Diamond DA40 IO-360

Bolt on Horsepower. Complete replacement of your exhaust system. 

FAA approved by STC and for DA40 with IO-360 engines, MT propellers and Compatible Hartzell Propellers (see below).

Replaces part number(s):D41-7800-70-00, D40-4, D41-7800-10-00, D41-7800-20-00, D41-7800-30-00, D41-7800-40-00

Product Brochure - Click Here to Download

Interesting Factoid: When Diamond Aircraft's engineers saw the performance gains we were advertising when we first introduced our system for the DA40 in 2006, they were convinced that we had to be wildly inflating those gains. They jumped at our offer to let them do their own testing of our system on a DA40 at their facility in London, Ontario. 

The results of those tests (which demonstrated performance improvements even higher than we were claiming) led Diamond to include the Power Flow System as standard, OEM equipment on all DA40-XL & XLS models since the 2007 model year.

For DA40’s that were not equipped with our system at the factory, we offer a complete replacement of your current exhaust system. Our system is FAA approved by STC for DA40’s with I/O-360 engines, MT propellers and Compatible Hartzell Propellers (see below). 

The same exhaust system that is now standard on all Diamond DA40-XL/XLS series, is available to all MT propeller equipped DA40's and is now compatible with the new Hartzell 2-blade aluminum prop (7497) or composite propeller installed under STC SA02476CH-D. 2004-2008 DA40s with the 7495s propeller must change propellers in order to install the PFS exhaust. Power Flow is an authorized distributor for this propeller and can include a current price quote from Hartzell with the quote for your new Tuned Exhaust along with a package discount for buying both from us.

The Power Flow System immediately gives your DA40 the following improvements:

• 5 - 8 knots faster cruise speeds

• 10% – 15% increase in rate of climb

• 0.5 – 1.5 gph reduction in fuel burn at equivalent airspeed

• Improved Take-Off Performance (100’ – 300’ reduction in ground roll)

• Increase in Service Ceiling of 2,000’ – 5,000’ with a corresponding improvement in safety margins during high density altitude operations

• Cooler CHT’s

Don't just take our word for it - listen to what just some of our happy Power Flow customers have to say about the Power Flow tuned exhaust system on their aircraft: 

Our system is a significant improvement over the stock Diamond DA40 exhaust. It is a versatile, quality constructed, complete replacement of your entire exhaust system. You are in control. For more speed, use the extra power. For fuel savings, throttle back and fly your pre Power Flow airspeeds. For improved safety, the entire system is constructed from stainless steel and includes minimal structural welds in the cabin heat section. 

The exhaust system easily installs in less than a day. Your original exhaust outlet in the cowling must be patched (requires additional time). The system can be installed by one of our dealers, by your local A&P, or you can fly your plane to us for a local install. Fly in with a standard Diamond DA40, fly out tuned for performance similar to the XL. 

Our industry leading 60 day money back guarantee means that if for some reason the performance benefits listed above fail to materialize on your DA40, you can return the system to us within 60 days of its installation for a full refund of your purchase price. Fine Print? You just read it. 

For lead times and discounts see table below or click the Cardinal to purchase directly through our online store!  

Polished or Ceramic? 

The Ceramic Coated tailpipe is a cosmetic enhancement that hides the heat induced discoloration that is characteristic of stainless steel (think of the "bluing" you see on the muffler of a motorcycle). 

This discoloration has absolutely no effect on performance or reliability but the ceramic coating covers it up permanently. Otherwise, the polished tailpipe begins to discolor after a few hours of flying time.

It can be re-polished anytime, but if you are proud of your Diamond’s appearance and would rather spend your time flying than polishing, the ceramic is a nice feature to have.

A couple of other important pieces of information:

#1) We strongly recommend that the aircraft's propeller be dynamically balanced to within 0.2 ips (inches per second) upon installation of the Power Flow System and every two to four years thereafter. If the propeller is dynamically balanced within 25 flight hours of the installation of the Power Flow System and you furnish PFS with copies of the logbook entries confirming this, PFS will extend the warranty on the Tuned Exhaust System from 12 months to 24 months or 500 Flight Hours (whichever occurs first). 

Doing so every 2 - 4 years thereafter will dramatically improve the useful life and the reliability of every component that is bolted to the engine, including the Power Flow System.

#2) The Power Flow System has no service life limit. It is designed and built to last several thousand flight hours and will quite likely be the last exhaust system you need to buy for your aircraft. As with any high performance system however, it must be maintained properly. Every 500 flight hours or annually (whichever comes first) the four slip joints on the system must be cleaned and lubricated with high temperature anti-seize compound. 

Most Customers have this maintenance performed during the aircraft's annual inspection which adds about 2 hours of labor to the inspection. We have had several of our Tuned Exhaust Systems rack up over 4,000 flight hours of trouble free performance (7,000+ flight hours is the current record in a commercial operation) as long as this maintenance is performed as required.