Doc # 6.02.01 Page 207
Rev. 4 09 Jan 2003
71-60-00
AMM
DA 40 Series
Detail Steps/Work Items Key Items/References
(6) Install the front adjusting nut to the Bowden cable outer sheath.
(7) Put the Bowden cable wire end through the swivel fitting on the lever and tighten the swivel fitting screw.
(8) Install the feed-thru to the engine side of the firewall with firewall sealant: S Put the 2 parts of the feed-thru round the bowden cable. S Push the feed-thru in the firewall. S Put the 2 shields in position over the feed-thru. S Install 2 pop-rivets to attach the shields to the firewall. Use PR 812 (MIL-S-38249 Type 1) Fire Wall Sealant.
(9) Do a test for correct range, full and free movement of the alternate air control system. Refer to the Alternate Air Valve Control Range of Movement Test in this Section.
(10) Do an inspection of the control connections which you disconnected. If necessary, for your airworthiness authority, do a second inspection of the controls.
(11) Connect the spark plug cables to the spark plugs. Torque to 12.4 - 13.6 Nm (110 - 120 in.lb).
(12) Connect the airplane battery. Refer to Section 24-31.
(13) Install the engine cowlings. Refer to Section 71-10.
(14) Do an engine run-up. Refer to the DA 40 Airplane Flight Manual.
71-60-00
Power Plant
AMM
5. Test/Adjust the Alternate Air Control Cable
DA 40 Series
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 lever 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 battery. Refer to Section 24-31.
(4) Disconnect the spark plug cables from the spark plugs.
(5) Move the alternate air control lever from OFF to ON: S Make sure the lever moves freely with no restrictions.
(6) Set the alternate air control lever in the cockpit to OFF and hold it in position: S Make sure that the alternate air valve is fully closed and that the swivel fitting contacts the end of the cut-out in the alternate air flanged housing. With the alternate air valve fully closed there must be at least 3 mm (0.125 in) clearance (bounce) between the alternate air control lever and the stop bush. Figure 2.
(7) Set the alternate air control lever in the cockpit to ON and hold it in position: S Make sure that the alternate air control valve is in the fully open position and that the 2 rows of holes in the valve align.
Doc # 6.02.01 Page 209
Rev. 4 09 Jan 2003
71-60-00
AMM
DA 40 Series
Detail Steps/Work Items Key Items/References
(8) If the adjustment of the control is not correct then you must adjust the 2 adjusting nuts at the alternate air control lever in the cockpit.
(9) Do items 5 - 8 again as necessary to get the correct settings.
(10) Do an inspection of the control connections which you disconnected. If necessary for your airworthiness authority, do a second inspection of the controls.
(11) Install the cables to the spark plugs. Torque to 12.4 - 13.6 Nm (110 - 120 in.lb).
(12) Connect the airplane battery. Refer to Section 24-31.
(13) Install the engine cowlings. Refer to Section 71-10.
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