/Work Items  Key Items/References 
WARNING: MAKE 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)  Remove the upper of the two expansion-joints: S Remove the four nuts, washers and bolts which hold the expansion-joint together. S Move the expansion joint halves clear of the airplane. 
(4)  Remove the exhaust gas temperature (EGT) probe. 
(5)  Remove the down-pipe: S Remove the two nuts and washers which attach the down-pipe to the cylinder head. S Move the down-pipe down and clear of the studs on the cylinder head. S Remove the gasket.  Discard the nuts. Discard the gasket. 

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C. Install an Exhaust Down-Pipe
DA 40 Series

Detail Steps/Work Items  Key Items/References 
(1)  Install a new gasket onto the cylinder head studs. 
(2)  Put the down-pipe into position on the cylinder head studs.  Make sure that the gasket is correctly positioned. 
(3)  Install the washers and the nuts which attach the down-pipe to the cylinder head.  Use new nuts! 
(4)  Tighten the nuts. 
(5)  Install the exhaust gas temperature (EGT) probe. 
(6)  Install the down-pipe to muffler expansion-joint: S Install a washer on the bolt. S Push the bolt through the joint halves. S Install a second washer on the bolt. S Install the nut. 
(7)  Tighten the four nuts. 
(8)  Install the engine cowlings.  Refer to Section 71-10. 
(9)  Do an engine run-up. Listen for sounds of exhaust gas leakage.  Refer to the DA 40 Airplane Flight Manual. 
(10)  Examine the inside of the engine cowlings for signs of exhaust gas leakage. 

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4. Inspect the Exhaust Muffler
WARNING:  YOU MUST DO A THOROUGH EXAMINATION OF THE EXHAUST MUFFLER. A DEFECTIVE MUFFLER WILL LET EXHAUST GASES INTO THE COCKPIT. THIS CAN CAUSE DEATH OR INJURY.
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Detail Steps/Work Items  Key Items/References 
(1)  Remove the exhaust muffler.  Refer to Paragraph 2.A. 
　
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