DA 40 Series

Detail Steps/Work Items  Key Items/References 
WARNING: MAKE SURE THE ENGINE IS SAFE BEFORE YOU DO ANY WORK ON IT. IF THE ENGINE STARTS THE PROPELLER CAN CAUSE INJURY OR DEATH. 
(1)  Make sure that the engine is safe: S Set the ELECTRIC MASTER key switch to OFF. S Set the ENGINE MASTER switch to OFF. S Set the power lever to IDLE. 
(2)  Remove the engine cowlings.  Refer to Section 71-11. 
(3)  Disconnect the electrical connector from the manifold pressure sensor. 
(4)  Remove the old sensor from the intercooler outlet pipe.  Turn the sensor counter-clockwise. Discard the seal. 
(5)  Install the new sensor to the intercooler outlet pipe.  Turn the sensor clockwise. Use a new seal. 
(6)  Connect the electrical connector to the manifold temperature sensor. 
(7)  Install the engine cowlings.  Refer to Section 71-11. 
(8)  Do a ground run-up.  Refer to Section 71-01. 

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CHAPTER 78
EXHAUST

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TABLE OF CONTENTS
CHAPTER 78
EXHAUST

% Section 78-00 % Exhaust - Lycoming Engine
1.
General ..............................................1

2.
Description............................................1

3.
Operation.............................................1

Trouble-Shooting
1. General ............................................101

Maintenance Practices
1.
General ............................................201

2.
Remove/Install the Exhaust Muffler .......................201

3.
Remove/Install an Exhaust Down-Pipe ....................203

4.
Inspect the Exhaust Muffler .............................205

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% Section 78-01 % Exhaust - TAE 125 Diesel Engine % 1. General ..............................................1 % 2. Description............................................1 % Trouble-Shooting % 1. General ............................................101 % Maintenance Practices % 1. General ............................................201 % 2. Remove/Install the Rear Exhaust Pipe.....................201 % 3. Remove/Install the Front Exhaust Pipe ....................203
78-CONTENTS
Exhaust
AMM

CHAPTER 78
EXHAUST

% Section 78-00 % Exhaust - Lycoming Engine
1. General
%  The DA 40 with the Lycoming engine has a single exhaust system. Four exhaust down-pipes connect the exhaust ports on the cylinder heads to an exhaust muffler. The muffler has a shroud. The shroud makes a heat-exchanger system for supplying heated air for the cabin heating system.
Refer to Section 21-40 for data about the cabin heating.
2. Description
Welded stainless-steel makes the exhaust system. Four down-pipes attach to the cylinder exhaust ports with nuts and washers. A special gasket makes a gas-tight seal between the exhaust port and the flange of the down-pipe.
%  The bottom end of the down-pipe connects to the exhaust muffler with two expansion joints which are
%  connected with a connection tube. The expansion joint allows the exhaust system to expand and move when it gets hot. Nuts, bolts and washers hold the expansion joint together.
%  A metal shroud and an inliner go around the outside of the muffler. Screws and thread plates clamp the muffler in position. The shroud has stub-pipes at the front and at the rear. The space between the
　
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