Jabiru 2200 User manual

MAINTENANCE MANUAL
FOR
JABIRU 2200 AIRCRAFT ENGINE
JABIRU 3300 AIRCRAFT ENGINE
DOCUMENT No. JEM0002-7
DATED: 30th June 2016
This Manual has been prepared as a guide to correctly operate, maintain and
service Jabiru 2200 & 3300 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. Failure to do this 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.
Every effort is made to ensure that the information provided is accurate and up to date. However,
there is an inherent risk in the use of Jabiru® engines in aircraft and in the operation of aircraft
generally. The operator of any type of aircraft powered by Jabiru® engines assumes any and all
risk relating to such use. Accordingly, use of the information herein is at the user's risk and Jabiru
disclaims any responsibility for any errors or omissions. In the event that you have any questions
or concerns with regard to any information herein, please contact Jabiru Aircraft Pty Ltd.

Engine Maintenance Manual
Jabiru Aircraft Pty Ltd
JEM0002-7
Jabiru 2200 & 3300 Aircraft Engines
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1.1 TABLE OF FIGURES.................................................................................................................................5
2GENERAL INFORMATION......................................................................................................6
2.1 LIST OF EFFECTIVE PAGES......................................................................................................................7
2.2 INTRODUCTION.......................................................................................................................................7
2.3 DESCRIPTION.........................................................................................................................................7
2.4 APPLICABILITY........................................................................................................................................9
2.5 READING THIS MANUAL ..........................................................................................................................9
2.6 DEGREE OF DIFFICULTY .........................................................................................................................9
2.7 ADDITIONAL SERVICE INFORMATION ........................................................................................................9
2.8 RECORDING ........................................................................................................................................ 10
2.9 MANUFACTURER.................................................................................................................................. 10
2.10 ENGINE MANUALS............................................................................................................................ 10
2.11 SOURCE OF PURCHASE PARTS......................................................................................................... 10
2.12 LIST OF DISPOSABLE REPLACEMENT PARTS...................................................................................... 10
2.13 OWNER/OPERATOR RESPONSIBILITES (LSA AIRCRAFT)...................................................... 11
3SPECIFICATIONS .................................................................................................................12
3.1 2200 ENGINE MODELS ........................................................................................................................ 12
3.1.1 2200J.........................................................................................................................................................12
3.1.2 2200B........................................................................................................................................................12
3.1.3 2200C........................................................................................................................................................12
3.1.4 2200A........................................................................................................................................................12
3.2 3300 ENGINE MODELS ........................................................................................................................ 13
3.2.1 3300L........................................................................................................................................................13
3.2.2 3300A........................................................................................................................................................13
3.3 DESIGN DETAILS ................................................................................................................................. 14
3.4 GENERAL SPECIFICATIONS &EQUIPMENT............................................................................................. 15
3.5 FULL POWER STATIC RPM .................................................................................................................. 16
3.6 PERFORMANCE ................................................................................................................................... 16
3.6.1 Engine Ratings..........................................................................................................................................16
3.7 FUEL................................................................................................................................................... 16
3.7.1 16
3.7.2 Recommended Fuel Types: ......................................................................................................................16
3.7.3 Fuel Consumption: ....................................................................................................................................17
3.8 LUBRICANT.......................................................................................................................................... 17
3.9 COOLING SYSTEM ............................................................................................................................... 18
3.10 OPERATING SPEEDS AND LIMITS....................................................................................................... 19
3.10.1 Ground Operating Limits ...........................................................................................................................19
3.10.2 In-Flight Operating Limits ..........................................................................................................................19
3.11 TORQUE SPECIFICATIONS................................................................................................................. 20
3.12 PROPELLER SELECTION &SPECIFICATIONS....................................................................................... 20
3.13 ELECTRICAL SYSTEM SPECIFICATIONS.............................................................................................. 21
3.14 2200 –DIMENSIONS ........................................................................................................................ 22
3.15 2200 –DENOMINATION OF CYLINDERS ............................................................................................. 22
3.16 3300 –DIMENSIONS ........................................................................................................................ 23
3.17 3300 –DENOMINATION OF CYLINDERS ............................................................................................. 23
3.18 DISTRIBUTOR CYLINDER MAP........................................................................................................... 24
3.19 2200 –POWER CURVE .................................................................................................................... 24
3.20 3300 –POWER CURVE .................................................................................................................... 25
4AIRWORTHINESS LIMITATIONS .........................................................................................26
5OPERATING INSTRUCTIONS...............................................................................................27
5.1 DAILY CHECKS .................................................................................................................................... 27
5.2 STARTING PROCEDURE........................................................................................................................ 27
5.2.1 Cold Engine...............................................................................................................................................28
5.2.2 Warm Engine.............................................................................................................................................28
5.3 WARMING UP PERIOD.......................................................................................................................... 28
5.4 GROUND RUNNING .............................................................................................................................. 28
5.5 TAKE-OFF........................................................................................................................................... 28
5.6 ENGINE STOP...................................................................................................................................... 28
5.7 ENGINE STOP AND START DURING FLIGHT............................................................................................ 29
5.8 OPERATION IN WINTER ........................................................................................................................ 29

Engine Maintenance Manual
Jabiru Aircraft Pty Ltd
JEM0002-7
Jabiru 2200 & 3300 Aircraft Engines
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5.9 CARBURETTOR ICING........................................................................................................................... 29
5.9.1 Icing Due to Water in fuel..........................................................................................................................29
5.9.2 Icing Due to High Air Humidity...................................................................................................................29
5.10 NEW ENGINE OPERATION................................................................................................................. 29
5.11 ENGINE INSTALLATION...................................................................................................................... 30
6MAINTAINER REQUIREMENTS ...........................................................................................31
6.1 FACILITIES........................................................................................................................................... 31
6.2 TRAINING ............................................................................................................................................ 31
6.3 RATING............................................................................................................................................... 31
6.4 EXPERIENCE ....................................................................................................................................... 31
6.5 TOOL &GAUGE CONTROL.................................................................................................................... 31
6.6 TOOLS:............................................................................................................................................... 31
6.7 EQUIPMENT:........................................................................................................................................ 32
6.8 GENERAL:........................................................................................................................................... 32
6.9 SEALANTS AND COMPOUNDS ............................................................................................................... 33
6.10 LOCTITE 620 &OTHER RETAINING COMPOUNDS............................................................................... 35
6.11 SPECIAL TOOLS............................................................................................................................... 36
6.12 TORQUE /TENSION WRENCH............................................................................................................ 39
6.13 TORQUE APPLICATION PROCEDURE.................................................................................................. 41
7STORAGE & CLEANING.......................................................................................................42
7.1 PARKING............................................................................................................................................. 42
7.2 STORAGE......................................................................................................................................... 42
7.2.1 Flyable Storage.........................................................................................................................................42
7.2.2 Returning Engine to Service From Flyable Storage ..................................................................................42
7.2.3 Temporary or Indefinite Storage................................................................................................................42
7.2.4 Inspection During Storage.........................................................................................................................43
7.2.5 Returning Engine to Service After Temporary / Indefinite Storage............................................................43
7.2.6 New Engine Storage .................................................................................................................................44
7.3 CLEANING ENGINE AND ENGINE COMPARTMENT..................................................................... 44
8MAINTENANCE.....................................................................................................................45
8.1 SERVICE INTERVAL TOLERANCE ........................................................................................................... 45
8.2 BASIC INSPECTION PROCEDURE........................................................................................................... 45
8.3 WORK SHEETS.................................................................................................................................... 45
8.4 MANDATORY INSPECTIONS &LIFED ITEMS............................................................................................ 45
8.4.1 Flexible Hoses...........................................................................................................................................45
8.4.2 Carburettor rubber mount..........................................................................................................................45
8.5 ENGINE INSPECTION CHART................................................................................................................. 45
8.6 PRE-MAINTENANCE INSPECTIONS: ....................................................................................................... 49
8.7 PROPELLER –INSPECTION DETAILS...................................................................................................... 50
8.8 ENGINE &ENGINE COMPARTMENT –INSPECTION DETAILS .................................................................... 50
8.9 FUEL SYSTEM –INSPECTION DETAILS................................................................................................... 52
8.10 SPECIAL MAINTENANCE -CHECK AFTER INITIAL 5HOURS –SOLID LIFTER ONLY ................................. 52
8.11 SPECIAL MAINTENANCE -CHECK AFTER INITIAL 10 HOURS................................................................. 53
8.12 SPECIAL INSPECTION -CHECK AFTER INITIAL 25 HOURS .................................................................... 53
8.13 SPECIAL INSPECTION -CHECK AFTER INITIAL 50 HOURS.................................................................... 53
8.14 SPECIAL MAINTENANCE –NON-APPROVED PROPELLERS................................................................... 54
9SERVICE & REPAIR PROCEDURES....................................................................................56
9.1 ENGINE TEST RUN............................................................................................................................... 56
9.2 PROPELLER TRACKING ........................................................................................................................ 56
9.3 SPINNER INSPECTIONS ........................................................................................................................ 57
9.4 RAM AIR DUCT INSPECTIONS ............................................................................................................... 57
9.5 OIL &FILTER CHANGE......................................................................................................................... 58
9.6 OIL PRESSURE RELIEF VALVE ADJUSTMENT ......................................................................................... 59
9.7 AIR INTAKE FILTER .............................................................................................................................. 60
9.8 IGNITION COIL GAP ADJUSTMENT......................................................................................................... 61
9.9 HIGH TENSION LEAD INSPECTION &MAINTENANCE ............................................................................... 61
9.10 SPARK PLUGS ................................................................................................................................. 62
9.11 CARBURETTOR INSPECTION &ADJUSTMENT...................................................................................... 63
9.11.1 Tuning .......................................................................................................................................................63

Engine Maintenance Manual
Jabiru Aircraft Pty Ltd
JEM0002-7
Jabiru 2200 & 3300 Aircraft Engines
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9.12 DISTRIBUTOR &ROTOR INSPECTION &ADJUSTMENT......................................................................... 64
9.13 FUEL SYSTEM.................................................................................................................................. 65
9.14 TACHOMETER AND SENDER.............................................................................................................. 66
9.15 HEAD BOLT TENSION CHECK............................................................................................................ 67
9.16 INSPECT TOP SPRING WASHERS,VALVE SPRINGS &ROCKERS .......................................................... 68
9.17 VALVE CLEARANCE ADJUSTMENT (SOLID LIFTER ENGINES ONLY)...................................................... 69
9.18 PRESSURE DIFFERENTIAL (LEAK-DOWN)TEST.................................................................................... 70
9.18.1 Identifying Compression Leaks .................................................................................................................70
9.19 FUEL FLOW RATE TEST.................................................................................................................... 71
9.20 HYDRAULIC VALVE LIFTER MAINTENANCE ......................................................................................... 71
9.20.1 Hydraulic Lifter Removal ...........................................................................................................................72
9.20.2 Valve Rockers...........................................................................................................................................73
9.21 IGNITION COIL &ALTERNATOR ELECTRICAL INSPECTIONS.................................................................. 73
9.22 FLYWHEEL SCREW BASIC INSPECTION.............................................................................................. 74
9.23 FLYWHEEL SCREW DETAILED INSPECTION......................................................................................... 74
9.24 USE OF SAFETY WIRE...................................................................................................................... 75
9.25 ENGINE OVERHAUL AND TBO........................................................................................................... 77
9.25.1 Full Overhaul.............................................................................................................................................77
9.25.2 Top End Overhaul.....................................................................................................................................78
9.26 ENGINE REMOVAL PROCEDURE........................................................................................................ 79
9.27 ENGINE INSTALLATION...................................................................................................................... 80
9.28 PROP STRIKE INSPECTION................................................................................................................ 81
9.29 PROPELLER FLANGE INSTALLATION /REMOVAL ................................................................................. 82
10 TROUBLE SHOOTING..........................................................................................................83
10.1 ENGINE WON'T START ..................................................................................................................... 83
10.2 ENGINE IDLES UNSTEADILY AFTER WARM-UP PERIOD:SMOKY EXHAUST........................................... 83
10.3 ENGINE RUNS ERRATICALLY OR MISFIRES OCCASIONALLY ................................................................ 83
10.4 FULL POWER STATIC RPM BELOW SPECIFICATIONS ......................................................................... 83
10.5ENGINE RUNS TOO HOT -OIL TEMPERATURE ABOVE 110OC(230OF)................................................ 84
10.6 CHT READING ERROR..................................................................................................................... 84
10.7 UNSATISFACTORY POWER OUTPUT .................................................................................................. 84
10.8 LOW OIL PRESSURE......................................................................................................................... 85
10.9 OIL PRESSURE VARYING.................................................................................................................. 85
10.10 ENGINE KEEPS RUNNING WITH IGNITION OFF .................................................................................... 85
10.11 EXCESSIVE OIL CONSUMPTION......................................................................................................... 85
10.12 OIL COLLECTOR BOTTLE ON FIREWALL FILLS QUICKLY...................................................................... 85
10.13 EXCESSIVE VIBRATION..................................................................................................................... 86
10.14 KNOCKING UNDER LOAD.................................................................................................................. 86
10.15 ENGINE HARD TO START AT LOW TEMPERATURE –COLD START CHECKLIST...................................... 87
10.16 IRREGULAR /LOW COMPRESSIONS................................................................................................... 88
10.17 HYDRAULIC VALVE LIFTERS.............................................................................................................. 89
11 ENGINE MAINTENANCE WORKSHEETS............................................................................90
11.1 25-HOUR INSPECTION WORKSHEET.................................................................................................. 90
11.1.1 Engine & Engine Compartment (refer to section 8.8)................................................................................90
11.2 50 HOUR,100 HOUR AND ANNUAL INSPECTION WORKSHEET ............................................................. 92
11.2.1 Engine & Engine Compartment (refer to section 8.8)................................................................................92
12 NEW ENGINE –JABIRU’S LIMITED, EXPRESS WARRANTY.............................................96
13 JABIRU’S LIMITED, EXPRESS WARRANTY: CLAIM FORM.............................................102
14 REVISIONS..........................................................................................................................103
15 FEEDBACK AND REPORTING...........................................................................................104
15.1.1 Continued Operational Safety Reporting.................................................................................................105
15.1.2 Owner Change of Address Notice...........................................................................................................105

Engine Maintenance Manual
Jabiru Aircraft Pty Ltd
JEM0002-7
Jabiru 2200 & 3300 Aircraft Engines
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1.1 Table of Figures
Figure 1 –Oil System Schematic .................................................................................................................... 18
Figure 3 –2200 Engine Dimensions ............................................................................................................... 22
Figure 4 –2200 Cylinder Denomination.......................................................................................................... 22
Figure 5 –3300 Engine Dimensions ............................................................................................................... 23
Figure 6 –3300 Cylinder Denomination.......................................................................................................... 23
Figure 7 –Distributor Cylinder Map................................................................................................................. 24
Figure 8 –Power / Torque Curve –Typical 2200A Engine............................................................................. 24
Figure 9 –Power Curve - Typical 2200C, 2200B, Engine............................................................................... 25
Figure 10 –Power / Torque Curves –Typical 3300 Engine............................................................................ 25
Figure 11 –Sealants, Compounds & Lubricants #1........................................................................................ 33
Figure 12 –Sealants, Compounds & Lubricants #2........................................................................................ 33
Figure 13 –Sealants, Compounds & Lubricants #4........................................................................................ 34
Figure 14 - Torque seal installed..................................................................................................................... 34
Figure 15 –Sealants, Compounds & Lubricants #4........................................................................................ 34
Figure 16 –Sealants, Compounds & Lubricants #3........................................................................................ 35
Figure 17 –Valve Compressor / Lifter Bleed Tools......................................................................................... 36
Figure 18 –Dimensional Details For Lifter Tool.............................................................................................. 36
Figure 19 –Valve Leakage Vacuum Tester.................................................................................................... 36
Figure 20 –Valve Spring Compressor / Collet Remover ................................................................................ 37
Figure 21 –Leak Down Tester ........................................................................................................................ 37
Figure 22 –Hand Press & Inserts ................................................................................................................... 37
Figure 23 –Optical Tachometer...................................................................................................................... 37
Figure 24 –Supplementary Oil Pressure Gauge ............................................................................................ 38
Figure 25 –“Finger Bar” .................................................................................................................................. 38
Figure 26 –Carburettor Needle Seat Remover and Installer.......................................................................... 38
Figure 27 –“Crowsfoot” Adaptor ..................................................................................................................... 39
Figure 28 –Universal Joint tool FU14B........................................................................................................... 39
Figure 29 –Safety Wire / Wire Pliers .............................................................................................................. 39
Figure 30 –Torque Wrench & Crowsfoot Adaptor Setting 1........................................................................... 39
Figure 31 –Torque Wrench & Crowsfoot Adaptor Setting 2........................................................................... 40
Figure 32 –Using A Crowsfoot Adaptor.......................................................................................................... 40
Figure 33 –Air Duct Hard Point Reinforcement.............................................................................................. 58
Figure 34 –Oil Pressure Relief Valve Assembly............................................................................................. 60
Figure 35 –Adjusting High Tension Lead Caps.............................................................................................. 62
Figure 36 –Spark Plug Terminal Nut.............................................................................................................. 62
Figure 37 –Fuel Hose Assembly –Engine Bay.............................................................................................. 65
Figure 38 –Tacho Sender #1.......................................................................................................................... 66
Figure 39 –Tacho Sender #2.......................................................................................................................... 67
Figure 40 –Head Bolt Locations ..................................................................................................................... 68
Figure 41 –Washer Thickness Measurement................................................................................................. 69
Figure 42 –Valve Clearance Adjustment (Solid Lifter) ................................................................................... 70
Figure 43 –Cam Identification Markings......................................................................................................... 72
Figure 44 –Ignition Coil Tests......................................................................................................................... 73
Figure 45 –Different Ignition Coil Models (Honda on Left, Jabiru on Right)................................................... 74
Figure 46 - Plain washers compared to Nordloc washers............................................................................... 75
Figure 47 –Safety Wire Details....................................................................................................................... 76
Figure 48 –Safety Wire Installation Using a Twister/Pliers & By Hand .......................................................... 77
Figure 49 –Dial Indicator Position for Crankshaft & Prop Flange Run Out.................................................... 81
Figure 50 –Choke Schematic ......................................................................................................................... 88

Engine Maintenance Manual
Jabiru Aircraft Pty Ltd
JEM0002-7
Jabiru 2200 & 3300 Aircraft Engines
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2 GENERAL INFORMATION
WARNING:
Jabiru Aircraft Pty Ltd has devoted significant resources and testing to develop the
Jabiru 2200 and 3300 aircraft engines. These engines are intended to be installed in
accordance with the details given in the “INSTALLATION MANUAL FOR JABIRU 2200
AIRCRAFT ENGINE”, document No. JEM2202 or “INSTALLATION MANUAL FOR JABIRU
3300 AIRCRAFT ENGINE”, document No. JEM3302 as appropriate. Any other uses or
applications may be extremely hazardous, leading to property damage, or injury or
death of persons on or in the vicinity of the vehicle. Jabiru Aircraft Pty Ltd does not
support the use of this engine in any applications which do not meet the requirements
of the appropriate installation manual. Any non-compliant installation may render the
aircraft un-airworthy and will void any warranty issued by Jabiru.
The Jabiru 2200 and 3300 aircraft engines are designed to be operated and maintained
only in strict accordance with this engine maintenance manual. Any variation of any
kind, including alteration to any component at all, whether replacement, relocation,
modification or otherwise which is not strictly in accordance with this manual may lead
to dramatic changes in the performance of the engine and may cause unexpected
engine stoppage, engine damage or harm to other parts of the aircraft to which it may
be fitted and may lead to injury or death. Jabiru Aircraft Pty Ltd does not support any
modifications to the engine, its parts, or components. Any such actions may render the
aircraft un-airworthy and will void any warranty issued by Jabiru.
Maintenance and modification cannot be supervised by the manufacturer. Maintenance
requires extreme cleanliness, exact parts, precise workmanship and proper
consumables. It is your responsibility to ensure absolute attention to detail no matter
who may become involved in work on this engine. Your safety, your life and your
passenger’s lives rely on precise and accurate following of instructions in this manual.
In exchange for the engine manual provided by Jabiru Aircraft Pty. Ltd. (“Jabiru”) I
hereby agree to waive, release, and hold 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. All information in this manual has been carefully researched
and compiled. It is possible that the information contained in this manual has changed in
the intervening time. Information may be missing, contain errors or be translated
incorrectly. As a result, Jabiru Aircraft Pty Ltd does not provide any guarantee not accept
any legal liability for the accuracy, completeness, currency or quality of the information
provided. We hereby waive liability for any damages, whether direct or indirect in nature
and whether tangible or intangible, resulting from the use or misuse of information or from
incomplete or incorrect information in this manual. Likewise, we shall not be liable for
damage arising should the owner and/or maintainer not have the necessary technical
expertise, the required knowledge of and/ or experience required. The extent to which the
information and technical methods described here will apply to future generations of Jabiru
products cannot be predicted and must be verified in individual cases.

Engine Maintenance Manual
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JEM0002-7
Jabiru 2200 & 3300 Aircraft Engines
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2.1 List of Effective Pages
This manual is revised as a complete document. All pages must display the same revision
number. See section 14 for the revision history.
2.2 Introduction
This Engine Maintenance Manual has been written for all 4-cylinder 2200 and 6-cylinder 3300
Jabiru engine models. These engines are a modular design which share many parts and
specifications. Consequentially the procedures in this Manual apply equally to both engines.
Before attempting an engine inspection the technician must be fully conversant with the Engine
Maintenance Manual and any relevant Service Bulletins, Service Letters or other
manufacturer’s data. Current information is available from the Jabiru Aircraft (Australia) web
site –www.jabiru.net.au .
Inspections, maintenance, repairs and overhauls must only be carried out by an approved
person. Depending on the country and the category of the aircraft this may be a Licensed
Aircraft Maintenance Engineer, an RA-Aus Level 2 or equivalent. The responsibility for
determining what qualifications are necessary to carry out an overhaul belongs to the person
carrying out the work.
2.3 Description
It is said that "aircraft are designed around available engines".
Jabiru believe that the Jabiru range of very light engines offers opportunities for light aircraft
designers to develop a new generation of light aircraft.
Jabiru engines are designed to be manufactured in small batch quantities using the very latest
Computer Numerically Controlled (CNC) machine tools. All Jabiru engines are manufactured and
assembled in a very modern factory in Bundaberg where each engine is run in on a Dynometer
and calibrated before delivery. The crankcase halves, cylinder heads, crankshaft, timing gear cover
and coil mounts –together with many smaller components are machined from solid. The sump (oil
pan) is cast aluminium. The cylinders are machined from bar 4140 chrome molybdenum alloy
steel, with the pistons running directly in the steel bores. The crankshaft is also machined from
4140 chrome molybdenum alloy steel, the journals of which are precision ground prior to being
Magnaflux inspected. The camshaft is cast iron with induction hardened cam lobes and bearing
journals.
The propeller is direct crankshaft driven and does not use a reduction gearbox. This facilitates its
light-weight design and keeps maintenance costs to a minimum. The crankshaft features a
removable propeller flange which enables the easy replacement of the front crankshaft seal and
provides for a propeller shaft extension to be fitted, should this be required for particular
applications. Cylinder heads are machined from solid aluminium billet, thereby providing a
substantive quality trail to material source. Connecting rods are machined from 4140 alloy steel
and the 45mm big end bearings are of the automotive slipper type.
Many components of the engines are sourced from outside suppliers. These items include
camshaft followers, and the bendix gear in the starter motor. The ignition coils are also sourced
from outside suppliers, and are modified by Jabiru for their own particular application.
An integral alternator using rare earth magnets provides alternating current for battery charging
and electrical accessories. The alternator is attached to the flywheel and is driven directly by the
crankshaft. The ignition system is a transistorised electronic system; two fixed coils mounted
adjacent to the flywheel are energised by rare earth magnets attached to the flywheel. The
passing of the coils by the magnets creates the high voltage current which is then transported by
high tension leads to the centre post of two automotive type distributors (which are simply rotors
and caps) before distribution to automotive spark plugs, two in the top of each cylinder head. The

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ignition system is fixed timing and, therefore, removes the need for timing adjustment. The ignition
system is fully redundant, self-generating and does not depend on battery power.
The crankshaft is designed with a double bearing at the propeller flange end and a main bearing
between each big end; it therefore does not have flying webs. 48mm main bearings are also of the
automotive slipper type. Thrust bearings are located fore and aft of the front double bearing
allowing either tractor or pusher installation.
Pistons are manufactured to Jabiru design by a major manufacturer, they are fitted with 3 rings, the
top rings being cast iron to complement the chrome molybdenum cylinder bores. Valves are 7mm
(stem dia) which are purpose manufactured for the Jabiru engine.
The valve gear includes pushrods from roller hydraulic cam followers to forged steel valve rockers
mounted on a shaft through a Teflon coated bronze-steel bush. Valve guides are manufactured
from aluminium/bronze, as is found in larger aero engines and high performance racing engines.
Replaceable valve seats are of nickel steel and are shrunk into the aluminium cylinder heads. The
valve gear is lubricated via the hollow pushrods.
An internal gear pump is driven directly by the camshaft & provides engine lubrication via an oil
circuit which includes an automotive spin-on filter, oil cooler and in-built relief valve.
The standard engines are supplied with two Ram-air cooling ducts, which have been developed by
Jabiru to facilitate the cooling of the engine and direct air from the propeller to the critical areas of
the engine, particularly the cylinder heads and barrels. The fitment of these ducts is a great bonus
for the home builder or engine installer, as they remove the need to design and manufacture
baffles and the establishment of a plenum chamber, which is the traditional method of cooling air-
cooled aircraft engines. The fact that these baffles and plenum chamber are not required also
ensures a "cleaner" engine installation, which in turn facilitates maintenance and inspection of the
engine and engine component. So the hard work of engine installation has largely been done for
you by the Jabiru design team. RAM AIR ducts are available for tractor or pusher configurations.
Special ducts are available for certain installations.
The engine is fitted with a 1.5 kW starter motor, which is also manufactured by Jabiru and provides
very effective starting. The engine has very low vibration levels, however it is also supported by
four large rubber shock mounts attached to the engine mounts at the rear of the engine. An
optional bed mount is available.
The fuel induction system comprises a BING pressure compensating carburettor. Following
carburation, the fuel/air mixture is drawn through a swept plenum chamber bolted to the sump
casting, in which the mixture is warmed prior to entering short stainless steel induction tubes
attached to the cylinder heads.
An effective stainless steel exhaust and muffler system is fitted as standard equipment, ensuring
very quiet operations, which in the Jabiru aircraft have been measured at around 62dB at 1000' full
power flyover.
The Jabiru engine is manufactured within an Australian Civil Aviation Safety Authority (CASA)
approved Quality Assurance System to exacting standards.
Jabiru Aircraft recommend a TBO of 2000 hours, with a top end overhaul done at 1000 hours, or
when engine condition indicates the need to overhaul earlier.

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Jabiru 2200 & 3300 Aircraft Engines
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2.4 Applicability
This manual is applicable to all Jabiru 2200 & 3300 Engines.
2.5 Reading This Manual
If you are reading this manual on a computer and want to be able to quickly zoom in and out:
Hold down the Ctrl key while rotating the wheel button on your mouse. In most programs this
will instantly zoom in or out.
To do the same thing on a modern laptop either plug in a wheel mouse as detailed above or
use the built-in track-pad. Put two fingers on the pad close together then move then apart
diagonally. To reverse, put two fingers on the pad at opposite diagonal points on the pad and
bring them together diagonally. This works on most modern PC-laptops.
This document has been created with hyperlinks between referenced items. So, when reading
the manual on a computer you can click on the page number of an item on the table of
contents and the computer will skip to that page. Also, if a paragraph says “refer to Section
8.10” –then you can click on the “8.10” and automatically skip to that page. Similarly, if
Figures or Tables are referenced.
To open a search window press “Ctrl-f”. Depending on the program, this will normally open a
small search window where you can enter keywords. For example, searching for the word “life”
will allow you to quickly find all reference to lifed maintenance items.
2.6 Degree Of Difficulty
In this manual we have used a “spanner scale” to help technicians approach a job. Anyone
considering undertaking a task in this manual must realistically assess themselves against this
scale and not attempt any task for which they lack knowledge or the required tools.
This manual is intended for use by experienced technicians. While all processes will be
explained as clearly as possible, some knowledge is assumed. This manual is not intended to
be sufficient reference for a person with no other training to safely complete inspections &
maintenance.
The Spanner Scale
Translation
Simple, basic, straightforward. A careful layman, with guidance, can
achieve this.
Straightforward, but with some technical bits. Basic knowledge, care
and guidance needed.
Straightforward, but requires special tools, training and/or judgement.
Sound basic knowledge guidance and a careful approach are required.
A technical job. Take your time, double-check everything. Only for the
experienced overhauler.
A difficult job. Requires special tools, solid skills, good judgement.
Only for experts.
2.7 Additional Service Information
Occasionally new or expanded service information will be made available to customers in the form
of Jabiru Service Bulletins or Jabiru Service Letters. Jabiru distributes this information to owners of
certain types of Jabiru product. However, it is strongly recommended that owners and operators
regularly visit the Jabiru Australia website –www.jabiru.net.au –or the website of their local Jabiru
representative to check for new or updated additional service information.

Engine Maintenance Manual
Jabiru Aircraft Pty Ltd
JEM0002-7
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
1
2
3
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Dated : 30th June 2016
Issued By: AS
Page: 10 of 106
2.8 Recording
Careful records of all maintenance work must be completed. Details recorded in the
maintenance logbooks must be as complete as possible.
To simplify recording a set of maintenance worksheets have been included in this manual in
Section 11. These sheets can be printed, glued into the maintenance logbook and filled out
quickly and easily.
2.9 Manufacturer
Jabiru Aircraft Pty Ltd,
P.O. Box 5792,
Bundaberg West,
Queensland 4670
2.10 Engine Manuals
JEM0002 - Engine Maintenance Manual
JEM0001 - Overhaul Manual
JEM2202 - 2200 Installation Manual
JEM2203 - 2200 Parts Book
JEM3302 - 3300 Installation Manual
JEM3303 - 3300 Parts Book
All manuals are available free of charge on the Jabiru web site www.jabiru.net.au
2.11 Source of Purchase Parts
All replacement parts can be sources from Jabiru Aircraft Pty Ltd (details listed below) or an
approved local agent
Jabiru Aircraft P/L
PO Box 5792
Bundaberg West,
QLD 4670
Phone: [phone]
Fax: [phone]
Email: in[email protected]
2.12 List of Disposable Replacement Parts
Part
Manufacturer
Part #
Air Filter
Joywell Motor Corp
TPG10242N
Fuel Filter
Joywell Motor Corp
ZFF0002
Oil Filter
Joywell Motor Corp
TPG10162N
Spark Plug
NGK
D9EA
Distributor Cap
BOSCH
GH506 (4 cyl)
GB74 (6 cyl)