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(10)  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. 
(11)  Do a test for correct range, full and free movement of the mixture control system.  Refer to the Mixture Control Range of Movement Test in this Chapter. 
(12)  Do an inspection of the control connections which you disconnected. If necessary, for your airworthiness authority, do a second inspection of the mixture control assembly. 
(13)  Do a check for loose items in the cockpit. Specially in the area of the engine control assembly. 
(14)  Do an engine controls freedom of movement check. 

76-00-00
Engine Controls
AMM

Detail Steps/Work Items  Key Items/References 
(15)  Connect the spark plug cables to the spark plugs.  Torque to 12.4 - 13.6 Nm (110 - 120 in.lb). 
(16)  Connect the airplane battery.  Refer to Section 24-31. 
(17)  Install the engine cowlings.  Refer to Section 71-10. 
(18)  Do an engine run-up.  Refer to the DA 40 Airplane Flight Manual. 

4. Throttle/Mixture Control Range of Movement Test
These procedures tell you how to do a throttle and mixture control range of movement test. They do not tell you how to adjust the engine fuel control units. Refer to the Lycoming Maintenance Manual for data on the engine fuel control units.
Do the throttle/mixture control range of movement test using two persons. You must make sure that the throttle/mixture control levers hit the stops in the throttle/mixture valve before they hit their stops in the engine control assembly. This will make sure that the throttle/mixture controls have the correct range of movement. You should set the controls to 3 mm (0.125 in) clearance (bounce) at the engine control assembly cover plate.
A. Throttle Control Range of Movement Test
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 to IDLE. S Set the mixture control 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. 

Doc # 6.02.01 Page 213
Rev. 4 09 Jan 2003

76-00-00
AMM

DA 40 Series

Detail Steps/Work Items  Key Items/References 
(5)  Move the throttle control lever between IDLE and FULL. S Make sure the lever moves freely with no restrictions. 
(6)  Set the throttle control lever to FULL and hold it in position. S Make sure that the throttle lever at the injector hits the stop. If necessary, adjust the Bowden cable outer sheath at the support bracket at the bottom of the engine.  With the throttle lever on the stop at the injector, there must be at least 3 mm (0.125 in) clearance (bounce) between the lever in the engine control assembly and the cover plate. 
(7)  Set the throttle control lever to IDLE and hold it in position: S Make sure that the throttle lever at the injector hits the IDLE stop. If necessary, adjust the Bowden cable outer sheath at the support bracket at the bottom of the engine.  With the throttle lever on the IDLE stop at the injector, there must be at least 3 mm (0.125 in) clearance (bounce) between the lever in the engine control assembly and the cover plate. 
　
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