L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx
5.8.7 New Engine Storage .................................................................................................................................26
5.8.8 Operation in Winter ...................................................................................................................................26
5.8.9 Carburettor Icing .......................................................................................................................................26
5.8.9.1 Icing Due to Water in fuel......................................................................................................................26
5.8.9.2 Icing Due to High Air Humidity. .............................................................................................................27
6MAINTENANCE.....................................................................................................................28
6.1 LUBRICATION SYSTEM ..........................................................................................................................28
6.2 AIR INTAKE FILTER ...............................................................................................................................28
6.3 CARBURETOR ADJUSTMENT..................................................................................................................28
6.4 COMPRESSION CHECK..........................................................................................................................29
6.4.1 Compression Gauge: ................................................................................................................................29
6.4.2 Pressure Differential Test:.........................................................................................................................29
6.5 IGNITION SYSTEM.................................................................................................................................30
6.5.1 High-Tension Lead Connections...............................................................................................................30
6.5.2 Spark Plugs...............................................................................................................................................31
6.6 EXHAUST SYSTEM................................................................................................................................31
6.7 BOLTS AND NUTS .................................................................................................................................31
6.8 TAPPET ADJUSTMENT /HYDRAULIC VALVE LIFTERS...............................................................................31
6.9 HEAD BOLTS........................................................................................................................................33
6.10 TACHOMETER AND SENDER...............................................................................................................33
6.11 ADDITIONAL CHECKS –POST SERVICE ..............................................................................................33
6.11.1 Propeller....................................................................................................................................................34
6.11.2 Engine.......................................................................................................................................................34
6.11.3 Fuel System..............................................................................................................................................34
6.12 ENGINE INSPECTION CHART..............................................................................................................35
7SERVICE & REPAIR..............................................................................................................37
7.1 SERVICE INTERVAL TOLERANCE............................................................................................................37
7.2 ENGINE OVERHAUL AND TBO...............................................................................................................37
7.2.1 Full Overhaul.............................................................................................................................................37
7.2.2 Top End Overhaul.....................................................................................................................................38
7.3 ENGINE REMOVAL PROCEDURE ............................................................................................................38
7.4 ENGINE DISASSEMBLY....................................................................................................................39
7.5 2200 ENGINE OVERHAUL................................................................................................................42
7.5.1 Jabiru 2200 Component Inspection and Assembly Procedure .................................................................43
7.5.1.1 Sub-Assembly A - Crankshaft, Prop Mount and Con-Rods...................................................................43
7.5.1.2 Sub-Assembly B –Crankcase and Camshaft.......................................................................................45
7.5.1.3 Crankcase Decking / Machining............................................................................................................48
7.5.1.4 Sub-Assembly C - Pistons, Cylinders and Cylinder Heads...................................................................48
7.5.1.5 Sub-Assembly D - Sump and Oil Pump................................................................................................54
7.5.1.6 Sub-Assembly E –Flywheel, Ignition Coils, Alternator & Alternator Operation.....................................55
7.5.1.7 Permanent Magnet Alternator (PMA) Operation ...................................................................................58
7.5.1.8 Regulator...............................................................................................................................................59
7.5.1.9 Sub-Assembly F - Gear Case ...............................................................................................................60
7.5.1.10 Sub-Assembly G - Fuel Pump, Carburetor and Carburetor Operation..............................................60
7.5.1.11 Sub-Assembly H - Final Assembly....................................................................................................65
7.5.1.12 Engine Run In ...................................................................................................................................74
7.6 ENGINE INSTALLATION..........................................................................................................................75
7.7 PROP STRIKE INSPECTION....................................................................................................................76
7.8 STARTER MOTOR OVERHAUL................................................................................................................77
7.8.1 Starter motor disassembly and inspection ................................................................................................77
7.8.2 Reassembly ..............................................................................................................................................78
7.9 BUILD SHEETS AND RUN IN PROGRAMME ..............................................................................................78
8NOTES BEFORE STARTING ENGINE..................................................................................79
9SERVICE DOCUMENTATION ...............................................................................................81
9.1 SUBASSEMBLY A–COMPONENT ASSEMBLY PROCEDURE ......................................................................81
9.2 SUBASSEMBLY A–COMPONENT REGISTER &PARTS INSPECTION RECORD............................................82
9.3 SUBASSEMBLY B–COMPONENT ASSEMBLY PROCEDURE ......................................................................83
9.4 SUBASSEMBLY B–COMPONENT REGISTER &PARTS INSPECTION RECORD............................................84
9.5 SUBASSEMBLY C–COMPONENT ASSEMBLY PROCEDURE......................................................................85
9.6 SUBASSEMBLY C–COMPONENT REGISTER AND PARTS INSPECTION RECORD........................................86