DA 40 Series
%
Cooling
AMM
Maintenance Practices
1. General
These maintenance practices tell you how to remove/install the cooling air baffle. See Figure 1 for location data.
Refer to the Lycoming Maintenance Manual for data on the inter-cylinder baffles.
2. Remove/Install the Cooling Air Baffle
A. Remove the Cooling Air Baffle
Detail Steps/Work Items Key Items/References
WARNING: MAKE SURE THAT THE ENGINE IS SAFE BEFORE YOU DO ANY WORK ON THE BAFFLES. IF THE ENGINE IS TURNED, 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 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) Disconnect the battery. Refer to Section 24-31.
(4) Disconnect the cables from the top spark plugs on No’s 2 & 4 cylinders. Move the spar plug cables clear of the baffle.
(5) Disconnect the cables from the top spark plugs on No’s 1 & 3 cylinders.
(6) Remove the nuts and bolts which attach the spark plug cable feed-thru to the rear of the baffle.
(7) Move the spark plug cables aft through the hole in the baffle.
(8) Disconnect the mixture cable from the fuel injector. Move the cable aft, through the rubber grommets in the baffle. Refer to Section 76-00.
Doc # 6.02.01 Page 201
Rev. 4 09 Jan 2003
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% Cooling
AMM
DA 40 Series
Detail Steps/Work Items Key Items/References
(9) Disconnect the propeller governor control cable. Move it aft through the rubber grommets in the baffle. Refer to Section 61-20.
(10) Disconnect the drain tube from the fuel flow divider. Move it aft through the rubber grommet in the baffle. Refer to Section 71-70.
(11) Release the tie-bars from the bottom of the baffle on the left side and on the right side.
(12) Remove the four screws which attach the cooling baffle to No’s 2 & 4 cylinder heads. Note the location of the P-clamps which hold the spark plug cables and which hold the manifold pressure pipe.
(13) Remove the four screws which attach the cooling baffle to No’s 1 & 3 cylinder heads. Note the location of the P-clamps which hold the spark plug cables.
(14) Remove the cooling air baffle.
B. Install the Cooling Air Baffle
Detail Steps/Work Items Key Items/References
(1) Make sure that : S The cooling baffle is clean. S The cooling baffle is not damaged. S That the rubber sealing strip is correctly attached and not damaged.
(2) Move the cooling baffle into position around the cylinders.
(3) Install the four screws which attach the baffle to No’s 1 & 3 cylinder heads. Make sure that the P-clamps holding the spark plug cables are in the correct position.
(4) Install the four screws which attach the baffle to No’s 2 & 4 cylinder heads. Make sure that the P-clamps holding the spark-plug-cables and the manifold pressure hose are in the correct position.
Page 202 Doc # 6.02.01 09 Jan 2003 Rev. 4
75-00-00
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Cooling
AMM
DA 40 Series
Detail Steps/Work Items Key Items/References
(5) Attach the tie-bars at the bottom of the baffle at the left side and at the right side.
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