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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, install and adjust the Bowden cables for the engine controls. They do not tell you how to adjust the carburetor.
Refer to the Lycoming Maintenance Manual for the data on the carburetor.
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 71-12.
(3) Disconnect the airplane battery. Refer to Section 24-31.
(4) Disconnect the spark plug cables from the spark plugs.
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DA 40 Series AMM
DA 40 F
Detail Steps/Work Items Key Items
(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.
(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 engine controls bracket at the carburetor: 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.
DA 40 Series AMM
DA 40 F
Detail Steps/Work Items Key Items
(11) Release the engine control assembly: S Loosen the throttle friction adjuster until the adjuster is disconnected from the shaft. S Remove the four cross-head screws which attach the engine control lower-cover-plate to the engine control assembly. S Remove the two hex-headed bolts from the top of the upper-cover -plate. S Lift and support the engine control assembly clear of the center console. Pull and hold the throttle friction adjuster clear. Make sure you do not pull on the control cables.
(12) Disconnect the eye-end fitting from the throttle control lever: S Remove the nut, two washers and bolt which attaches the eye-end to the lever.
(13) Remove the eye-end fitting from the throttle cable: S Loosen the lock-nut for the eye-end. S Remove the eye-end from the cable.
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