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cable rotates the valve body to align the holes in the valve body with the holes in the flanged housing.
Warm air from the engine bay will now flow through the alternate air valve into the fuel injector.
The alternate air valve can be selected to the alternate air position to supply warm air for anti-icing or
to maintain the air supply should the air filter become blocked. The alternate air supply is not filtered.
AIRCRAFT
Power Plant DA 40 Series
AMM
Page 4
20 Sep 2007 71-60-00 Doc # 6.02.01
Rev. 5
Left Inner Wall of
Floor Panel
Pivot
Bush
Lever
Swivel Fitting
Alternate Air Cable
Adjusting Nuts
Stop Bush
Cold Air
Alternate Air
Figure 2: Alternate Air Control
AIRCRAFT
DA 40 Series
AMM
Power Plant
Doc # 6.02.01
Rev. 5 71-60-00 Page 101
20 Sep 2007
Trouble-Shooting
1. General
The table below lists the defects you could have with the air intake system. If you have the trouble
detailed in the Trouble column read across to the Possible Cause column. Then do the repair given in
the Repair column.
Trouble Possible Cause Repair
Engine does not develop full
power.
Air filter blocked/defective.
Alternate air valve not closed.
Alternate air control incorrectly
set.
Alternate air control cable
broken.
Replace air filter.
Set alternate air control to OFF.
Do a test of the alternate air
control adjustment. Adjust the
alternate air control.
Replace alternate air control
cable.
AIRCRAFT
Power Plant DA 40 Series
AMM
Page 102
20 Sep 2007 71-60-00 Doc # 6.02.01
Rev. 5
Intentionally left blank
AIRCRAFT
DA 40 Series
AMM
Power Plant
Doc # 6.02.01
Rev. 5 71-60-00 Page 201
20 Sep 2007
Maintenance Practices
1. General
These maintenance practices tell you how to remove and install the air filter and the alternate air valve
assembly. They also tell you how to adjust, remove and install the alternate air control cable.
They do not tell you how to adjust the engine fuel injector.
Refer to the Lycoming Maintenance Manual for the data on the fuel injector.
2. Remove/Install the Air Filter
A. Remove the Air Filter
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 CUTOFF.
(2) Remove the engine cowlings. Refer to Section 71-10.
(3) Disconnect the airplane battery. Refer to Section 24-31.
(4) Loosen the worm-drive clamp that holds the air
filter to air filter housing.
(5) Pull the air filter forward and clear of the air filter
housing.
AIRCRAFT
Power Plant DA 40 Series
AMM
Page 202
20 Sep 2007 71-60-00 Doc # 6.02.01
Rev. 5
B. Install the Air Filter
Detail Steps/Work Items Key Items/References
(1) Make sure that the worm-drive clamp is in
position on the air filter.
(2) Put the air filter in position on the air filter
housing.
(3) Tighten the worm-drive clamp which holds the air
filter.
(4) Connect the airplane battery. Refer to Section 24-31.
(5) Install the engine cowlings. Refer to Section 71-10.
(6) Do an engine run-up. Refer to the DA 40 Airplane Flight
Manual.
3. Remove/Install the Alternate Air Valve
A. Remove the Alternate Air Valve
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 CUTOFF.
(2) Remove the engine cowlings. Refer to Section 71-10.
(3) Disconnect the airplane battery. Refer to Section 24-31.
AIRCRAFT
DA 40 Series
AMM
Power Plant
Detail Steps/Work Items Key Items/References
Doc # 6.02.01
Rev. 5 71-60-00 Page 203
20 Sep 2007
(4) Disconnect the spark plug cables from the spark
plugs.
(5) Loosen the worm-drive clamp that holds the air
　
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