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AMM
Page 202
20 Sep 2007 73-00-00 Doc # 6.02.01
Rev. 5
Air Filter
Worm-Drive
Clamp
Flexible Seal
Air Filter Housing
(Cut Away)
Fuel Injector
Alternate Air Inlets (6)
Usual Air Inlet
ALTERNATE AIR
VALVE ASSEMBLY
Figure 2: Air Filter Installation
AIRCRAFT
DA 40 Series
AMM
Engine Fuel and Control
Doc # 6.02.01
Rev. 5 73-00-00 Page 203
20 Sep 2007
B. Install the Engine 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 spark plug leads to the spark plugs. Torque: 12.4 - 13.6 Nm (110 - 120
in.lb).
(5) Connect the airplane battery. Refer to Section 24-31.
(6) Install the engine cowlings. Refer to Section 71-10.
(7) Do an engine run-up. Refer to the Airplane Flight Manual.
3. Remove/Install the Fuel Injector
A. Remove the Fuel Injector
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) Disconnect the spark plug cables from the spark
plugs.
AIRCRAFT
Engine Fuel and Control DA 40 Series
AMM
Page 204
20 Sep 2007 73-00-00 Doc # 6.02.01
Rev. 5
To Fuel Distributor
Fuel Supply
From Pump
RH SIDE
LH SIDE
Gasket
Idle
Stop Screw Idle Mixture
Adjustment
Mixture
Control
Throttle Control
Fuel Pressure
Sensor
Figure 3: Fuel Injector Installation
AIRCRAFT
DA 40 Series
AMM
Engine Fuel and Control
Doc # 6.02.01
Rev. 5 73-00-00 Page 205
20 Sep 2007
Detail Steps/Work Items Key Items/References
(5) Remove the air filter and the alternate air
assembly.
Refer to Section 71-60.
(6) Disconnect the throttle control:
S Remove the nut and washer from the throttle
lever.
S Pull the eye-end from the lever.
S Remove the second washer and bolt from the
lever.
Refer to Figure 3.
(7) Disconnect the mixture control:
S Remove the nut and washer from the mixture
lever.
S Pull the eye-end from the lever.
S Remove the spacer and the bolt from the
lever.
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO
NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN INJURE
PERSONS AND DAMAGE EQUIPMENT.
(8) Disconnect the fuel hose to the fuel distributor. Put a container to catch the fuel.
Put caps on the hose and the injector.
(9) Disconnect the fuel supply hose to the injector. Put a container to catch the fuel.
Put caps on the hose and the injector.
(10) Remove 4 nuts, serrated washers and plain
washers that attach the fuel injector to the
engine.
(11) Pull the injector forward off the studs and away
from the engine.
Discard the gasket.
Put caps on the injector and cover on
the engine intake.
AIRCRAFT
Engine Fuel and Control DA 40 Series
AMM
Page 206
20 Sep 2007 73-00-00 Doc # 6.02.01
Rev. 5
B. Install the Fuel Injector
Detail Steps/Work Items Key Items/References
WARNING: DO NOT GET FUEL ON YOU. FUEL CAN CAUSE SKIN DISEASE. DO
NOT ALLOW FIRE NEAR FUEL. FUEL BURNS AND CAN INJURE
PERSONS AND DAMAGE EQUIPMENT.
(1) Prepare the new injector:
S Remove the caps from the inlet and outlet
connections of the new injector.
S Clean the inlet fuel strainer.
S Flush the injector with clean fuel until clean
fuel flows from the outlets.
Use a syringe. Do not use more than 1
bar (15 psi) pressure.
(2) Remove the cover from the engine air intake and
the caps from the injector.
(3) Put the injector in position on the engine sump. Refer to Figure 3. Use a new gasket.
(4) Install the 4 plain washers, serrated washers and
nuts that attach the injector.
Torque 23 Nm (17 ft.lb).
(5) Connect the fuel hose to the fuel distributor.
(6) Connect the fuel supply hose to the fuel injector.
　
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