Doc # 6.02.01 Page 247
71-02-00
DA 40 Series AMM
DA 40 F

11. Engine Break-In
You must do this procedure after a new engine has been installed. Refer to Lycoming Service Instruction No. 1427, latest issue.
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Detail Steps/Work Items  Key Items/References 
(1)  Do a careful pre-flight inspection.  Refer to Airplane Flight Manual. 
(2)  Do a normal take-off. S Mixture control lever .............. RICH S Throttle .................... MAX PWR  Reduce to 2400 RPM as soon as possible. 
CAUTION: CLIMB WITH A SMALL CLIMB ANGLE TO AVOID ENGINE OVER-HEATING. 
(3)  Climb to an altitude which is suitable for cruise.  Stay below 5000 ft. 
CAUTION: AVOID LOW MANIFOLD PRESSURE DURING HIGH ENGINE SPEEDS. 
(4)  Cruise for 2 hours and 30 minutes. S Cruise at 75 % power during the first hour. S Change power setting a few times between 65 % and 75 % during the second hour. S Cruise with 2400 RPM and full throttle during the last 30 minutes. 
CAUTION: DESCEND AT A MODERATE RATE AND LOW CRUISE POWER SETTINGS. 
(5)  Descend and land.  Refer to Airplane Flight Manual. 

DA 40 F

The title of Section 71-10 is amended to read:
Section 71-10 % Engine Cowlings - Lycoming IO-360-M1A Engine
DA 40 Series AMM
DA 40 F

Intentionally left blank
DA 40 F

Section 71-12
Engine Cowlings - Lycoming O-360-A4M Engine

1. General
The DA 40 F has two glass fiber reinforced plastic (GFRP) panels which make the engine cowlings. A top cowling and a bottom cowling. GFRP is very strong and is easy to maintain. The cowlings give a good aerodynamic shape to the nose of the airplane. They are very easy to remove and give good access to the engine.
Refer to Section 51-20 for repair data for the cowlings. Refer to Section 51-60 for data on the quick-release fasteners.
2. Description
Figure 1 shows the cowlings.
Quick-release fasteners attach the cowlings to each other and to the fuselage. Both the cowlings are very light and one person can hold them easily.
The top cowling has two small access panels for the engine oil filler and dipstick. The access panels attach to the top cowling with hinges.
The bottom cowling has the air intakes. The left intake gives cooling air for the engine. The right intake supplies air for the engine, the oil cooler, cabin heating, battery cooling and alternator cooling. The cowling has an air intake at the bottom-center for the carburetor.
Doc # 6.02.01 Page 1
71-12-00
DA 40 Series AMM
DA 40 F AIRCRAFT
Figure 1: Engine Cowlings
DA 40 F

Trouble-Shooting
1. General
The table below lists the defects you could have with the engine cowlings. If you have the trouble detailed in the Trouble column read across to the Possible Cause column. Then do the repair in the Repair column.
 Trouble  Possible Cause  Repair 
Outer surface of the cowling discoloured. Paint blistered. Black soot on the inner surface.  Engine overheating. Hot gas leak. Engine fire.  Examine the engine for hot gas leaks. Examine the exhaust for cracks and leaking gaskets. Replaced damage items. Repaint the cowlings. 
Oil/fuel on the inner surface of the cowling.  Oil/fuel leak.  Examine the engine. Look specially for oil/fuel leaks. Correct problems which you have found. Clean the cowling. 

Doc # 6.02.01 Page 101
71-12-00
DA 40 Series AMM
DA 40 F

Intentionally left blank
DA 40 F

Maintenance Practices
1. General
This section contains the maintenance practices for the cowlings. It tells you how to remove/install the cowlings. It also tells you how to clean and paint the cowlings.
　
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