Ruh-Roh

Any DA40 related topics

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Steve
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Re: Ruh-Roh

Post by Steve »

Arnaud: Yes, that is the Arizona baffle. I don't have any pictures of the baffle not installed. Sorry,

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Steve
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Re: Ruh-Roh

Post by Steve »

Getting closer...
IMG_3103.jpg
Unfortunately, I broke the fuel drain (Sniffle) valve installing it, so I'll have to wait for a part. Plus, going out of town tomorrow for a few days. We should be able to finish everything in an hour or two when I get back.
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Steve
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Re: Ruh-Roh

Post by Steve »

Well, my airplane is fixed and in the air again! This morning we ran the engine for about 10 minutes on the ground, and checked for leaks. None were found, so I installed the cowlings and took it up for a 20 minute test flight. Everything went well, and after de-cowling the airplane again, no leaks were found.

All of the engine readings were in the green, and the fuel pressure, which I had noticed was slightly lower than normal for the airplane, was back up to 26 PSI with the installation of the new engine-driven fuel pump.

I actually learned a lot from the experience, but I hope I don’t have to do it again any time soon. The whole deal took just shy of 10 weeks. Now, to fly it a lot...

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Steve
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Re: Ruh-Roh

Post by Steve »

Some pix:
IMG_3147.jpg
Ready to go...
IMG_3148.jpg
Test flight
IMG_3149.jpg
Back in hangar...
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Rich
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Re: Ruh-Roh

Post by Rich »

10 weeks already? Good news you're back in the air with useful information for all of us :thumbsup:
2002 DA40: MT, PowerFlow, 530W/430W, KAP140, ext. baggage, 1090 ES out, 2646 MTOW, 40gal., Surefly, Flightstream 210, Orion 600 LED, XeVision, Aspen E5
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Steve
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So, what did it cost me?

Post by Steve »

So, how expensive was that loose set screw?

Parts: Bearings, set screw, gasket set: $779
Fuel pump (not necessary): $395
Fuel drain valve (I broke it): $114
Various small hoses, clamps, etc. $175

Tools: 2 ton engine hoist (I always wanted one, told my wife we had to get it, but in reality, my mechanic would have let me use his): $200

Labor: Engine teardown and repair: $2000

I removed and installed the engine, disassembled it, and assisted with reassembly.

So, the total was $3663. That is a lot less than I thought it would be, but I am lucky that my mechanic is on my field, has worked on my airplane for 18 years, and trusts my wrench-turning skills enough to allow me to owner-assist.

Still, an expensive evolution I would have rather not experienced...

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Re: Ruh-Roh

Post by PeterK »

That didn't reset the TBO count, did it?
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Re: Ruh-Roh

Post by Lance Murray »

If this was done at a shop it would have been 10k minimum.
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Steve
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Re: Ruh-Roh

Post by Steve »

PeterK wrote:
Fri Aug 23, 2019 8:40 pm
That didn't reset the TBO count, did it?
No, we didn't overhaul, just inspected and repaired - there was only about 750 hours on the engine...

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Re: Ruh-Roh

Post by Thomas »

thanks Steve,
I have same engine 2003 - 725hrs - plane always in a hangar, 2 owners since new. I am thinking about to open it also and check the general condition. I do oil analysis, but with the low annual flight time ( 2 oil change/year each at 20-25 FH) the analysis is not much saying. All parameters are perfect, but unfortuantly with the VM1000 a full data analysis is not possible. Thinking to change to EDM900 to get better data check - or even full G3X …. but first tell my wife :) -
How did your engine look inside in general. thomas
Thomas Bienz DA40-180 40.337 D-ENMA
Home Airport LSZC Buochs Switzerland
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