Ruh-Roh

Any DA40 related topics

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Steve
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Re: Ruh-Roh

Post by Steve »

So, my mechanic is back from vacation. He put me in charge of disassembly...
IMG_3045.jpg
Engine on the stand
IMG_3050.jpg
Sump removed
IMG_3051.jpg
Valve covers off in preparation for pulling cylinders
DSCN5949.jpg
Accessory case off, showing crankshaft gear, camshaft gear, and the 2 idler gears
IMG_3053.jpg
Engine parts, anyone?

Tomorrow, I will have the cylinders off and the case split...

Steve
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Rich
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Re: Ruh-Roh

Post by Rich »

I would never open up the interior of an engine in my hangar. Dust/sand finds its way into it constantly :scream:

Partly it's the fact it's high desert. But stationing fire-fighting helicopters right in front of the hangar is the real kicker :thumbsd:
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
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Steve
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Re: Ruh-Roh

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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).
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Steve
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Re: Ruh-Roh

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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.

DSCN5957.jpg
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.
DSCN5983.jpg
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.
DSCN5971.jpg
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.
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Colin
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Re: Ruh-Roh

Post by Colin »

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.
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Steve
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Re: Ruh-Roh

Post by Steve »

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...
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Colin
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Re: Ruh-Roh

Post by Colin »

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.
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Steve
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Re: Ruh-Roh

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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!
DSCN5998.jpg
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.
DSCN6001.jpg
Hopefully, I'll have it ready to run soon...

Steve
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Steve
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Re: Ruh-Roh

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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:
DSCN6007.jpg
IMG_3095.jpg
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astaib
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Re: Ruh-Roh

Post by astaib »

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.
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