Exhaust and Intake Risers Touching?

Any DA40 related topics

Moderators: Rick, Lance Murray

User avatar
shoffert
2 Diamonds Member
2 Diamonds Member
Posts: 28
Joined: Wed Jan 15, 2020 2:20 am
First Name: Stephen
Aircraft Type: DA40
Aircraft Registration: 506DS
Airports: KAVL
Been thanked: 11 times

Re: Exhaust and Intake Risers Touching?

Post by shoffert »

The intake has a thin gasket, the exhaust a thick one. I don't think we can play with gasket size to make space.

There is only a little room to shorten up the intake before it would hit that bump on the block that has the engine data plate on it...probably a short 1/2" to work with there, but enough to match Steve's 1/4" of space.

I'll definitely read the new engine logs closely to see if there are part numbers. A call to that shop appears in order. They should have caught it, who knows...maybe they'll still stand behind their work?

Thanks for your help! Consensus answer is they shouldn't be touching and you guys gave me a great lead on patching it up with the part numbers.
User avatar
shoffert
2 Diamonds Member
2 Diamonds Member
Posts: 28
Joined: Wed Jan 15, 2020 2:20 am
First Name: Stephen
Aircraft Type: DA40
Aircraft Registration: 506DS
Airports: KAVL
Been thanked: 11 times

Re: Exhaust and Intake Risers Touching?

Post by shoffert »

The intake has a thin gasket, the exhaust a thick one. I don't think we can play with gasket size to make space.

There is only a little room to shorten up the intake before it would hit that bump on the block that has the engine data plate on it...probably a short 1/2" to work with there, but enough to match Steve's 1/4" of space.

I'll definitely read the new engine logs closely to see if there are part numbers. A call to that shop appears in order. They should have caught it, who knows...maybe they'll still stand behind their work?

Thanks for your help! Consensus answer is they shouldn't be touching and you guys gave me a great lead on patching it up with the part numbers.
User avatar
Rich
5 Diamonds Member
5 Diamonds Member
Posts: 4592
Joined: Mon Aug 30, 2010 12:40 pm
First Name: Rich
Aircraft Type: DA40
Aircraft Registration: N40XE
Airports: S39 Prineville OR
Has thanked: 145 times
Been thanked: 1180 times

Re: Exhaust and Intake Risers Touching?

Post by Rich »

It'll be tricky modifying any of those those pipes. They are only solidly mounted at the cylinder heads and are just sort of rammed against the seals where the airflow transitions from the engine sump to the pipes. This is a location where air leaks can develop.
IO-360-M1A Intake Pipes.jpg
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
User avatar
Lance Murray
5 Diamonds Member
5 Diamonds Member
Posts: 1163
Joined: Tue Jul 06, 2010 11:25 pm
First Name: Lance
Aircraft Type: DA40
Airports:
Has thanked: 7 times
Been thanked: 118 times

Re: Exhaust and Intake Risers Touching?

Post by Lance Murray »

Take the systems apart and confirm they are assembled correctly. It is possible that an exhaust tube or intake tube is in the wrong place. They absolutely should not touch. Ground the aircraft.
User avatar
shoffert
2 Diamonds Member
2 Diamonds Member
Posts: 28
Joined: Wed Jan 15, 2020 2:20 am
First Name: Stephen
Aircraft Type: DA40
Aircraft Registration: 506DS
Airports: KAVL
Been thanked: 11 times

Re: Exhaust and Intake Risers Touching?

Post by shoffert »

It looks like you can adjust this out by loosening the bolts in the exhaust expansion joints, twisting the muffler to a better position, and then re-tightening.

The Austrians also put that in the manual in 78-00, page 203, step 2. Love that manual.
Exhaust Install Page.JPG
I'm 45 minutes away from the plane...does anyone happen to know the bolt information for the 32 bolts in the the 8 sleeves on the exhaust expansion joints (4 per sleeve) to save a guy a trip? I'll replace all of them while I'm at it.
Image of Expansion Joints.JPG
User avatar
Rich
5 Diamonds Member
5 Diamonds Member
Posts: 4592
Joined: Mon Aug 30, 2010 12:40 pm
First Name: Rich
Aircraft Type: DA40
Aircraft Registration: N40XE
Airports: S39 Prineville OR
Has thanked: 145 times
Been thanked: 1180 times

Re: Exhaust and Intake Risers Touching?

Post by Rich »

From the illustrated parts list:

Bolts: AN3C-4A
Washers: AN960-10L
Nuts: MS21043-3
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
User avatar
shoffert
2 Diamonds Member
2 Diamonds Member
Posts: 28
Joined: Wed Jan 15, 2020 2:20 am
First Name: Stephen
Aircraft Type: DA40
Aircraft Registration: 506DS
Airports: KAVL
Been thanked: 11 times

Re: Exhaust and Intake Risers Touching?

Post by shoffert »

I found the "illustrated parts catalog" online... Is that where you looked?

I was able to order the parts from AMI...an exhaust company the engine rebuilder sent me to.

https://awi-ami.com/1-75-riser-clamp-se ... 61-25.html

They split out the bolts from the kit and shipped in 2 days. No endorsement intended.
Last edited by shoffert on Mon May 18, 2020 6:28 pm, edited 1 time in total.
User avatar
Rich
5 Diamonds Member
5 Diamonds Member
Posts: 4592
Joined: Mon Aug 30, 2010 12:40 pm
First Name: Rich
Aircraft Type: DA40
Aircraft Registration: N40XE
Airports: S39 Prineville OR
Has thanked: 145 times
Been thanked: 1180 times

Re: Exhaust and Intake Risers Touching?

Post by Rich »

shoffert wrote: Mon May 18, 2020 6:26 pm I found the "illustrated parts catalog" online... Is that where you looked?
Yep. I notice it only shows 16 bolts, but I've found this to be a common type of error in the catalog.
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
User avatar
shoffert
2 Diamonds Member
2 Diamonds Member
Posts: 28
Joined: Wed Jan 15, 2020 2:20 am
First Name: Stephen
Aircraft Type: DA40
Aircraft Registration: 506DS
Airports: KAVL
Been thanked: 11 times

Re: Exhaust and Intake Risers Touching?

Post by shoffert »

I'll wait for the parts to show and let everyone know if this solved the issue.

Thank you!
User avatar
Rich
5 Diamonds Member
5 Diamonds Member
Posts: 4592
Joined: Mon Aug 30, 2010 12:40 pm
First Name: Rich
Aircraft Type: DA40
Aircraft Registration: N40XE
Airports: S39 Prineville OR
Has thanked: 145 times
Been thanked: 1180 times

Re: Exhaust and Intake Risers Touching?

Post by Rich »

shoffert wrote: Mon May 18, 2020 6:29 pm I'll wait for the parts to show and let everyone know if this solved the issue.

Thank you!
If the "touching" is happening on the #1 exhaust riser itself, above the first joint, I don't see it helping. There is extremely little "wiggle" room for the intake pipe or the #1 riser. But there's only so much one can glean from the photographs. You're in a better position to assess this than I.
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
Post Reply