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(5)  Install the air filter: S Put the worm-drive clamp into position on the air filter. S Put the air filter in position on the air filter housing. S Tighten the worm-drive clamp. 
(6)  Do a test for correct range, full and free movement of the alternate air valve control system.  Refer to the Alternate Air Valve Control System Range of Movement Test in this Section. 
(7)  Do an inspection of the control connections which you disconnected. If necessary, for your airworthiness authority, do a second inspection of the controls. 
(8)  Connect the spark plug leads to the spark plugs.  Torque to 12.4 to 13.6 Nm (110 - 120 in.lb). 
(9)  Connect the airplane battery.  Refer to Section 24-31. 
(10)  Install the engine cowlings.  Refer to Section 71-10. 
(11)  Do an engine run-up.  Refer to the DA 40 Airplane Flight Manual. 

4. Remove/Install the Alternate Air Valve Control Cable
A. Remove the Alternate Air Control Cable
Detail Steps/Work Items  Key Items/References 
WARNING: WARNING:  DO NOT STAND WITHIN THE DANGER AREA OF THE PROPELLER IF THE ENGINE STARTS, THE PROPELLER CAN CAUSE DEATH OR INJURY TO PERSONS. 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. 

Doc # 6.02.01 Page 205
Rev. 4 09 Jan 2003

71-60-00
AMM

DA 40 Series

Detail Steps/Work Items  Key Items/References 
(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 CUT-OFF. 
(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. 
(5)  Release the alternate air control Bowden cable from the alternate air valve assembly: S Loosen the swivel fitting at the alternate air valve body. S Pull the Bowden cable wire end clear of the swivel fitting. S Remove and keep the swivel fitting. S Remove the retaining nut which holds the Bowden cable outer sheath in the support bracket at the alternate air valve spacer. S Move the Bowden cable clear of the alternate air valve.  Refer to Figure 1. 
(6)  Remove the firewall feed-thru from the engine side of the firewall: S Remove the fire wall sealant from the feed-thru. S Drill out the two rivets which hold the shields to the firewall. S Remove the shields. S Pull the 2 parts of the feed-thru clear of the firewall. 

71-60-00
Power Plant
AMM

DA 40 Series

Detail Steps/Work Items  Key Items/References 
(7)  Release the alternate air control Bowden cable from the alternate air control lever in the cockpit: S Release the screw in the swivel fitting and pull the Bowden cable wire end out from the swivel fitting. S Remove the front adjusting nut from the Bowden cable outer sheath at the control lever bracket. S Pull the Bowden cable clear from the control lever bracket.  Refer to Figure 2. 
(8)  Pull the alternate air cable through the firewall from the engine bay side and clear of the airplane. 

B. Install the Alternate Air Control Cable
Detail Steps/Work Items  Key Items/References 
(1)  Put the alternate air cable through the firewall. 
(2)  Put the Bowden cable through the support bracket at the alternate air valve assembly.  Refer to Figure 1. 
(3)  Install the retaining nut on the Bowden cable outer sheath. 
(4)  Put the Bowden cable wire end through the swivel fitting in the alternate air valve and tighten the swivel fitting screw. 
(5)  Put the Bowden cable through the support bracket at the alternate air control lever in the cockpit.  Refer to Figure 2. 
　
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