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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 71-12. 
(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. 

DA 40 Series AMM

DA 40 F

Detail Steps/Work Items  Key Items/References 
(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. 

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 71-12. 
(9)  Do an engine run-up. Listen for sounds of exhaust gas leakage.  Refer to the DA 40 F Airplane Flight Manual. 
(10)  Examine the inside of the engine cowlings for signs of exhaust gas leakage. 

DA 40 Series AMM
DA 40 F

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D. 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.
Detail Steps/Work Items  Key Items/References 
(1)  Remove the exhaust muffler.  Refer to Paragraph 2.A. 
(2)  Remove the muffler shroud: S Remove the screws which hold the shroud. S Carefully pull the shroud apart at the joint and move the shroud down the muffler-outlet-pipe. S Move the shroud clear of the muffler. S Carefully remove the inliner. 
(3)  Look carefully at the shroud and the inliner. Look specially at the inside for signs of gas leakage from the muffler.  Use a bright light and use a magnifying glass. 
(4)  Look carefully at the muffler assembly. Look specially for: S Cracks in the welds, specially around the joints. S Cracks in the muffler skin. S Damage to surface of the muffler. S Corrosion.  Use a bright light and use a magnifying glass. NO CRACKS ARE PERMITTED ANYWHERE ON THE MUFFLER. 
(5)  If you find a crack you must replace the muffler. 

DA 40 Series AMM

DA 40 F

Detail Steps/Work Items  Key Items/References 
(6)  Install the shroud on the muffler: S Put the inliner onto the muffler. S Move the shroud over the muffler-outlet-pipe. S Gently pull the shroud apart and over the muffler. S Install the screws which hold the shroud ends together.  Make sure that the shroud is positioned correctly. 
(7)  Install the muffler on the airplane.  Refer to Paragraph 2.B. 

DA 40 Series AMM
DA 40 F

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DA 40 F

TABLE OF CONTENTS
CHAPTER 79 OIL SYSTEM
　
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