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Complaint  Possible Cause  Remedy 
Engine will not start.  Mixture controls not correctly adjusted.  Do a range of movement check. Adjust the mixture controls. 
Engine will not cut-off.  Mixture controls not correctly adjusted.  Do a range of movement check. Adjust the mixture controls. 
Cannot control the engine.  Broken throttle Bowden cable. Throttle control not set correctly. Bowden cable not free to move.  Replace the broken cable. Do a range of movement check. Adjust the throttle controls. Replace the Bowden cable. 
Throttle lever hard to move.  Friction adjuster incorrectly set. Throttle control lever restriction.  Check/adjust friction adjuster. Remove the restriction. 
Engine does not give full power.  Throttle lever touches the cockpit stop before the lever on the engine touches its stop.  Do a range of movement check. Adjust the throttle controls. 
Idle RPM changes each time idle is set.  Throttle lever touches the cockpit stop before the lever on the engine touches its stop.  Do a range of movement check. Adjust the throttle controls. 

Doc # 6.02.01 Page 101
Rev. 4 09 Jan 2003

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Engine Controls
AMM

Maintenance Practices
1. General
These maintenance practices tell you how to remove, install and adjust the Bowden cables for the engine controls. They do not tell you how to adjust the engine fuel injector.
Refer to the Lycoming Maintenance Manual for the data on the fuel injector.
WARNING:  DO ALL THE STEPS OF THE CONTROL INSTALLATION AND ADJUSTMENT CAREFULLY. ENGINE FAILURE CAN OCCUR IF THE CONTROL INSTALLATION AND ADJUSTMENT ARE NOT DONE CORRECTLY. THIS CAN CAUSE DEATH OR INJURY TO PERSONS.
2. Remove/Install the Throttle Bowden Cable
A. Remove the Throttle Bowden Cable
Detail Steps/Work Items  Key Items 
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 airplane battery.  Refer to Section 24-31. 
(4)  Disconnect the spark plug cables from the spark plugs. 
(5)  Disconnect the throttle eye end at the throttle lever in the engine bay: S Remove the nut, bolt and washers from the Bowden cable eye end.  Refer to Figure 2. 

Doc # 6.02.01 Page 201
Rev. 4 09 Jan 2003

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DA 40 Series

Detail Steps/Work Items  Key Items 
(6)  Remove the eye end from the Bowden cable: S Loosen the lock-nut and remove the eye end. 
(7)  Remove the Bowden cable from the bracket at the bottom of the engine: S Remove the front adjustment nut from the outer sheath. S Move the Bowden cable clear of the bracket. S Remove the rear adjustment nut from the outer sheath.  Make a note of the cable adjustment! 
(8)  Remove the P-clamp which attaches the Bowden cable to the engine mount.  Note the position of the P-clamp. 
(9)  Remove the feed-thru from the engine side of the firewall: S Remove the fire resistant sealant from where the cable goes through the firewall. S Remove the two rivets that attach the split shields to the firewall. S Remove the split-shields. S Move the two halves of the split-bush forward and clear of the cable. 
(10)  Remove the knob from the fuel selector valve: S Remove the cross-head screw from the center of the control-knob and pull the knob up and off the fuel selector valve. S Remove the mounting plate. 
　
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