DERS Project No. 2006-020

EO-2006-020-1 

ENGINEERING ORDER REV F 

DATE 08/18/2011 PROGRESSIVE FINAL

PAGE 1 OF 91 

Service Order Generating OPS RFTS No. 

Title Installation of the Seamech Vapor Cycle System (VCS) Air Conditioning System on the Diamond DA40-180

Operator/Customer 

Aircraft Model 

DIAMOND DA40 AIRCRAFT 

Effectivity: ATA 

Component Name 

 

Component Part No. 

 

Component S/N 

Part Name Part No. 

AD/PSE/SSI 

N/A 

Basis of Approval (Major only) 

STC 

 Major 

 Minor 

 N/A 

Initial Inspection Threshold N/A 

Repeat Inspection Interval N/A 

Life Limit N/A 

Aircraft Time 

Hours CYCLES 

 Permanent Repair 

 Time Limited Repair 

 Part Fabrication 

 Modification/Alteration 

 Inspection 

 Other 

References 

 

 

Prepared By 

 R. J. Belgau 

Date 

08/18/2011 

Approved By 

Robert Belgau 

Date 

08/18/2011 
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ENGINEERING ORDER REV F 

DATE 08/18/2011 Installation of the Seamech Vapor Cycle System (VCS) 

Air Conditioning System PAGE 2 OF 91 

DERS Project No. 2006-020

LOG OF REVISIONS 

Revision Date Description Pages 

Revised 

Approval 

I/R 08/31/2007 Initial Release 

A 04/30/2008 Added Relay Instl on Fig 6-5 

Added Relay Instl to work step 6.5 

Deleted work step 2.4 

Deleted 2.5" Hole From Fig 2-2 

Deleted 2.5" Hole From Fig 3-1 

Changed Sec 14 Title to include 

Control Head Installation. 

Re wrote Work instructions 14.1 thru 

14.4. 

Added work instructions 14.5 thru 14.9 

Changed Fig. 14-1 

Added Fig. 14-2 

Added 3 Adel to Clamps Fig 5-3 

Deleted Sec. 12 

Deleted Fig 12-1 

Corrected Typo Fig 13-5 

Added Ply Orientation Detail Fig 13-7 

Added PD-2006-020-1 to References 

Added Part # to work instruction 11.4 

Updated Part # Fig. 11-1 

Revise Fig 15-1 

Added (Ref. PD-2006-020-1) to Work 

Instructions 2.3, 2.5, 2.8, 

7.7, & 

13.9 

Pg 34 

 Pg 10 

Pg 9 

Pg 19 

Pg 24 

Pg 14 

Pg 14 & 15 

Pg 15 

Pg 51 

Pg 52 

Pg 29 

Pg 13 

Pg 43 

Pg 48 

Pg 50 

Pg 5 

Pg 13 

Pg 42 

Pg 55 

Pg 9 

Pg 11 

Pg 13 

 

B 01/06/2009 Changed Starter PN 

Changed PN Sec. 3.2 & 3.4 

Completed Sec 15 

Added Figures 15-1 to 16-4 

Pg 10 

Pg 9 

Pg 15 

Pgs 53-70 

C 06/02/2009 Added Work Instructions 4-2 thru 4-12 

Change Fig. 9-1 

Changed Reading Light Sec. 11 

Add Switch 

Added Work Instructions 11-5 thru 

11-7 

Pgs 10 & 11 

Pg. 51 

Pg. 14 
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Air Conditioning System PAGE 3 OF 91 

DERS Project No. 2006-020

C 

Continued 

Changed Fig. 11-1 

Added Fig. 11-2 

Added Notice to Figs. 15-11 & 15-12 

Change Sec. 18 to "Interior Reassembly 

Added Work Instructions 18-1 & 18-2. 

Added Figure 18-1 Through 18-5 

Move "Record Keeping" to Sec. 19 

Added “Note” to beginning of Sec. 8 

Pg. 53 

Pg. 54 

Pgs. 74 & 75 

Pg. 18 

Pg. 19 

Pgs. 82 - 86 

Pg. 18 

Pg. 14

D 07/06/2010 Changed Fig. 5-1 & 5-2 

Modified Work Instructions 5-1 thru 

5-3 

Pgs. 39 - 40 

Pgs. 11 - 12 

E 04/29/2011 Changed Fig. 5-2 Hardware & Note 

Change 

Modified Work Instruction 5-3 

Pg. 39 

F 08/18/2011 Changed Fig. 5-1 & 5-2 

Modified Work Instructions 5-1 thru 

5-3 

Update all references to ASI-772216A 

to reflect Rev. G or latest approved 

revision. 

Changed Fig. 15-9 

Added work instruction 15.5 

& Figs. 15-15 &15-16 

Deleted Work Instruction 15.10 

Deleted Fig. 15-10 

Changed Figs. 15-11 & 15-12 to reflect 

screen removal. 

Pgs. 39 - 40 

 Pgs. 11 - 12 

All 

Pg.71 

Pg.17 

Pgs. 78 – 79 

Pg. 17 

Pg.73 

Pgs. 74 & 75 
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Air Conditioning System PAGE 4 OF 91 

DERS Project No. 2006-020

This Sheet Intentionally Left Blank 
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DATE 08/18/2011 Installation of the Seamech Vapor Cycle System (VCS) 

Air Conditioning System PAGE 5 OF 91 

DERS Project No. 2006-020

 1.0 DESCRIPTION 

The purpose of this document is to provide work instructions for the installation of the Seamech Vapor Cycle System (VCS) 

Air Conditioning system on the Diamond DA40 aircraft. 

The Diamond DA-40 Vapor Cycle System (VCS) air-conditioning system is not a primary flight system. However, the 

system does perform the very important function of providing pilot and passengers comfort while the aircraft is on the 

ground, taxiing or in flight. Aircraft air-conditioning systems must not only provide effective passenger cooling, but must 

also maintain a high reliability level to minimize aircraft downtime. 

The Diamond DA-40 VCS air conditioning system consists of an engine driven compressor, a condenser/fan module, a 

receiver-dryer with Trinary pressure switch and an evaporator with an expansion valve and evaporator coil temperature 

sensor. Refrigerant barrier hoses connect the components. A combination of Steel and Aluminum fittings are used. 

-EvaporatorThe refrigerant vaporizes in the

evaporator. Heat and moisture

from the aircraft are removed.

Low-temperature,

low-pressure gas -CondenserThe condenser receives the

high-temperature, high-pressure

vapor from the compressor.

This vapor is converted to a

liquid by removing heat.

-Expansion ValveThe expansion valve provides a regulated restriction

and thus a pressure drop for the liquid refrigerant.

Refrigerant cools as it passes through the valve.

High-temperature,

high-pressure liquid

Low-temperature,

low-pressure liquid

-CompressorThe compressor has three jobs:

1. Circulates the refrigerant through the system

2. Removes low-pressure vapor from the evaporator

3. Compresses low-pressure vapor to a high-pressure,

 high-temperature vapor.

Refrigeration Cycle of the Diamond DA-40.

The refrigeration cycle can be broken into four

phases:

->Compression-done by the VCS compressor

->Condensation-done in the condenser

->Expansion-done in the expansion valve

->Evaporation-done in the evaporator

High-temperature,

high-pressure gas

Refrigeration Cycle
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Air Conditioning System PAGE 6 OF 91 

DERS Project No. 2006-020

2216507 HOSE ASSY

2216110

EVAPORATOR/BLOWER

ASSY

2216515 HOSE ASSY

PART NUMBERS LISTED HERE ARE FOR GENERAL REFERENCE

ONLY. PLEASE REFER TO THE CURRENT PARTS CATALOG FOR

CORRECT, UP TO DATE, PART NUMBERS.

BULKHEAD FITTING

(INCL. W/ 2216513) 4842115

COMPRESSOR ASSY

2216513 HOSE ASSY

BULKHEAD FITTING

(INCL. W/ 2216503)

2216501 HOSE ASSY

2216503 HOSE ASSY 0857372

DRYER ASSY

2216509

HOSE ASSY

CONDENSER/FAN ASSY

2216051

2216505 HOSE ASSY

R-134a SERVICE

PORT-HIGH

2216511 HOSE ASSY

R-134a SERVICE

PORT-LOW

VCS Schematic 
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DATE 08/18/2011 Installation of the Seamech Vapor Cycle System (VCS) 

Air Conditioning System PAGE 7 OF 91 

DERS Project No. 2006-020

2.0 REFERENCES 

1. Diamond DA40 Maintenance Manual Rev 4 

2. Diamond DA40 IPC 

3. ASI-772216A, Rev.G or latest approved revision.Vapor Cycle Air Conditioning With 

Automatic Climate Control Instructions For Continued Airworthiness 

4. PD-2006-020-1, DA40-180 Composite Penetration Reinforcement. 

5. Lycoming Overhaul Manual 60294-7 December 1974. 

3.0 LIST OF FIGURES 

 2-1. Refrigerant line holes in firewall shelf. 

 2-2. Refrigerant line holes in forward seat bulkhead. 

 2-3. Refrigerant line holes in baggage compartment frame.

 2-4. Receiver / Dryer mount holes in baggage compartment frame. 

 2-5. Refrigerant line holes in fuselage belly. 

 2-6. Hole sealing procedure. 

 3-1. Refrigerant line installation in forward seat bulkhead. 

 3-2. Refrigerant line installation in firewall shelf. 

 3-3. Refrigerant line installation in baggage compartment frame. 

 4-1. Fuel line disconnect. 

 4-2. Fuel line assembly removal. 

 4-3. Re-install oil pan bolts. 

 4-4. Disassemble fuel line assembly. 

 4-5. Re-assemble fuel line assembly. 

 4-6. Fuel line assembly fitting alignment. 

 4-7. Re-install chafe sleeve. 

 4-8. Fuel line assembly installation. 

 4-9. Starter installation. 

 5-1. Compressor bracket installation

 5-2. Compressor installation

 5-3. Refrigerant line installation in engine compartment.

 6-1. Refrigerant line slot in baggage compartment insert.

 6-2. Evaporator drain hose hole in baggage compartment insert.

 6-3. Baggage compartment insert shoring. 

 6-4. Evaporator Assembly installation. 

 6-5. ECU & Relay installation. 

 6-6. Blower controller installation. 

 6-7. Evaporator Cover Assembly installation. 

 7-1. Condenser Assembly installation. 

 7-2. Hard point fabrication procedure. 
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Air Conditioning System PAGE 8 OF 91 

DERS Project No. 2006-020

 8-1. Receiver / Dryer installation. 

 10-1. Air duct installation. 

 11-1. Reading Light Wiring. 

 11-2. Reading Light / Vent Installation. 

 12-1. Deleted. 

 13-1 thru 13-7. Cowling Blister installation. 

 14-1. Control Head / Temp Sensor assembly installation. 

 15-1. Wire Routing Overview 

 15-2. Wire Routing Detail 

 15-3. Wire Routing Detail. 

 15-4. Wire Routing Detail. 

 15-5. Wire Routing Detail. 

 15-6. Wire Routing Detail. 

 15-7. Wire Routing Detail. 

 15-8. Wire Routing Detail. 

 15-9. Bonding Strap Routing Overview. 

 15-10.Bonding Strap Routing Detail. Deleted 

 15-11.Bonding Strap Routing Detail. 

 15-12.Bonding Strap Routing Detail. 

 15-13.Bonding Strap Routing Detail. 

 15-14.Bonding Strap Routing Detail. 

 15-15 Compressor Bonding Strap Routing Overview. 

 15-16 Compressor Bonding Strap Routing & Connection Detail. 

 16-1. Master Switch Installation. 

 16-2. Master Switch Installation. 

 16-3. Master Switch Installation. 

 16-4. Master Switch Installation. 

 18-1. Hose Carpet Cover Installation. 

 18-2. Hose Carpet Cover Installation. 

 18-3. Hose Carpet Cover Installation. 

 18-4. Hose Carpet Cover Installation. 

 18-5. Hose Carpet Cover Installation. 

 

 

4.0 Accomplishment Instructions 
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Air Conditioning System PAGE 9 OF 91 

DERS Project No. 2006-020

General Notes: 

1. Maintenance personnel should thoroughly familiarize themselves with this Engineering 

Order, the Diamond DA40 Maintenance Manual (MM) and the Vapor Cycle Air 

Conditioning with Automatic Climate Control Instructions for Continued Airworthiness 

(ICA) prior to starting this modification. 

2. Follow all guidelines of Diamond DA40 MM. 

3. Contact DER Services Inc. for any discrepancies with paperwork or there are any problems 

associated with installation or removal of structure. 

4. Torque all refrigerant connections Per.ASI-772216A Rev. G or latest approved revision 

Section 3. 

Work Instructions MECH INSP 

1. Prepare Aircraft for Installation 

1.1 Begin by unpacking the installation kit. Check the condition of 

each part. If any items are damaged or missing contact Seamech

 

1.2 Prepare aircraft for maintenance by disconnecting the battery, 

and following recommended procedures in the Diamond DA40 

Maintenance Manual Rev 4. Sec. 6.02.01 

 

2. Refrigeration Line Pre-Installation 

2.1 Gain access to the aircraft and prepare it for the installation of the 

system by: 

a. Disconnect power to aircraft per MM Sec. 24-60-00. 

b. Removing the upper and lower engine cowling. 

c. Remove spinner, propeller and propeller hub. 

d. Remove starter ring gear and identify it with a 

identification tag stating aircraft model, S/N and date 

removed, and airworthiness. Route to stores. 

e. Remove starter and tag and route to stores. 

f. Remove front and rear passenger seats. 

g. Remove aft baggage compartment 

h. Remove glare shield 

i. Remove L/H fwd side liner (near pilots feet) 

 

2.2 Begin installation by drilling holes in the firewall for 

refrigeration lines and compressor clutch (Ref. Fig. 2-1) 

 

2.3 Drill two 1-3/8” holes in the fwd seat bulkhead (Ref. Fig. 2-

2)(Ref. PD-2006-020-1 Section 3.1 for penetration 

reinforcement) 

 

2.4 DELETED 
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Air Conditioning System PAGE 10 OF 91 

DERS Project No. 2006-020

Work Instructions MECH INSP 

2.5 Drill two 1-3/8” holes in the baggage compartment frame (Ref. 

Fig. 2-3) (Ref. PD-2006-020-1 Section 3.2 for penetration 

reinforcement) 

 

2.6 Drill two 1⁄4” holes in the baggage compartment frame to 

support the receiver drier (Ref. Fig. 2-4). 

 

2.7 Fabricate template as shown (Ref. Fig. 2-5). Align template and 

drill two holes, 1-1/4” and 1” respectfully in the fuselage belly. 

(Ref. Fig. 2-5) 

 

2.8 Seal holes drilled in fuselage belly as shown (Ref. Fig. 2-6). 

(Ref. PD-2006-020-1 Section 3.3 for penetration reinforcement)

 

3. Refrigerant Line / Primary Electrical Harness Installation 

3.1 Starting in the center of the aircraft, route the refrigerant lines, 

PNs 22116513 & 22116503, and electrical harness, PN 

2216392, forward over the main spar, under the pilots seat 

support, over the secondary fwd bulkhead and through the two 

1-3/8” holes in the forward bulkhead. (Ref. Figs. 3-1 & 9-1) 

 

3.2 Install the two rubber grommets P/N 2216516-11 onto the lines 

and harness and into the 1-3/8” holes in the forward bulkhead. 

Secure lines with two P/N MS21919WDG14 & 

MS21919WDG16 Adel clamps (Ref. Figs. 3-1 & 9-1) 

 

3.3 Install refrigeration lines and compressor clutch wire through 

firewall and secure locking nuts as (Ref. Figs. 3-2 & 9-1). 

 

3.4 Prior to routing the refrigerant lines and electrical harness aft, 

install the two rubber grommets P/N 2216516-11 onto the aft 

end of the refrigerant lines and electrical harness. 

 

3.5 Route the refrigerant lines and electrical harness aft through the 

1-3/8” holes in the aft baggage compartment frame and install 

the rubber grommets. (Ref. Figs. 3-3 & 9-1) 

 

3.6 Leave excess lines and electrical harness coiled in the baggage 

compartment at this time. 

 

4. Starter Installation 

4.1 Remove existing starter. (Ref. Diamond DA40 Maintenance 

Manual Rev 4. Sec. 80.00.00 pgs. 206-207) 

 

4.2 Disconnect fuel line at fuel servo and fuel pump. (Ref. 

Diamond DA40 Maintenance Manual Rev 5. Sec. 77.40.00 pgs. 

204-206) 

 

4.3 Remove fuel flow sensor bracket and fuel line assembly (Ref. 

Fig. 4-2) 

 

4.4 Re-install oil pan bolts (Ref. Lycoming maintenance manual 
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Air Conditioning System PAGE 11 OF 91 

DERS Project No. 2006-020

Work Instructions MECH INSP 

60294-7, December 1974, Sec.3 Para. 3-46, which refers to 

table of limits, Lycoming document SSP2070 which is 

superseded and replaced by Lycoming document SSP1776 

dated April 30 1979, Ref. Sec. V, Torque & Springs, Table 1, 

Bolts, Threads and Nuts, for torque requirements, Sec.9-39 for 

corrosion prevention and Fig. 4-3) 

4.5 Remove fuel flow sensor from fuel line assembly (Ref. Fig.4-4) 

4.6 Replace existing fuel line by attaching the straight end of the 

new fuel line PN 124F001-6CR0106 to the "OUT" end of the 

existing fuel flow sensor and either end of the other new fuel 

line PN 124F001-6CR0097 to the "IN" side of the fuel flow 

transducer. Hand tighten only. (Ref. Fig. 4-5) 

 

4.7 With 90° fitting at fuel servo end, dry run fuel line assembly 

installation to achieve proper fitting alignment prior to 

tightening fuel line to transducer fittings (Ref. Fig. 4-6) 

 

4.8 With proper alignment achieved, tighten fuel line to transducer 

fittings (Ref. Diamond DA40 Maintenance Manual Rev 5. Sec. 

77.40.00 pgs. 204-206 for torque requirements and Fig. 4-6) 

 

4.9 Remove dry run fuel line assembly and re-cover fuel flow 

transducer using existing chafe sleeve. Replace steel hose 

clamps with tie wraps PN TY525M or equivalent. 

(Ref. Fig. 4-7) 

 

4.10 Install fuel line assembly (Ref. Diamond DA40 Maintenance 

Manual Rev 5. Sec. 77.40.00 pgs. 204-206 for torque 

requirements). 

 

4.11 Re-connect fuel flow transducer connector and tie wrap to fuel 

line assembly using PN TY525M or equivalent (Ref. Fig. 4-8). 

 

4.12 Install starter Sky-Tec PN 149-NL/ec per manufacturer's 

installation instructions (Be sure to remove 12V/24V jumper 

per manufacturer's instructions) Ref. Fig. 4-9 

 

5. Compressor / Compressor Wire Installation 

5.1 Install Lycoming P/N 38-13 threaded studs into existing 

threaded holes on engine block & remove nut and spacer from 

existing stud. (Ref. Fig 5-1). 

 

5.2 Install compressor clevis bracket assembly onto the engine 

using existing 1⁄2 threaded stud and added 3/8 studs 

(Ref. Fig. 5-1). Torque in accordance with SII2216155 Rev. D 

or latest approved revision. Drawing Note 9 

 
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Air Conditioning System PAGE 12 OF 91 

DERS Project No. 2006-020

Work Instructions MECH INSP 

5.3 Install compressor, drive belt tension bracket, and aft 

compressor bracket onto the compressor clevis bracket 

(Ref. Fig. 5-2). Ref. SII2216155 Rev. D or latest approved 

revision. Drawing Notes 8 thru 16 for installation & torque 

requirements. 

 

5.4 Install Lycoming Flywheel P/N LW15882, alternator belt and 

AC belt P/N 2216145-9 per. MM Sec. 80-00-00. 

 

5.5 Tension belt alternator belt per the aircraft MM Sec. 24-30-00 

figure 4, section 4. 

 

5.6 Tension the AC belt per Seamech document ASI-772216A Rev. 

G or latest approved revision. 

 

5.7 Reinstall the propeller hub, propeller and spinner per the 

aircraft MM Section 61-10-0 section 2 or Hartsell tech data. 

 

5.8 Install refrigeration lines P/N 2216501 and P/N 2216515 

between the compressor and firewall fittings. (Ref. Fig. 5-3). 

 

5.9 Secure refrigeration lines and compressor wire (Ref. Fig. 5-3). 

Tie rap and secure (Ref. Fig. 15-2). 

 

6. Baggage Compartment Modification 

6.1 Modify baggage compartment to accept refrigeration lines by 

cutting a 1-1/2” wide by 3” long slot in lower LH baggage 

compartment floor (Ref. Fig. 6-1). 

 

6.2 Drill hole for drain tube in the base of the baggage 

compartment (Ref. Fig. 6-2). 

 

6.3 Support baggage compartment upside down on work bench, 

plumb and secure (Ref, Fig. 6-3). 

 

6.4 Install evaporator assembly in aft baggage compartment 

(Ref. Fig. 6-4). 

 

6.5 Locate and install ECU P/N 2216613 and Relay Module P/N 

2209328 (x3) on R/H wall of the aft section of the baggage 

compartment (Ref. Fig. 6-5). 

 

6.6 Locate and install Blower Controller P/N 4844297 on R/H wall 

of the aft section of the baggage compartment (Ref. Fig. 6-6). 

 

6.7 Right baggage compartment, locate and install P/N 2216403 

Evaporator Cover (Ref. Fig. 6-7). 

 

7. Condenser Installation 

7.1 Attach hose assembly P/N 2216503 to hose assembly 

P/N 2216505 and torque to 16 – 20 foot-pounds. 

 

7.2 Pass refrigeration hose assembly P/N 2216505 through the LH 

1-1/4” hole. 

 

7.3 Pass refrigeration hose assembly P/N 2216507 through the RH 
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DERS Project No. 2006-020

Work Instructions MECH INSP 

1” hole. 

7.4 Connect refrigeration hoses to P/N 2216051 and hand tighten 

only. 

 

7.5 Hold the condenser against the belly of the aircraft and align 

parallel to the fuselage center line. (Ref. Fig. 7-1) 

 

7.6 Locate and pilot the condenser attachment holes in fuselage 

(Ref. Fig. 7-1). 

 

7.7 Remove the condenser and create hard points (Ref. Fig. 7-2). 

(Ref. PD-2006-020-1 Section 3.4 for penetration reinforcement)

 

7.8 Pass fan wire and OAT sensor wire through the adjacent 

refrigerant holes and secure the condenser to the fuselage using 

AN525-1032R16 screws and AN960-10 washers. Torque to 20 

in-lbs. 

 

8. Receiver Dryer Installation / Electrical Connection 

Note: 2 oz of POE oil must be added to the receiver dryer inlet fitting 

prior to attaching any hoses. 

 

8.1 Attach hose assembly P/N 2216507 coming from the condenser 

to the inlet port on the Dryer Assembly P/N 0857372. 

Hand tight only 

 

8.2 Attach hose assembly P/N 2216509 to the outlet port on the 

Dryer Assembly P/N 0857372 dryer assembly. Hand tight only 

 

8.3 Install the dryer assembly to the baggage compartment frame 

(Ref. Fig. 8-1). 

 

8.4 Torque the hoses on the dryer assembly (Ref. Seamech 

Document ASI-772216 Sec. 3.0 for torque values). 

 

8.5 Connect electrical connector J315 (Ref. SII 2216392 & 

Fig. 15-7) 

 

9. Baggage Compartment / Refrigerant Line / Relay Harness Finalization 

9.1 Reinstall baggage compartment per the aircraft MM Sect. 

22-10-00 5(A)1. 

 

9.2 Attach hose assembly P/N 2216511 to evaporator assembly 

9.3 Attach hose assembly P/N 2216511 to hose assembly 

P/N 2216513 coming from the compressor. (Ref. Seamech 

Document ASI-772216A Rev. G or latest approved revision. 

Sec. 3.0 for torque values). 

 

9.4 Attach hose assembly P/N 2216509 from the dryer assembly to 

the expansion valve on the P/N 2216110 evaporator assembly. 

(Ref. Seamech Document ASI-772216A Rev. G or latest 

approved revision. Sec. 3.0 for tourque values). 

 

9.5 Connect electrical connectors J301, J310, J321 (Ref. SII 
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DERS Project No. 2006-020

Work Instructions MECH INSP 

2209328 & Fig. 15-8) 

9.6 Pressure test the system per Seamech instructions. (Ref. ASI772216A Rev. G or latest approved revision. Sec. 5.3)  

After successful system pressure test secure refrigerant lines and wire harness as follows 

9.9 Install "Click Bond Cable Tie Standoffs" P/N CB4021G3N12P 

using "Click Bond P/N CB200 Acrylic Structural Adhesive" to 

bond to fuselage, per "Click Bond Adhesive Diagram CB9813" 

beside refrigeration lines (Ref. Fig. 9-1). 

 

9.10 Secure refrigeration lines secondary forward bulkhead 

(Ref. Fig. 3-1). 

 

9.11 Secure wire harness to refrigeration lines (Ref. Fig. 9-1 

& Sec.15) 

 

10. Air Duct Installation 

10.1 Locate aft air duct P/N 2216401 in cabin by aligning the large 

opening onto the flange of the evaporator outlet, holding the 

narrow end to the aircraft center line on the overhead structure. 

(Ref. Fig. 10-1). 

 

10.2 Pilot drill the four attachment holes in the overhead structure 

and two attachment holes into the evaporator outlet flange 

(Ref. Fig. 10-1) and then remove the duct. 

 

10.3 Layout and cut the air inlet opening in the overhead roll bar 

front structure. CUT ONLY THE INNER STRUCTURE. IPC 

53-10 pg 2. (Ref. Fig. 10-1). 

 

10.4 Install six folded Tinnerman nuts P/N A1350-10Z-1D and 

install duct (Ref. Fig. 10-1 Detail G). 

 

10.5 Install P/N 2216403 evaporator closeout panel with 

AN526C1032R8 screws into previously installed nutplates 

(Ref. Fig. 6-7). 

 

11. Air Duct Modification 

11.1 Remove both overhead reading lights (ref. DA40 IPC 33-10, 

pg. 2 & MM Sec. 33-10 pg. 201). 

 

11.2 Remove both overhead gasper vents (Ref. DA40 IPC 21-20 

pg.2) 

 

11.3 Ref. Fig. 11-1 for reading light wiring modification. 

11.4 Cut 2 switch holes in overhead. (Ref. Fig. 11-2). 

11.5 Install 2 switches PN CWT12AAS1 (Ref. Fig. 11-2) 

11.6 Ream out original gasper vent holes to 2.00" and install 2 

Reading Lights PN RL6927 using RTV732 silicone adhesive 

(Ref. Fig. 11-2). 

 

11.7 Install PN 2216415 vent assemblies using RTV732 silicone 
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DERS Project No. 2006-020

Work Instructions MECH INSP 

adhesive in original reading light location (Ref, Fig. 11-2). 

12. Deleted 

12.1 Deleted 

12.2 Deleted 

12.3 Deleted 

12.4 Deleted 

12.5 Deleted 

12.6 Deleted 

13. Lower Engine Cowling Modification 

 Prior to undertaking this procedure, review thoroughly DA40 

MM Sec. 51-20 & 51-30 for accepted practices concerning 

preparation and execution of composite structure repairs. 

 

13.1 Apply protective covering to avoid finish damage 

(Ref. Fig. 13-1). 

 

13.2 Mark cowling (Ref. Fig. 13-1). 

13.3 Mark blister P/N 2216245 (Ref. Fig. 13-1). 

13.4 Align blister with cowling (Ref. Fig. 13-1). 

13.5 Trace blister (Ref. Fig. 13-1). 

13.6 Remove blister. 

13.7 Mark center line on cowling (Ref. Fig. 13-2). 

13.8 Mark cowling for view hole (Ref. Fig. 13-2). 

13.9 Cut view hole in cowling (Ref. Fig. 13-2). 

(Ref. PD-2006-020-1 Section 3.5 for penetration reinforcement)

 

13.10 Align cowling with mounts and clear remaining interference 

material (Ref. Fig. 13-2). 

 

13.11 Mount cowling to aircraft & verify clearance (Ref. Fig. 13-2). 

13.12 Verify blister location on cowling (Ref. Fig. 13-3). 

13.13 Remove blister and cowling. 

13.14 Scarf Cowling (Ref. Fig. 13-3 & 13-4) & DA40 MM Sec. 51-

20 pg. 214, Table 2 for minimum scarf dimensions. 

 

13.15 Scarf blister flange (Ref. Fig. 13-3 & 13-4) & DA40 MM Sec. 

51-20 pg. 214, Table 2 for minimum scarf dimensions. 

 
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DATE 08/18/2011 Installation of the Seamech Vapor Cycle System (VCS) 

Air Conditioning System PAGE 16 OF 91 

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Work Instructions MECH INSP 

13.16 Mount cowling to aircraft to avoid distortion during bonding 

process. 

 

13.17 Align blister on cowling in final position and tape in place. 

13.18 Drill 8 #40 locating holes (Ref. Fig. 13-5). 

13.19 Prepare area for bonding process (Ref. DA40 MM sec. 51-20). 

13.20 Prepare locating screws (Ref. Fig. 13-5). 

13.21 Mix bonding paste (Ref. DA40 MM Sec. 51-20 pg. 206 

Table 1). 

 

13.22 Apply sufficient amount of bonding paste to both mating 

surfaces. 

 

13.23 Align blister on cowling and fasten with prepared screws at the 

8 predrilled locating holes. 

 

13.24 Clean up all excess bonding paste and allow to cure (Ref. DA40 

MM Sec. 51-20 pg. 207 item 7). Cowling may be removed from 

aircraft after step (1) has been completed. 

 

13.25 Remove locator screws and fill holes (Ref. Fig. 13-6). 

13.26 Trim overhanging material (Ref. Fig. 13-6). 

13.27 Smooth joint radius (Ref. Fig. 13-6). 

13.28 Prepare joint for lamination (Ref. DA40 MM Sec. 51-20). 

13.29 Laminate joint (Ref. Fig. 13-7). 

13.30 Laminate joint continued (Ref. Fig. 13-7). 

13.31 Laminate joint continued (Ref. Fig. 13-7). 

13.32 Prepare and paint both surfaces (Ref. DA40 MM Sec. 51-20 

pgs.208 - 212) 

 

14. Cabin Temperature Sensor / Control Head Installation 

Temperature Sensor / Control Head Electrical Connection 

14.1 Remove Map Pocket Assembly PN DA4-2583-65-00 from 

Rudder Cable Cover PN DA4-2583-61-00 (Ref. DA40 IPC Sec. 

25-10 Pgs. 10 & 11). Remove Velcro and clean any residual 

glue. 

 

14.2 Align Control Head And Cabin Temp Sensor Assembly 

Installation PN 2216351 on the outboard side of Rudder Cable 

Cover so the mount panel extends past both the fore and aft 

ends of the opening for the removed map pocket assembly 

(roughly 1" on each end), and reasonably matches the shape of 

Rudder Cable Cover. Match drill the 2 existing mount holes in 

the panel to the mount plate. Cleco both parts together. 

(Ref. Fig. 14-1) 

 

14.3 Press mount plate snug against mating surface and match drill 

existing holes in mount plate to Cable Cover from outboard 

 
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DATE 08/18/2011 Installation of the Seamech Vapor Cycle System (VCS) 

Air Conditioning System PAGE 17 OF 91 

DERS Project No. 2006-020

Work Instructions MECH INSP 

side using a # 30 drill bit. Cleco together as you go. (Ref. Fig. 

14 - 1) 

14.4 Remove Clecos, separate parts and drill out # 30 holes to #10. 

14.5 Fasten parts together using supplied fasteners. (Ref. Fig. 14-1) 

14.6 Connect Harness Extension PN 2216301 to J307 

(Ref. PN 2216392) 

 

14.7 Connect J314 (Ref. PN 2216392) to Control Head PN 2216345 

14.8 Attach Cable Tie Mount PN MB-3A to outboard side of Rudder 

Cable Cover. Create 4.0" service loop and tie wires using wire 

ties T (Ref. Fig. 15-3) 

 

14.9 Install Rudder Cable Cover (Ref. DA40 IPC Sec. 25-10 Pgs. 10 

& 11) 

 

15. Electrical / Wire Routing Detail 

15.1 Review Wire & Hose Routing Overview (Fig. 15-1) 

15.2 Sleeve clutch wire using SE12PSC-TR0 Expandable sleeve, 

from harness to extend from firewall opening to 2.00" past butt 

connector. 

 

15.3 Connect clutch wire from compressor and secure to lower 

refrigerant hose. (Ref. Fig. 15-2) 

 

15.4 Continue to secure wire harness in forward cabin. 

(Ref. Fig. 15-3) 

 

15.5 Continue to secure wire harness in mid cabin. 

(Ref. Fig. 15-4) 

 

15.5 Continue to secure wire harness in aft cabin. 

(Ref. Fig. 15-5) 

 

15.6 Continue to secure wire harness and refrigerant under aft seat 

and baggage floor. 

(Ref. Fig. 15-6 & 15-7) 

 

15.8 Continue to secure wire harness in aft baggage compartment. 

(Ref. Fig. 15-8) 

 

15-9 Review Bonding Strap Overview (Fig. 15-9) 

15-10 Install compressor bonding strap (Ref. Fig. 15-10) Deleted 

15-11 Install forward grill strap.

(Ref. Fig. 15-11) Deleted 

 

15.12 Install condenser fan jumper bonding strap. 

(Ref. Fig. 15-12) 

 

15.13 Connect jumper from condenser, evaporator fan, and evaporator 

bonding straps to existing aircraft bonding strap. 

(Ref. Fig. 15-13) 

 

15.14 Connect evaporator fan and evaporator bonding straps. 
EO-2006-020-1 

ENGINEERING ORDER REV F 

DATE 08/18/2011 Installation of the Seamech Vapor Cycle System (VCS) 

Air Conditioning System PAGE 18 OF 91 

DERS Project No. 2006-020

Work Instructions MECH INSP 

(Ref. Fig. 15-14) 

15.15 Install and connect compressor bonding strap. Ref. Figs. 5-2, 

15-15, & 15,16. 

 

16. A/C System Master Switch Installation 

16.1 Drill a ø.125" x .375" deep pilot hole through lens and 

aluminum flange. (Ref. Fig. 16-1) 

 

16.2 Remove MFD, flaps switch guard, and aux power outlet. 

(Ref. Fig. 16-1) 

 

16.3 Remove plastic lens. (Ref. Fig. 16-2) 

16.4 Upsize holes to accommodate switch breaker 

PN W31X2M16-1 (Ref. Fig. 16-3) 

 

16.5 Reinstall all items removed to accommodate installation. 

16.6 Placard switch. (Ref. Fig. 16-4) 

17. Ground Test 

17.1 Perform Ground Test Plan SR-2006-020-4 Rev I/R 

Dated 05/01/2008 

 

18. Interior Re-assembly 

18.1 Re-install all removed items to accommodate installation. 

18.2 Install "Carpet Hose Cover Assy" PN F2009-019-1. (Ref. 

Fig. 18-1 through 18-5) 

 

19. Record Keeping 

19.1 Refer to Diamond DA40-180 Weight and Balance Manual. Reweigh aircraft and update weight and balance record. 

 
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Figure 6-6