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data about the engine exhaust manifold and turbo-charger.
2. Description
Figure 1 shows the exhaust installation. The exhaust system has two large-diameter tubes connected
by a spherical joint. A large flange attaches the front tube to the front of the turbo-charger. The tube
goes round the engine mounting frame to the spherical joint below the engine. A bracket from the tube
% braces it to the bottom of the engine. This bracket has been removed with design change
% MÄM 40-138.
The front tube has the ball part of a spherical coupling welded to the end. The rear tube has the female
fitting of the coupling welded to the end. Flanges with 3 lugs are welded to each tube adjacent to the
spherical end fittings. Three strong springs attach to the lugs of the flanges to hold the coupling
together.
The rear tube has 2 hooks that engage with rubber mountings. The top of the rubber mountings
engage with 2 hooks welded to the engine mounting frame.
The system has no muffler.
AIRCRAFT
Exhaust DA 40 Series
AMM
Page 2
20 Sep 2007 78-01-00 Doc # 6.02.01
Rev. 5
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Figure 1: Exhaust Installation
AIRCRAFT
DA 40 Series
AMM
Exhaust
Doc # 6.02.01
Rev. 5 78-01-00 Page 101
20 Sep 2007
Trouble-Shooting
1. General
The table below lists the defects you could have with the exhaust 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
More noise than usual. Exhaust pipe cracked. Look for signs of exhaust gas
leaks. Replace cracked pipes.
Signs of exhaust gas leaks in
the engine compartment.
Exhaust pipe cracked. Look for signs of exhaust gas
leaks. Replace cracked pipes.
Spherical coupling springs
failed.
Replace the spherical coupling
springs.
Exhaust manifold gasket failed. Refer to the engine
manufacturer.
Gasket between exhaust
manifold and turbo-charger
failed.
Refer to the engine
manufacturer.
Rear exhaust pipe loose. Rubber mountings failed. Replace the rubber mountings.
AIRCRAFT
Exhaust DA 40 Series
AMM
Page 102
20 Sep 2007 78-01-00 Doc # 6.02.01
Rev. 5
Intentionally left blank
AIRCRAFT
DA 40 Series
AMM
Exhaust
Doc # 6.02.01
Rev. 5 78-01-00 Page 201
20 Sep 2007
Maintenance Practices
1. General
These maintenance practices tell you how to remove and install the front and rear exhaust pipes. Only
TAE approved repair shops or the manufacturer can do maintenance on the engine part of the exhaust
system (manifold and turbo-charger).
2. Remove/Install the Rear Exhaust Pipe
WARNING: MAKE SURE THAT THE EXHAUST SYSTEM IS COOL BEFORE YOU
TOUCH IT. THE EXHAUST SYSTEM CAN BE VERY HOT, THIS CAN
CAUSE INJURY TO PERSONS.
A. Remove the Rear Exhaust 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 Set the ELECTRIC MASTER key switch to
OFF.
S Set the ENGINE MASTER switch to OFF.
S Set the power lever to IDLE.
(2) Remove the engine cowlings. Refer to Section 71-11.
(3) Release the 3 springs at the spherical coupling. Refer to Figure 1.
(4) Release the 2 rubber mountings from the rear
exhaust pipe.
(5) Remove the rear exhaust pipe from the airplane.
AIRCRAFT
Exhaust DA 40 Series
AMM
Page 202
20 Sep 2007 78-01-00 Doc # 6.02.01
Rev. 5
B. Install the Rear Exhaust 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) Put the rear exhaust pipe in position below the
engine.
Refer to Figure 1.
(2) Attach the 2 rubber mountings at the rear
exhaust pipe.
(3) Engage the rear pipe part of the spherical
coupling with the ball of the front part.
(4) Install the 3 springs at the spherical coupling.
(5) Do a ground run-up. Look for leaks at the
spherical joint.
Refer to Section 71-01.
(6) Install the engine cowlings. Refer to Section 71-11.
AIRCRAFT
DA 40 Series
AMM
Exhaust
Doc # 6.02.01
Rev. 5 78-01-00 Page 203
　
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