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(2)  Remove the muffler shroud: S Remove the screws which hold the shroud. S Carefully pull the shroud apart at the joint and move the shroud down the muffler-outlet-pipe. S Move the shroud clear of the muffler. S Carefully remove the inliner. 
(3)  Look carefully at the shroud and the inliner. Look specially at the inside for signs of gas leakage from the muffler.  Use a bright light and use a magnifying glass. 
(4)  Look carefully at the muffler assembly. Look specially for: S Cracks in the welds, specially around the joints. S Cracks in the muffler skin. S Damage to surface of the muffler. S Corrosion.  Use a bright light and use a magnifying glass. NO CRACKS ARE PERMITTED ANYWHERE ON THE MUFFLER. 
(5)  If you find a crack you must replace the muffler. 

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Detail Steps/Work Items  Key Items/References 
(6)  Install the shroud on the muffler: S Put the inliner onto the muffler. S Move the shroud over the muffler-outlet-pipe. S Gently pull the shroud apart and over the muffler. S Install the screws which hold the shroud ends together.  Make sure that the shroud is positioned correctly. 
(7)  Install the muffler on the airplane.  Refer to Paragraph 2.B. 

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% Section 78-01 % Exhaust - TAE 125 Diesel Engine % 1. General
% The DA 40 with the TAE 125 Diesel engine has a simple 2-piece exhaust system. This Section tells % you only about the exhaust from the outlet of the turbo-charger. Refer to the engine manufacturer for % data about the engine exhaust manifold and turbo-charger.
% 2. Description
% Figure 1 shows the exhaust installation. The exhaust system has two large-diameter tubes connected % by a spherical joint. A large flange attaches the front tube to the front of the turbo-charger. The tube % goes round the engine mounting frame to the spherical joint below the engine. A bracket from the tube % braces it to the bottom of the engine.
% The front tube has the ball part of a spherical coupling welded to the end. The rear tube has the % female fitting of the coupling welded to the end. Flanges with 3 lugs are welded to each tube adjacent % to the spherical end fittings. Three strong springs attach to the lugs of the flanges to hold the coupling % together.
% The rear tube has 2 hooks that engage with rubber mountings. The top of the rubber mountings % engage with 2 hooks welded to the engine mounting frame.
% The system has no muffler.
%

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Engine Exhaust Manifold
Turbo-Charger
Mounting Flange Rear Pipe
Rubber MountingFront Pipe Engine Mounting FrameFront Bracket Spherical Coupling
% Figure 1: Exhaust Installation %
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% Trouble-Shooting % 1. General
% The table below lists the defects you could have with the exhaust system. If you have the trouble % detailed in the Trouble column read across to the Possible Cause column. Then do the repair given % in the Repair column.
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Trouble  Possible Cause  Repair 
More noise than usual.  Exhaust pipe cracked.  Look for signs of exhaust gas leaks. Replace cracked pipes. 
Signs of exhaust gas leaks in the engine compartment.  Exhaust pipe cracked. Spherical coupling springs failed. Exhaust manifold gasket failed. Gasket between exhaust manifold and turbo-charger failed.  Look for signs of exhaust gas leaks. Replace cracked pipes. Replace the spherical coupling springs. Refer to the engine manufacturer. Refer to the engine manufacturer. 
　
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