Doc # 6.02.01 Page 101
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DA 40 Series AMM
DA 40 F

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DA 40 F

Maintenance Practices
1. General
These maintenance practices tell you how to remove and install the air filter and the alternate air valve
assembly. They also tell you how to adjust, remove and install the alternate air control cable.
They do not tell you how to adjust the engine carburetor.
Refer to the Lycoming Maintenance Manual for the data on the fuel injector.

2. Remove/Install the Air Filter
A. Remove the Air Filter
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 control to IDLE. S Set the mixture control lever to LEAN CUT-OFF. 
(2.)  Remove the engine cowlings.  Refer to Section 71-12. 
(3.)  Disconnect the airplane battery.  Refer to Section 24-31. 
(4.)  Remove the 4 bolts which attach the air filter and the front baffle to the alternate air valve housing.  Hold the air filter. 
(5.)  Pull the air filter forward and clear of the airplane. 

Doc # 6.02.01 Page 201
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DA 40 Series AMM
DA 40 F

B. Install the Air Filter
Detail Steps/Work Items  Key Items/References 
(1.)  Put the air filter in position on the front baffle. 
(2.)  Align the holes of the air filter and the front baffle. 
(3.)  Tighten the 4 bolts which attach the air filter and the front baffle to the alternate air valve. 
(4.)  Connect the airplane battery.  Refer to Section 24-31. 
(5.)  Install the engine cowlings.  Refer to Section 71-12. 
(6.)  Do an engine run-up.  Refer to the DA 40 F Airplane Flight Manual. 

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3. Remove/Install the Alternate Air Valve
A. Remove the Alternate Air Valve
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 control to IDLE. S Set the mixture control lever to LEAN CUT-OFF. 
(2)  Remove the engine cowlings.  Refer to Section 71-12. 
(3)  Disconnect the airplane battery.  Refer to Section 24-31. 

DA 40 Series AMM

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DA 40 F

Detail Steps/Work Items  Key Items/References 
(4)  Disconnect the spark plug cables from the spark plugs. 
(5)  Loosen the worm-drive clamps and remove and detach the hoses:: S the oil cooler hose S two alternator cooling hoses 
(6)  Remove the 4 bolts which attach the air filter and the front baffle to the alternate air valve housing.  Support the air filter. 
(7)  Pull the air filter clear of the airplane. 
(8)  Remove the screws which attach the front baffle to the engine.  Support the front baffle. 
(9)  Move the front baffle clear of the airplane. 
(10)  Release the alternate air control Bowden cable from the alternate air valve assembly: S Loosen the swivel fitting at the alternate air valve body. S Pull the Bowden cable wire end clear of the swivel fitting. S Remove and keep the swivel fitting. S Remove the retaining nut which holds the Bowden cable outer sheath in the support bracket at the alternate air valve spacer. S Move the Bowden cable clear of the alternate air valve. 
　
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