DA42-TDI Exhaust Update

As you may be aware we have had numerous challenges in 2024 with the exhaust systems on our two twin-engine DA42-TDI aircraft. We are not alone, all DA42-TDI aircraft from serial number 4 and up are subject to the same problem (as outlined in a mandatory service bulletin MSB 42-129). Exhaust parts installed by the factory are typically lasting between 6 and 15 hours of flight time before replacement is required. 

Both of our DA42 aircraft are currently grounded and are expected to be back online this week (C-GXSU is now back online as of yesterday afternoon). As you can see from the attached summary report, we have replaced multiple exhaust parts this year. Each time we replace exhaust parts, we are typically looking at a two (2) week turnaround from Continental (USA) because they do not allow the Diamond factory or DFC London to stock exhaust parts (until just recently). 

We have had very few problems with exhaust parts until this year and we believe the problem stems from the weld on the heat shield portion of the part not being deep enough into the material to be secure on a long term basis (compared to the previously manufactured parts). 

Short Term Solution: 

We have now (finally) been permitted to purchase 2 complete sets of exhaust parts and those parts have arrived at the factory and have completed the factory quality control process for installation (today and tomorrow). With parts now in stock locally, we are looking at a turnaround time of hours in contrast to the 2+ weeks that it was taking previously. This recent change to having local inventory of the exhaust parts available will help us minimize the downtime for students and should keep the mullti-engine training moving forward with minimal disruptions. 

Long Term Solution: 

A local welding shop has been working with the factory to apply for a special Supplemental Type Certificate (STC) for a welding repair that should fix the problem with the weld on the heat shield portion of the part. This process will take time to get approved and implemented, but should provide a longer term fix to all DA42-TDI aircraft operators. 

We will continue to keep everyone updated as things progress. Please do not hesitate to contact us at any time should you have any further questions, comments or concerns. 

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- Diamond Flight Centre Team