Ruh-Roh
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- Steve
- 5 Diamonds Member
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- First Name: Steve
- Aircraft Type: DA40
- Aircraft Registration: N432SC
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Re: Ruh-Roh
So, my mechanic is back from vacation. He put me in charge of disassembly...
Engine on the stand
Sump removed
Valve covers off in preparation for pulling cylinders
Accessory case off, showing crankshaft gear, camshaft gear, and the 2 idler gears
Engine parts, anyone?
Tomorrow, I will have the cylinders off and the case split...
Steve
Engine on the stand
Sump removed
Valve covers off in preparation for pulling cylinders
Accessory case off, showing crankshaft gear, camshaft gear, and the 2 idler gears
Engine parts, anyone?
Tomorrow, I will have the cylinders off and the case split...
Steve
- Rich
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Re: Ruh-Roh
I would never open up the interior of an engine in my hangar. Dust/sand finds its way into it constantly
Partly it's the fact it's high desert. But stationing fire-fighting helicopters right in front of the hangar is the real kicker
Partly it's the fact it's high desert. But stationing fire-fighting helicopters right in front of the hangar is the real kicker
2002 DA40-180: MT, PowerFlow, 530W/430W, KAP140, ext. baggage, 1090 ES out, 2646 MTOW, 40gal., Surefly, Flightstream 210, Orion 600 LED, XeVision, Aspen E5
- Steve
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Re: Ruh-Roh
Dust is not usually a problem in mine, but I have the sensitive parts interior side - down, or covered. I was amazed at how clean the interior of the engine is (I'm comparing to auto engines I have torn down in the past).
- Steve
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Re: Ruh-Roh
So, today I finished opening up the engine. We kept the cylinders sealed by pushing the connecting rod pins out with the pistons still in the cylinders.
This is where the flippin' set screw came from. Luckily, we couldn't find any damage from it migrating around inside the case. As a matter of fact, the engine looks pristine inside. Almost no cam, tappet, or bearing wear is visible.
A lot of (my) labor involved cleaning the mating surfaces of the case, so they won't leak after reassembly. All of the parts are ordered (gaskets, seals, and a SET SCREW). I'm also replacing the engine-driven fuel pump, just because it is 18 years old and has a rubber diaphragm, and it is easy to do it now, hard to do after the engine is mounted.
The only thing left assembled is the crankshaft and connecting rods!
Steve
This is where the flippin' set screw came from. Luckily, we couldn't find any damage from it migrating around inside the case. As a matter of fact, the engine looks pristine inside. Almost no cam, tappet, or bearing wear is visible.
A lot of (my) labor involved cleaning the mating surfaces of the case, so they won't leak after reassembly. All of the parts are ordered (gaskets, seals, and a SET SCREW). I'm also replacing the engine-driven fuel pump, just because it is 18 years old and has a rubber diaphragm, and it is easy to do it now, hard to do after the engine is mounted.
The only thing left assembled is the crankshaft and connecting rods!
Steve
Last edited by Steve on Thu Jul 25, 2019 10:51 pm, edited 1 time in total.
- Colin
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Re: Ruh-Roh
My DA40's engine had a TINY oil leak where the thread was wound the wrong direction around one of the screws mating the case back together. My mechanic had never seen anything like it. The only way to stop the leak would be cracking the case and re-sealing.
Watch your thread direction winding, I guess.
Watch your thread direction winding, I guess.
Colin Summers, PP Multi-Engine IFR, ~3,000hrs
colin@mightycheese.com * send email rather than PM
http://www.flyingsummers.com
N972RD DA42 G1000 2.0 s/n 42.AC100 (sold!)
N971RD DA40 G1000 s/n 40.508 (traded)
colin@mightycheese.com * send email rather than PM
http://www.flyingsummers.com
N972RD DA42 G1000 2.0 s/n 42.AC100 (sold!)
N971RD DA40 G1000 s/n 40.508 (traded)
- Steve
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Re: Ruh-Roh
Yes, my A&P/IA will definitely be doing that portion of the job! I did have a very small oil leak from one of the bolt holes for years, maybe a few drops every oil change. Of course, we will be installing new O-rings on the 4 case studs that require them. I've actually had 'fun' taking my engine apart. I would have had more fun taking someone else's engine apart...
- Colin
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Re: Ruh-Roh
Yes, it was the few drops per oil change. It bothered me way more than it should have because other than that seep the engine was so clean.
Colin Summers, PP Multi-Engine IFR, ~3,000hrs
colin@mightycheese.com * send email rather than PM
http://www.flyingsummers.com
N972RD DA42 G1000 2.0 s/n 42.AC100 (sold!)
N971RD DA40 G1000 s/n 40.508 (traded)
colin@mightycheese.com * send email rather than PM
http://www.flyingsummers.com
N972RD DA42 G1000 2.0 s/n 42.AC100 (sold!)
N971RD DA40 G1000 s/n 40.508 (traded)
- Steve
- 5 Diamonds Member
- Posts: 1953
- Joined: Thu Aug 12, 2010 1:23 am
- First Name: Steve
- Aircraft Type: DA40
- Aircraft Registration: N432SC
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Re: Ruh-Roh
Progress report: So, today we started reassembling the engine. First order of business was installing that g#@(KH)^G set screw. You can see the excess Loctite (green) and the areas where we staked the set screw and hole. That sucker ain't coming out!
Steve
Then, all the rest of the assembly followed. Spent about 7 hours on it (in 100 degree weather). We actually have the engine assembled and almost ready to go back on the airframe tomorrow.
Hopefully, I'll have it ready to run soon...Steve
- Steve
- 5 Diamonds Member
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- Joined: Thu Aug 12, 2010 1:23 am
- First Name: Steve
- Aircraft Type: DA40
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Re: Ruh-Roh
So, the engine is back on, today I installed the starter, alternator, and fuel control unit, plus various sensors, wiring harnesses, etc. That was all I could stand to do in the 100 degree heat. Tomorrow, I'll attach the mixture cable, and install the exhaust system. Monday my mechanic and I will hang the prop and install the mags, then a few last hoses and the battery will go on. Should be ready for its startup on Monday...
A few photos:
A few photos:
- astaib
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Re: Ruh-Roh
Hi Steve,
Is it the Arizona baffle that we see on cylinder #1?
Do you, by chance, have some pictures of this baffle when it was uninstalled ?
Thank you.
Arnaud.
Is it the Arizona baffle that we see on cylinder #1?
Do you, by chance, have some pictures of this baffle when it was uninstalled ?
Thank you.
Arnaud.
Arnaud
DA40 Star 180 / 40.026 / 2001
Wingtip, landing and taxing LED (Whelen)
Skitube
GNS430 NON-WAAS
Steam gauges
Non certified ADS-b
DA40 Star 180 / 40.026 / 2001
Wingtip, landing and taxing LED (Whelen)
Skitube
GNS430 NON-WAAS
Steam gauges
Non certified ADS-b