Jabiru 2200 Overhaul Manual
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Jabiru 2200 Overhaul Manual

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See also: Maintenance Manual , Installation Manual
OVERHAUL MANUAL
FOR
JABIRU 2200 & 3300 AIRCRAFT ENGINES
DOCUMENT No. JEM0001-7
th
Date: 28
October 2014
This Manual has been prepared as a guide to correctly overhaul Jabiru 2200 & 3300 aero engines.
It is the owner's responsibility to regularly check the Jabiru web site at www.jabiru.net.au for
applicable Service Bulletins and have them implemented as soon as possible. Manuals are also
updated periodically with the latest revisions available from the web site. Failure to maintain the
engine or aircraft with current service information may render the aircraft un-airworthy and void
Jabiru's Limited, Express Warranty.
This document is controlled while it remains on the Jabiru server. Once this no longer applies the
document becomes uncontrolled.
Should you have any questions or doubts about the contents of this manual, please contact Jabiru
Aircraft Pty Ltd.
This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.
ISSUE
1
2
3
4
5
6
Dated : 26/6/2014
Issued By: DPS
Page: 1 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx

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Summary of Contents for Jabiru 2200

  • Page 1 Should you have any questions or doubts about the contents of this manual, please contact Jabiru Aircraft Pty Ltd. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 2 Tools: ....................................... 23 3.7.3 Equipment: ...................................... 23 3.7.4 General: ......................................24 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 2 of 201...
  • Page 3 5.8.2 High temperature operation ................................57 5.8.3 Bearing surfaces ....................................57 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 3 of 201...
  • Page 4 Ignition Coils ....................................118 7.5.2 Alternator ...................................... 118 7.5.3 Flywheel ......................................118 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 4 of 201...
  • Page 5 .............................. 179 VERHAUL OOKLET 9.10.1 Engine Details ................................... 179 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 5 of 201...
  • Page 6 UMBER ECODE 13.2 ..............................199 PDATE ISTORY ABLE This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 6 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...
  • Page 7 Figure 58 – Split Crankcase ............................49 Figure 59 – Remove Oil Strainer............................. 50 Figure 60 – Remove Con-Rods ............................50 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...
  • Page 8 Figure 120 – Fit Connecting Rods ..........................102 Figure 121 – Crankcase Assembly Preparation ......................104 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...
  • Page 9 Figure 181 – Applying Thread Lubricant & Tightening Lower Head Screw ..............144 Figure 182 – Fitting Rockers #1 ............................ 144 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 10 Figure 212 – Drilling & Reaming Flywheel – ILLUSTRATION ONLY................197 Figure 213 – Flywheel to crankshaft assembly drawing ....................198 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 11 Table 39 – Wear Factors ............................... 189 Table 40 – Mandatory Updates ............................. 190 Table 41 – Update History ............................199 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 12: General Information

    Jabiru harmless from any injury, loss, damage, or mishap that I, my spouse, heirs, or next of kin may suffer as a result of my use of any Jabiru product, except to the extent due to gross negligence or willful misconduct by Jabiru. I understand that proper skills and training are essential to minimize the unavoidable risks of property damage, serious bodily injury and death that arise from the use of Jabiru products.

  • Page 13: Basi

    Also, if a paragraph says “refer to Section 5.9” – then you can click on the “5.9” and automatically skip to that page. Similarly, if Figures or Tables are referenced. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 14: F D Ifficulty

    2 cycles. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 15 The overhaul booklets included in Section 9 are to be used for a top end overhaul – using only those pages relevant to the parts of the engine being renewed. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 16: Engine Identification

    – i.e. S/No. 200 – 250 use a triple-flexed widget while engines outside that range have double-flexed widgets. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 17: Part Identification

    The connecting rods are machined from solid bar 4140 chrome molybdenum alloy steel. They have replaceable bearing inserts in the crankshaft ends (big ends) and the piston ends (small This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 18: Crankshaft

    Fuel-air mix is distributed from the manifold to the cylinder heads by individual tubes. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 19: Ignition System

    Jabiru Engines. Guidance material is available in the Jabiru Engine Installation Manuals and Instruction & Maintenance Manuals. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 20: Bulk Strip

    700 hours will still only have 300 hours left to run after the bulk strip has been This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.

  • Page 21: Propeller Strike Procedures

    Details on removing these screws are included in Section 4.5.4. The procedure to be used for replacing the screws in the propeller flange is the same. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 22: Abrupt Engine Stop

    Record – The records of the overhaul must be completed, including lists of parts replaced and the records of the run-in (temperatures, pressures etc). This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 23: Facilities

     Degree wheel  Dial indicator and magnetic stand, vee blocks This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 23 of 201...

  • Page 24: General

     Lubricants: engine oil, Nulon L90  TorqueSeal brand security marking compound This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 24 of 201...

  • Page 25: Recommended Sealants Compounds & Lubricants

    Loctite 577 is designed for the locking and sealing of metal threaded pipes and fittings. Used to seal fuel, oil and brake fittings. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 26: Figure 6 – Sealants, Compounds & Lubricants #4

    High-temp grease – used to give initial start-up lubrication to many parts of the engine, including the oil seals.  “Cam Honey” (Molybdenum Disulphide) for cam journals and lobes. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 26 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 27: L Octite 620 & O Ther R Etaining C Ompounds

    A medium-strong threadlock. Typically used for cap screws into castings or Aluminium. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 28: Special Tools

    Used to compress the valve springs, allowing the rocker shaft to be removed and the hydraulic valve lifters to be bled. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 29: Figure 12 – Valve Leakage Vacuum Tester

    Sizes 7.03 / 7.04 / 7.05 / 7.06 / 7.07 / 7.08 Figure 15 – Valve Guide Size Gauges This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 30: Figure 16 – Leak Down Tester

    Used during honing with a “Christmas tree” hone to make the base of the cylinder complete. Without the hone helper the hone would catch on the cylinder skirts. 4” “Christmas tree” hone shown at right. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 31: Figure 20 – Piston Circlip Remover And Installer

    Jabiru Service Bulletin JSB012 refers. Figure 23 – Crankshaft / Flywheel Drilling Jig (for Dowels) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 32: Figure 24 – Degree Wheel

    Used to test ignition coil performance. Figure 27 – Ignition Coil Tester This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 32 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 33: Figure 28 – "Finger Bar

    Figure 30 – Carburettor Needle Seat Remover and Installer This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 34: Figure 31 – "Crowsfoot" Adaptors

    Figure 34 – Crankcase Stud Remover This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 35: Figure 35 – Crankcase Dowel Remover

     FU16B is the equivalent part with ½” socket for use on 7/16” 12-point nuts. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 36: Torque / Tension Wrench

    If the extension is oriented at 90° to the wrench as shown in Figure 40 then no correction is needed because L2 is zero. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 37: Torque Application Procedure

    Where directed otherwise it is vital that the directions are followed exactly. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 38: L:filesmanuals_For_Productsengine_Manualsoverhaul_Manualjem0001-7_Overhaul_Manual_Draft_(29_10_14).Docx

    Excessive twisting of the wire will weaken the wire. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 39: H Ardware

    Custom hardware – such as through bolts – must be as described in this manual. WARNING Failure to use correct hardware may lead to an unsafe condition. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 40: Disassembly Procedure

    Note that for a top end overhaul the engine can remain in the aircraft, although the use of an engine stand may be more convenient and is usually faster. Figure 44 – Engine Stand This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 41: S Pecial C Hecks B Efore D Isassembly

    The results of this test are an indicator only. False negatives and positives are possible. If in doubt, disassemble the engine and inspect to be sure. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 42: E Ngine S Trip : C Omplete O Verhaul

     Undo the retaining grub screw and extract the oil filler tube from between #1 and #3 cylinders. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 43: Flywheel Cap Screws

    Figure 47.  Drive the oil seals out of the drive housings. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 44: Flywheel

    Engine mount plate Engine mount plate Figure 49 – Remove Timing Gearbox Case This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 44 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 45: Engine Mount Plate And Sump

    Older motors used a different starter motor (on left, Figure 51). These motors are undone via Phillips- head screws through the cap of the motor. Figure 51 – Starter Motor Disassembly This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 46: Crankshaft Gear

    Some of the cylinder studs will come away with the cylinders: clamp these studs carefully in the padded jaws of a vice and remove the remaining base nuts from the studs. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 47: Pistons

    The seal housing cannot be removed completely at this stage but it should be freed from the crankcase (again, a soft hammer may be necessary). This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 48: Oil Return Manifolds

    Locking Plate Locking plate slot in case Figure 57 – Crankcase & Locking Plate This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 48 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 49: Crankcase

    Remove the main bearing shells. Remove all ‘O’ rings. The front and rear retained studs should be left in the cases at this stage; if necessary they will be removed after the inspection stage. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 50: Oil Pickup Tube And Strainer

     Remove the rod and end cap and the rod and then remove the big end bearing shells. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 51: Crankshaft

    This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 52: Accessories

    This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 53: Inspection And Assessment

    Oil cooler adaptor Engine mount rubbers Cylinder heads – upgrade earlier head types Cylinders This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 53 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 54: M Andatory R Eplacement I Tems – T Op E Nd O Verhaul

    Rubber T – from rocker oil feed line Starter motor & starter motor clutch Camshaft (visual check of lobes) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 55: G Eneral

    Any part for which this information is known will have a “Mandatory Discard” note in the inspection section below. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 56: C Leaning

    Apply a liberal coating of engine oil or other anti-corrosion product to all steel surfaces. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 57: I Nspection

    If pitting exists on any of the surfaces mentioned to the extent that it cannot be removed by polishing with crocus cloth or other mild abrasive, the part must be rejected. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 58: Magnetic Particle Inspection (Mpi)

    It is a very effective tool and the only screw extractor recommended by Jabiru Aircraft. Figure 62 – Stud & Broken Cap Screw Removal This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 59: Crankshaft And Propeller Flange

    This may require the replacement or modification of the propeller flange and crankshaft. Refer to Table 40 for S/No. at which this was introduced to production engines. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 60: Figure 64 – Starfish Flywheel

    This must be checked before deciding if a replacement is necessary or not – acceptable clearances are given in Table 12. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 61: Connecting Rods

    Older alloy or alloy-steel rods must be replaced with new steel rods. Figure 67 – Steel Con-Rod This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...
  • Page 62 Uneven bearing wear or abnormal little end wear are indicators of an untrue rod. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 63: Crankcase

    Radius each side of the hole and clean away any drilling debris.  Very old 2200 engines did not have a “strainer” fitted to the oil pump pickup. For these engines a strainer must be fitted at overhaul – this may also require fitting a new oil pump pickup tube.

  • Page 64: Figure 70 – Crankcase Fretting

    Where cases have been skimmed the main bearing and cam tunnels must be line bored per Table 10 for correct bearing fit up. This job can only be done by competent machine shop operators. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 65: Figure 72 – Removing Studs And Dowels From Crankcase

    This puts a lot more pressure on the oil and unless the oil is specifically designed for the application it can break down, leading to rapid wear of the engine. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 66: Hydraulic Valve Lifters

    The base of the inside of the lifter tends to accumulate sludge and must be cleaned if it is to be re-used.  Lifters must be cleaned and dried thoroughly before re-installation. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 67: Camshaft

    This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 68: Figure 76 – 2-Ring Camshaft

    (rounded lobes) for roller follower engines. Engines with other configurations must be updated to an approved configuration at overhaul. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 69: Oil Pump

    Figure 79 – Modified Port Details  This work can be carried out by hand using a Die Grinder or similar tool. Jabiru Aircraft can provide a 1:1 template if required. This work requires the disassembly of the oil pump and should only be carried out by an approved person with appropriate skills.

  • Page 70: Oil Pressure Relief Valve

    5.10.5 Oil Pressure Relief Valve 5.10.5.1 Mandatory updates Figure 81 – Oil Pressure Relief Valve This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 70 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...
  • Page 71 – more than 3 will result in coil-binding of the spring and relief valve malfunctions. Valve function can be checked by depressing the poppet and to ensure it can move off the seating washer. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 72: Pistons And Cylinders

    – any other type of metal scraper is discouraged for the same reasons. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 73: Figure 83 – Measuring Cylinders & Pistons

    If the clearance is greater outside the limits given in Table 12, then parts must be changed – pistons or cylinders – to obtain correct clearance. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 74: Cylinder Heads

    CHT’s. This is not acceptable for re-use as it alters the engines compression ratio. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 75: Valves

    45° - there is no undercutting. Figure 86 – Valve Measuring This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 76: Figure 87 – Valve Damage

    Tests like this will normally catch a poorly sealing valve before damage becomes critical. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 77: Valve Guides

    It is unusual for guides to need to be replaced after 1 cycle however it can happen. Figure 89 – Measure Guide Wear (Telescopic Gauge Left & Middle, Go-No-Go Gauge Right) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 78: L:filesmanuals_For_Productsengine_Manualsoverhaul_Manualjem0001-7_Overhaul_Manual_Draft_(29_10_14).Docx

     If new valve guides are fitted then the valve seats will need to be recut. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 79: Valve Seats

    Figure 91 (2 right pictures, above) shows a valve / valve seat being cut using a hand grinder and valve lapping paste on the sealing face. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 80: Figure 92 – Vacuum Test Rig

    Normal valve tip to rocker clearance with lifter fully bled is around 1.8 / 1.9mm. With later shortened pushrods of 215mm, add 1.0mm to above dimensions. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 81: Cylinder Head – Cylinder Seal

    Inspect valve spring washers (top and bottom) for wear. Worn parts must be replaced. Measure top spring washer thickness – minimum thickness 1.3mm. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 82: Figure 94 – Valve Springs, Pushrods

    Figure 96 – Pushrod Tube End This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 83: Rockers

    In solid valve lifter engines the rocker adjusters & lock nuts must also be examined & assessed for wear This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 84: Sump

    Oil drain New 2200 sump Old 2200 sump Figure 99 – 2200 Engine Sumps This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 84 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 85: Figure 100 – 3300 Engine Sumps

    Figure 100 – 3300 Engine Sumps  Very old type 2200 & 3300 engines used sumps where the induction manifold was cast as a part of the sump, with the intake tubes exiting the manifold at 90°. These sumps must be replaced with a newer type at overhaul.

  • Page 86: Induction Manifold

    3300 engines: Most 3300 engines are equipped with a bolt-on induction manifold assembly similar in appearance to the 2200 engine part shown in Figure 187 (note the shape of the diffuser used in this part – circled in the figure).

  • Page 87: Ignition Coils & Alternator

    Ensure the new connectors are a tight fit when test-assembled with a male connector. Figure 101 – Different Ignition Coil Models (Honda on Left, Jabiru on Right). This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 88: Flywheel/Starfish Attachment

     Older (Black) starter motors were less powerful. It is recommended that these be replaced at overhaul. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 89: Figure 103 – Starter Motor Old & New

    Check the bushes at each end of the clutch and bendix gear for wear and replace as required, lubricate the bushes with grease. Figure 104 – Typical Disassembled Starter Motor This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 90: Engine Mount Plate

    Using a straight edge, carefully check the plate in both directions for trueness. Often an engine which has been in an accident or had a severe propeller strike will be bent. Figure 106 refers This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 91: Gear Case & Distributors

    Each cap should fit with a clear “click” as it connects to the distributor cap or spark plug. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 92: Figure 108 – Adjusting High Tension Lead Caps

    JEM0001-7 Jabiru 2200 & 3300 Aircraft Engines Figure 108 – Adjusting High Tension Lead Caps This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 92 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 93: Carburettor

    The float bowl needle seat must be checked. 3300 engines use a 2.4mm diameter, specially shaped orifice in this part while the 2200 engine uses 2.0mm – though the 2.4mm seat is also acceptable for 2200 applications. Figure 30 shows the tools needed to change the seat which is located in the carburettor body above the float needle.

  • Page 94: Figure 109 – Carburettor Updates

    Float needle valve Jet Carrier Main Jet Figure 110 – Carburettor Schematic This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 94 of 201...

  • Page 95: Figure 111 – Disassembling Carburettor #1

    Do not use drills or wire to clean jets as this can alter their internal size and affect the engine tuning. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 96: Fuel Pump

    The float bowl needle seat must be checked. 3300 engines use a 2.4mm diameter, specially shaped orifice in this part while the 2200 engine uses 2.0mm (though the 2200 can also use a 2.4mm seat if required). Figure 30 shows the tools needed to change the seat which is located in the carburettor body above the float needle.

  • Page 97: Exhaust System

    Spring tags that are excessively worn must be replaced.  Systems that show signs of excess leakage must be adjusted or replaced. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 98: Assembly – Top-End Overhaul

    Assemble the connecting rods, cylinders, piston and cylinder head assemblies in accordance with the full overhaul procedures detailed in Section 7 below. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 99 For critical fasteners torque specifications are given in Table 9. Table 9 also gives generic torque values for other applications. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 100: Crankshaft, Propeller Flange

    Note that the propeller flange will be finally fitted after the front crankshaft seal housing has been fitted when the engine is removed from the workbench/engine stand. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 101: Connecting Rods

    Record the clearances on the build sheet. A typical crankshaft journal will measure around 45.00mm, requiring a typical big end bearing inner diameter of 45.04 – 45.06mm (see Table 10 for details). Again This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 102: Assemble

    L90 to the bearing surface and the journal and fit the rod and bearing cap to the crankshaft with the This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.
  • Page 103 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 104: Crankcase

    WARNING Ensure correct size dowels are used for final assembly. Figure 122 – Crankcase Dowels This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 104 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 105: Figure 123 – Crankcase Clamping Preparation

    Fit the thrust washers to the machined positions either side of the second front main bearing: use some general purpose grease to hold them in place. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 106: Figure 125 – Fitting Oil Pickup Tube

    Measure crankshaft end float Fit solid lifters in crankcase Figure 126 – Checking Crankshaft End Float, Installing Solid Lifters This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 107: Camshaft

    Lockwire camshaft bolts Check camshaft end float Figure 128 – Assembling Cam & Fitting to Crankcase This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 108: Pistons

    Figure 130. Figure 130 – Installation of Pistons With Valve Relief This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 108 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 109: Figure 131 – Fitting Circlip To Piston

    – one side will be “sharp” and the other “round”. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.

  • Page 110: Figure 133 – The Two Sides Of Circlips

    Figure 133 – The Two Sides of Circlips Test load directions Figure 134 – Clip Installation Detail This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 111: Figure 135 – Over-Compressed And New Clips

    Fitting rings to barrel Measuring Ring Gap Figure 136 – Checking Piston Ring Gap This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 111 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 112: Figure 137 – Compression Ring Cross Section

     Fit the gudgeon pin to the piston on the side where the circlip has not been fitted. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 113: Cylinders

    Ensure that the thrust direction markings of the pistons are oriented correctly Ensure that the cylinders are oriented correctly (top/bottom). This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 114: Through-Bolt Nuts

    7/16” nut, 12-Point (& washer) Figure 140 – 12-Point Nuts, 7/16” Hardware (on right) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 115: Cylinder Heads

     Note that the 2200 engine uses two different cylinder heads – one for cylinders 1 & 4 and another for 2 and 3 - Figure 141 refers. The Jabiru 3300 engine uses the same cylinder head for all cylinders –...

  • Page 116: Figure 142 – Fitting Valves To Head, Fitting Bushes To Rockers

    Welch plug ready to be pressed into head Figure 143 – Cylinder Head Welch Plug & Lube Tube Installation. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 117 After dry fitting, ensure that all dowels are in place (if applicable – early engines had none).  Fit a new O ring to the oil filler housing and to the dipstick. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 118: Ignition Coils

    Finally the “starfish” adaptor itself is screwed to the flywheel using 8 off 1/4" x 5/8" UNF cap screws & Belleville washers (torque per Table 9). Loctite 620 is applied to these screws. Note that the “starfish” This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 119: Starter Motor

    The assembly is now ready to be fitted to the engine rear plate with the 3 socket head screws and Belleville washers, torque per Table 9. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 120: S Ubassembly F – G Ear Case And Distributors

    Figure 146 – Installation of Oil Feed Tubes & Tacho Pickup Post Figure 147 – Hall affect Tacho Sender This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 121: Distributor Case & Distributor Mounts

    – otherwise they can work loose in service and damage the engine. Figure 149 – New Distributor Shaft Bush Fitted – nopic x 1 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 122: Figure 150 – Assembling Distributor Gear To Shaft

    Rivets – tails have been driven out. yet been driven out of this one. Figure 150 – Assembling Distributor Gear to shaft This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 123: S Ubassembly G – F Uel P Ump A Nd C Arburettor

     Apply Loctite 243 to the 5/16 x 1 1/4” cap screws and tighten as detailed in Table 9. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 124: S Ubassembly H – F Inal Assembly

    14. Confirm that the cam is assembled to its gears, ready to fit. 15. Apply a little grease to the cam and to the lifters. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 125: Figure 151 – Applying Sealant To Case, Fitting To Crank

    Figure 151 – Applying Sealant to Case, Fitting to Crank Figure 152 – Fitting The Second Case Half This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 126: Figure 153 – Tightening The Front Crankcase Studs

    Fit the second side of the crankcase. The front and rear studs must now have nuts fitted and tightened lightly. Figure 154 – Applying Sealant and O-Ring to Cylinder Base This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 127: Figure 155 – Fitting Gudgeon Pin

    Figure 155 – Fitting Gudgeon Pin Figure 156 – Fitting Cylinder, Inserting & Tightening Through-Bolts Figure 157 – Piston Orientation This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 128: Figure 158 – Torque Seal Applied

    – eliminating the need to make an allowance for the crowsfoot arm on the torque setting. FU16B is the equivalent tool with a ½” socket for use on 7/16” 12-point nuts. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 129: Option – Fitting Oil Pump

     Full fitting details are given in Section 7.8.17. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 130: Setting Cam Timing

    Peak lift occurs about 70 – 72° after Bottom Dead Centre (71° typical) for the exhaust lobe and 68 – 72° (71° typical) before Bottom Dead Centre for the intake lobe. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 131: Figure 161 – Setting Cam Timing

    – peak lift is halfway between these points Figure 162 – Checking Cam Timing #1 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 132: Sump

     The dipstick can now be fitted. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 132 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 133: Figure 164 – Fitting Sump

    Oil filler tube fitted. Tighten grubscrew here Figure 165 – Oil Filler Tube Installation This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 133 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 134: Engine Mount Plate

    7.8.5 Engine Mount Plate Figure 166 – Sealing Engine Mount Plate Figure 167 – Fitting Engine Mount Plate This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 135: Figure 168 – Engine Mount Plate Screw Locations

    Loctite 243 is applied to the holes for the gearbox mounting screws. Figure 168 – Engine Mount Plate Screw Locations This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 136: Distributor Drives

    Rotor timing mark Figure 170 – Setting Distributors, Checking Rotor Position This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 137: Figure 171 – Checking Rotors, Tightening Distributor Case

    Overhaulers must check the thread depth before final fitment of these screws. Figure 172 – Gearbox Installation This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 137 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 138: Flywheel And Alternator Rotor

    While the engine is still set at 25° before TDC (or as required to set the distributor timing) the flywheel will fit onto the engine with its magnets aligned at the ignition pole positions. For the 2200 engine this means the magnets are pointing to the left and right of the engine. For the 3300 the magnets are at the 1 o’clock, 5 o’clock and 9 o’clock positions.

  • Page 139: Figure 174 – Flywheel & Crank Timing Marks

    Figure 174 – Flywheel & Crank Timing Marks Figure 175 – Fitting & Tightening Flywheel Cap Screws This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 140: Ignition Posts & Alternator Stator

    When installing the coils note the orientation – in all cases the output lead from the coil must point in the direction of propeller rotation. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 141: Distributor Caps

    In early engines these clamps tended to be slightly too long so clamps may be modified – inspection of the cap will show if it has worn or if the clamps are the wrong length. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 142: Cylinder Heads

    Eventually the thread can be worn so much that the tapered plug will not lock in. A tension of about 6lb.ft is sufficient for this plug. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 143: Figure 178 – Fitting Hydraulic Lifter To Crankcase

    & roller follower (1) fitted Figure 179 – Crankcase & Locking Plate Figure 180 – Oil Return Manifold Fitted This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 144: Figure 181 – Applying Thread Lubricant & Tightening Lower Head Screw

    Lubricated rockers ready to fit Fitting rocker shaft Figure 183 – Fitting Rockers #2 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 144 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 145: Figure 184 – Fitting Rockers #3

    2. Using a spanner and screwdriver (or special tool as shown below) adjust the clearance to 0.010”. 3. Repeat this process for each valve in the engine. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 146: Induction Plenum & Tubes

    Then tighten the hose clamps – orient the clamps for easy access when installed on the aircraft. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 147: Figure 188 – Fitting Induction Pipes To Plenum Chamber

    Carburettor mount screwed to plenum chamber Carburettor earth strap Figure 189 – Fitting Carburettor This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 147 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 148: Exhaust Pipes

    Do not use lubricant to fit the HT lead boots as this can result in the lead slipping out of the socket in service. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 149: Front Crankshaft Seal Housing

    REMOVE ENGINE FROM STAND. 7.8.15 Front Crankshaft Seal Housing Figure 193 – Fitting Seal To Housing This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 150: Propeller Flange

    Before beginning the fit up, use taps to ensure that all threaded holes in the crankshaft have been cleaned and the old retaining compound removed. This must be done carefully and by hand to make This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 151 Loctite to the threads inside the crankshaft. Apply in the range 1 – 6mm from the front face of the crank. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 152: Oil Pump

    Outlet port O ring Oil pump dimples Figure 197 – Fitting Oil Pump & Port Plate This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 153: Oil Pressure Relief Valve

     After lapping ensure that all parts are thoroughly cleaned to remove all valve grinding paste. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 154: Figure 200 – Oil Pressure Relief Valve Assembly

    Figure 200 – Oil Pressure Relief Valve Assembly This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 155: Post-Assembly

    – running an engine on the ground using aircraft cooling ducts can quickly overheat and ruin an engine. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 156: Ground Run-In & Test Procedure

    A sample ground run-in procedure is included in the engine overhaul booklets in Section 9 below. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 157: Final Task

    Jabiru Aircraft are all included in Section 9 and it is strongly recommended that these are used. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 158: T Roubleshooting

    1. Corrosion in cylinder barrels Excess Metal in Oil Filter 2. Dirty oil This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 158 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...
  • Page 159 Piston Pick Up 2. Lack of oil 3. Overheating, especially during ground running This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 159 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 160: Appendix A - Build Sheets & Test Cards – Approved Section

    Generic torque setting: 3/16” UNC thread 3/16” Generic torque setting: 3/16” UNF thread 3/16” This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 160 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 161: B Uild T Olerances

    7.045 – 7.050 Valves Guide ID Inlet Per New Build Per New Build This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 161 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 162: Multi-Cycle Item

    Retaining compound need not be used on fasteners with inbuilt locking (such as MS21042 type lock nuts) unless specified otherwise. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 163: M Aximum A Llowable C Learances (W Ear L Imits )

    0.23 – 0.30 Valve clearance (solid lifter engines) Per New Build Per New Build This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 163 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 164: Oil Pump Clearance Measurement

    170 Ω Coil resistance 0.40mm – 0.50mm Gap, flywheel tags to sender This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 164 of 201...

  • Page 165: Figure 203 – Magnet Tests

    Tension requirement is detailed in Table 13. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 166: D Isassembly R Ecord S Heet

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  • Page 167: S Ample C Ompleted B Uild S Heet

    9.9 Jabiru Engine Build Booklet 9.9.1 Engine Details Engine Serial #: Date: This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 167 of 201...

  • Page 168: Subassembly A Build Sheet – Crankshaft, Propeller Mount Flange And Conrods

    Jabiru Aircraft Pty Ltd MPI Release Note No. (N/A for new engine builds) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 168 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 169: Subassembly B Build Sheet – Crankcase And Camshaft Assembly

    Pty Ltd Instructions and Maintenance procedures. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 169 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 170: Subassembly C Build Sheet – Pistons, Cylinders And Cylinder Heads

    Pty Ltd Instructions and Maintenance procedures. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 170 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 171: Subassembly D Build Sheet – Sump

    Pty Ltd Instructions and Maintenance procedures. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 171 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 172: Subassembly F Build Sheet – Gear Case

    Pty Ltd Instructions and Maintenance procedures. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 172 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 173: Subassembly G – Fuel Pump And Carburettor

    Pty Ltd Instructions and Maintenance procedures. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 173 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 174: Subassembly H – Final Assembly

    Pty Ltd Instructions and Maintenance procedures. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 174 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 175: Ground Run-In Procedure

    Process Specification TR01 and is fit for use. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 175 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...
  • Page 176 Engine Overhaul Manual Pty Ltd JEM0001-7 Jabiru 2200 & 3300 Aircraft Engines This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 176 of 201...

  • Page 177: Engine Post Run Procedure – Stage J

    Jabiru Pty Ltd Instructions and Maintenance procedures. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 177 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 178: Jabiru Engine Build: Parts Measure And Clearance Record Sheet

    I hereby certify that the above parts have been measured, engraved & installed as recorded. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 178 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 179: Top End Overhaul Booklet

    Signed: Date: for Jabiru Aircraft Pty Ltd MPI Release Note No. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 179 of 201...

  • Page 180: Top End Subassembly C Build Sheet – Pistons, Cylinders And Cylinder Heads

    Pty Ltd Instructions and Maintenance procedures. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 180 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 181: Top End Subassembly F Build Sheet – Gear Case

    Pty Ltd Instructions and Maintenance procedures. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 181 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 182: Top End Subassembly G – Fuel Pump And Carburettor

    Pty Ltd Instructions and Maintenance procedures. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 182 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 183: Top End Subassembly H – Final Assembly

    9.10.9 Top End – Engine Post Run Procedure – Stage J Use the procedure given in Table 25 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 184: Parts Measure And Clearance Record Sheet

    I hereby certify that the above parts have been measured, engraved & installed as recorded. Signed: Date: for Jabiru Aircraft Pty Ltd This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 184 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 185: Appendix B – Other Documentation

    Engine Serial Number: Date Received: Owner: TSO: Work to be done (iaw Jabiru Approved Data & certified for in the applicable section of the engine overhaul booklet): - Trade-In (Full Overhaul) - Full overhaul & return to owner - Top End Inspection...
  • Page 186 Dizzy Case Fuel Line Dizzy Posts Mount Coils This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 186 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 187: Bulk Strip Checklist

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  • Page 188 Refer to engine maintenance manual (normally JEM0002) for initial running requirements for overhauled engines. ii. Engine shipped with NO OIL. Oil must be added to sump (2.2 L for 2200 engines, 3.3L for 3300) before starting. iii. Oil grade must comply with requirements of the engine maintenance manual (normally JEM0002).

  • Page 189: Appendix C - Wear Factors

    Ring Gaps 1.50 Typical Ring Gaps - On Oil Additive Engines 3.00 - 4.50 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 189 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 190: Appendix D - Mandatory Replacement Parts

    – both engines. “Standard”, “2-inch” or “3-inch” extensions may be used. Propeller Drive Flange This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 190 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 191: C Amshaft

    12.3.1 Maximum Surfacing / Decking Limit  A maximum of 0.15mm may be taken from each case half over its life. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 192: Fretting General Information

    First the crankcases need to be completely stripped. All bolts, studs, dowels, fittings and plugs must be removed. Heat may be required to extract some items. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 193: Figure 205 – Stripping Crankcases

    Refer to the main body of the manual above for detailed instructions on how to carry out this work. Figure 206 – De-Burring Crankcase After Surfacing & Line Boring This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 194: C Rankshaft

    Note that some early engines use ¼” bolts to attach the flywheel. These crankshafts cannot be drilled to accept dowels. The crank must be replaced with a new part. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 195: Figure 208 – 15/64" Drill (Left), 6Mm Ream (Centre), Unf Cap Screws (Right)

    Always keep two of the bolts tight so the guide can’t move. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 196: Figure 210 – Drilling & Reaming Crankshaft – Illustration Only

    Being aluminium it is very easy to ruin the fit of the hole if the guide is not used. Figure 211 – Aligning Guide & Fitting To Flywheel. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014...

  • Page 197: Figure 212 – Drilling & Reaming Flywheel – Illustration Only

    Knock dowels through flywheel until their tips are approximately 2mm recessed into the flywheel. Tighten flywheel bolts to specifications. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 198: Figure 213 – Flywheel To Crankshaft Assembly Drawing

    JEM0001-7 Jabiru 2200 & 3300 Aircraft Engines Figure 213 – Flywheel to crankshaft assembly drawing This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 198 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...

  • Page 199: Appendix E – History Of Updates

    All engine records require reference to the “A number”.  The master list of A numbers and the cross-reference to B (C or J) numbers is kept in the Jabiru Engines department, and all enquiries should be directed there: engines@jabiru.net.au Please note: Configuration detailed below is at time of new build and may have been changed with service work.
  • Page 200 01 – 728 01 – 67 Plenum chamber integral with sump Induction Passage This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 200 of 201 L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx...
  • Page 201 Vacuum Pump Drive 2732 - Current 1522 - Current Push-in type This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated : 28/10/2014 Issued By: AS Page: 201 of 201...

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