Doc # 6.02.01 Page 203
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DA 40 Series AMM
B. Install the Alternate Air Valve
DA 40 F
Detail Steps/Work Items Key Items/References
(1) Move the alternate air valve assembly into position on the airplane so that the attaching bolts align with the holes in the carburetor.
(2) Tighten the 4 attaching bolts.
(3) Install the alternate air Bowden cable: S Install the swivel onto the alternate air valve body. S Move the Bowden cable outer sheath into position in the support bracket at the alternate air valve. S Install the retaining nut which holds the Bowden cable outer sheath in the support bracket. S Push the Bowden cable wire end through the swivel fitting. S Tighten the swivel fitting.
(4) Attach the alternate air hose to the alternate air valve housing and tighten the worm-drive clamp.
(5) Do a test for correct range, full and free movement of the alternate air valve control system. Refer to the Alternate Air Valve Control System Range of Movement Test in this Section.
(6) Do an inspection of the control connections which you disconnected. If necessary for your airworthiness authority do a second inspection of the controls.
(7) Move the front baffle into position on the airplane so that the holes align with the holes on the on the engine and the alternate air valve assembly.
(8) Mount the front baffle to the engine.
DA 40 Series AMM
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DA 40 F
Detail Steps/Work Items Key Items/References
(9) Attach the cooling hoses and tighten the worm-drive clamps: S the oil cooler hose S two alternator cooling hoses
(10) Put the air filter in position on the front baffle.
(11) Align the holes of the air filter and the front baffle.
(12) Tighten the 4 bolts which attach the air filter and the front baffle to the alternate air valve.
(13) Connect the spark plug leads to the spark plugs. Torque to 12.4 to 13.6 Nm (110 - 120 in.lb).
(14) Connect the airplane battery. Refer to Section 24-31.
(15) Install the engine cowlings. Refer to Section 71-12.
(16) Do an engine run-up. Refer to DA 40 F Airplane Flight Manual.
4. Remove/Install the Alternate Air Valve Control Cable
A. Remove the Alternate Air Control 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 to IDLE. S Set the mixture control lever to LEAN CUT-OFF.
Doc # 6.02.01 Page 205
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DA 40 Series AMM
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DA 40 F
Detail Steps/Work Items Key Items/References
(2) Remove the engine cowlings. Refer to Section 71-12.
(3) Disconnect the airplane battery. Refer to Section 24-31.
(4) Disconnect the spark plug cables from the spark plugs.
(5) Release the alternate air control Bowden cable from the alternate air valve assembly: S Loosen the swivel fitting at the alternate air valve body. S Pull the Bowden cable wire end clear of the swivel fitting. S Remove and keep the swivel fitting. S Remove the retaining nut which holds the Bowden cable outer sheath in the support bracket at the alternate air valve spacer. S Move the Bowden cable clear of the alternate air valve. Refer to Figure 1.
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