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exhaust gas leakage.
Refer to the DA 40 Airplane Flight
Manual.
(9) Examine the inside of the engine cowlings for
signs of exhaust gas leakage.
AIRCRAFT
DA 40 Series
AMM
Exhaust
Doc # 6.02.01
Rev. 5 78-00-00 Page 203
20 Sep 2007
3. Remove/Install an Exhaust Down-Pipe
A. Expendable Items
Item Quantity Part Number
Nut. 8 IPC
Gasket. 4 IPC
B. Remove an Exhaust Down-Pipe
Detail Steps/Work Items Key Items/References
% WARNING: MAKE SURE 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 71-10.
(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.
(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.
AIRCRAFT
Exhaust DA 40 Series
AMM
Page 204
20 Sep 2007 78-00-00 Doc # 6.02.01
Rev. 5
C. Install an Exhaust Down-Pipe
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 71-10.
(9) Do an engine run-up. Listen for sounds of
exhaust gas leakage.
Refer to the DA 40 Airplane Flight
Manual.
(10) Examine the inside of the engine cowlings for
signs of exhaust gas leakage.
AIRCRAFT
DA 40 Series
AMM
Exhaust
Doc # 6.02.01
Rev. 5 78-00-00 Page 205
20 Sep 2007
4. 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-outletpipe.
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.
AIRCRAFT
Exhaust DA 40 Series
AMM
Detail Steps/Work Items Key Items/References
Page 206
20 Sep 2007 78-00-00 Doc # 6.02.01
Rev. 5
(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.
AIRCRAFT
DA 40 Series
AMM
Exhaust
Doc # 6.02.01
Rev. 5 78-01-00 Page 1
20 Sep 2007
Section 78-01
Exhaust - TAE 125 Diesel Engine
1. General
The DA 40 with the TAE 125 Diesel engine has a simple 2-piece exhaust system. This Section tells
you only about the exhaust from the outlet of the turbo-charger. Refer to the engine manufacturer for
　
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