DA 40 Series AMM
DA 40 F
Detail Steps/Work Items Key Items/References
(7) Release the alternate air control Bowden cable from the alternate air control lever in the cockpit: S Release the screw in the swivel fitting and pull the Bowden cable wire end out from the swivel fitting. S Remove the front adjusting nut from the Bowden cable outer sheath at the control lever bracket. S Pull the Bowden cable clear from the control lever bracket. Refer to Figure 2.
(8) Pull the alternate air cable through the firewall from the engine bay side and clear of the airplane.
B. Install the Alternate Air Control Cable
Detail Steps/Work Items Key Items/References
(1) Put the alternate air cable through the firewall.
(2) Put the Bowden cable through the support bracket at the alternate air valve assembly. Refer to Figure 1.
(3) Install the retaining nut on the Bowden cable outer sheath.
(4) Put the Bowden cable wire end through the swivel fitting in the alternate air valve and tighten the swivel fitting screw.
(5) Put the Bowden cable through the support bracket at the alternate air control lever in the cockpit. Refer to Figure 2.
(6) Install the front adjusting nut to the Bowden cable outer sheath.
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DA 40 Series AMM
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DA 40 F
Detail Steps/Work Items Key Items/References
(7) Put the Bowden cable wire end through the swivel fitting on the lever and tighten the swivel fitting screw.
(8) 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.
(9) Do a test for correct range, full and free movement of the alternate air control system. Refer to the Alternate Air Valve Control Range of Movement Test in this Section.
(10) Do an inspection of the control connections which you disconnected. If necessary, for your airworthiness authority, do a second inspection of the controls.
(11) Connect the spark plug cables to the spark plugs. Torque to 12.4 - 13.6 Nm (110 - 120 in.lb).
(12) Connect the airplane battery. Refer to Section 24-31.
(13) Install the engine cowlings. Refer to Section 71-12.
(14) Do an engine run-up. Refer to the DA 40F Airplane Flight Manual.
DA 40 Series AMM
5. Test/Adjust the Alternate Air Control Cable
DA 40 F
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) Move the alternate air control lever from OFF to ON: S Make sure the lever moves freely with no restrictions.
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