Jabiru 2200 User manual

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OVERHAUL MANUAL
FOR
JABIRU 2200 & 3300 AIRCRAFT ENGINES
DOCUMENT No. JEM0001-7
Date: 28th 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.

Engine Overhaul Manual
Jabiru Aircraft Pty Ltd
JEM0001-7
Jabiru 2200 & 3300 Aircraft Engines
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1.1 TABLE OF FIGURES .................................................................................................................................................................. 7
1.2 TABLE OF TABLES.................................................................................................................................................................. 11
2GENERAL INFORMATION.................................................................................................................................................. 12
2.1 LIST OF EFFECTIVE PAGES /ISSUE STATUS ................................................................................................................................. 12
2.2 INTRODUCTION .................................................................................................................................................................... 13
2.3 APPLICABILITY...................................................................................................................................................................... 13
2.4 CERTIFICATION BASIS ............................................................................................................................................................ 13
2.5 READING THIS MANUAL ........................................................................................................................................................ 13
2.6 DEGREE OF DIFFICULTY ......................................................................................................................................................... 14
2.7 MANUAL LAYOUT ................................................................................................................................................................. 14
2.8 ENGINE LIFE......................................................................................................................................................................... 14
2.9 COMPLETE OVERHAUL,TOP END OVERHAUL,WEAR TOLERANCES.................................................................................................... 14
2.10 MANDATORY UPDATES .......................................................................................................................................................... 15
2.11 MANDATORY REPLACEMENT OF PARTS...................................................................................................................................... 15
2.12 RECORDING......................................................................................................................................................................... 15
2.13 GENERAL DESCRIPTION.......................................................................................................................................................... 16
2.13.1 Engine identification ...................................................................................................................................................................16
2.13.2 Build Configurations ...................................................................................................................................................................16
2.13.3 Part Identification.......................................................................................................................................................................17
2.13.4 Cylinder Numbering Convention .................................................................................................................................................17
2.13.5 Cylinder heads ............................................................................................................................................................................17
2.13.6 Valves, valve guides and seats....................................................................................................................................................17
2.13.7 Cylinders .....................................................................................................................................................................................17
2.13.8 Pistons ........................................................................................................................................................................................17
2.13.9 Connecting rods ..........................................................................................................................................................................17
2.13.10 Crankshaft ..................................................................................................................................................................................18
2.13.11 Crankcase ...................................................................................................................................................................................18
2.13.12 Camshaft ....................................................................................................................................................................................18
2.13.13 Valve operating mechanism .......................................................................................................................................................18
2.13.14 Solid lifters ..................................................................................................................................................................................18
2.13.15 Hydraulic lifters...........................................................................................................................................................................18
2.13.16 Roller Followers ..........................................................................................................................................................................18
2.13.17 Lubricating system......................................................................................................................................................................18
2.13.18 Cooling system............................................................................................................................................................................18
2.13.19 Induction system.........................................................................................................................................................................18
2.13.20 Ignition system ...........................................................................................................................................................................19
2.13.21 Electrical charging system ..........................................................................................................................................................19
2.13.22 Starter motor ..............................................................................................................................................................................19
2.13.23 Sump...........................................................................................................................................................................................19
2.14 ASSESSING AN ENGINE .......................................................................................................................................................... 19
3GENERAL OVERHAUL PROCEDURES ................................................................................................................................. 20
3.1 MANUAL LAYOUT ................................................................................................................................................................. 20
3.2 DIRECTIONAL REFERENCES ..................................................................................................................................................... 20
3.3 TOP END OVERHAUL VS FULL OVERHAUL .................................................................................................................................. 20
3.4 SPECIAL CLASSES OF OVERHAUL .............................................................................................................................................. 20
3.4.1 Bulk Strip .........................................................................................................................................................................................20
3.4.2 Propeller strike procedures..............................................................................................................................................................21
3.4.3 Abrupt Engine Stoppage..................................................................................................................................................................22
3.5 SEQUENCE OF EVENTS ........................................................................................................................................................... 22
3.6 MAINTAINER REQUIREMENTS ................................................................................................................................................. 23
3.6.1 Facilities...........................................................................................................................................................................................23
3.6.2 Training ...........................................................................................................................................................................................23
3.6.3 Rating ..............................................................................................................................................................................................23
3.6.4 Experience .......................................................................................................................................................................................23
3.7 OVERHAUL TOOLS &EQUIPMENT............................................................................................................................................ 23
3.7.1 Tool & Gauge Control ......................................................................................................................................................................23
3.7.2 Tools: ...............................................................................................................................................................................................23
3.7.3 Equipment: ......................................................................................................................................................................................23
3.7.4 General: ...........................................................................................................................................................................................24

Engine Overhaul Manual
Jabiru Aircraft Pty Ltd
JEM0001-7
Jabiru 2200 & 3300 Aircraft Engines
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3.7.5 Recommended Sealants Compounds & Lubricants..........................................................................................................................25
3.8 LOCTITE 620 &OTHER RETAINING COMPOUNDS ....................................................................................................................... 27
3.8.1 Special Tools ....................................................................................................................................................................................28
3.8.2 Torque / Tension Wrench ................................................................................................................................................................36
3.8.3 Torque Application Procedure .........................................................................................................................................................37
3.9 SAFETY WIRE....................................................................................................................................................................... 38
3.10 HARDWARE......................................................................................................................................................................... 39
4DISASSEMBLY PROCEDURE .............................................................................................................................................. 40
4.1 PRELIMINARY CLEANING ........................................................................................................................................................ 40
4.2 REMOVE THE ENGINE FROM THE AIRCRAFT............................................................................................................................... 40
4.3 ENGINE STAND .................................................................................................................................................................... 40
4.4 SPECIAL CHECKS BEFORE DISASSEMBLY..................................................................................................................................... 41
4.4.1 In-Situ Propeller Flange & Crankshaft Run-Out Measurement ........................................................................................................41
4.4.2 Engine Through-Bolt Check..............................................................................................................................................................41
4.5 ENGINE STRIP:COMPLETE OVERHAUL ...................................................................................................................................... 42
4.5.1 Accessories ......................................................................................................................................................................................42
4.5.2 Cylinder Heads And Valve Gear .......................................................................................................................................................42
4.5.3 Cam Followers, Rocker Oil Lines ......................................................................................................................................................42
4.5.4 Flywheel Cap Screws........................................................................................................................................................................43
4.5.5 Distributor Drive Housings...............................................................................................................................................................43
4.5.6 Flywheel...........................................................................................................................................................................................44
4.5.7 Timing Case .....................................................................................................................................................................................44
4.5.8 Engine Mount Plate And Sump........................................................................................................................................................45
4.5.9 Starter Motor...................................................................................................................................................................................45
4.5.10 Crankshaft Gear..........................................................................................................................................................................46
4.5.11 Cylinders .....................................................................................................................................................................................46
4.5.12 Pistons ........................................................................................................................................................................................47
4.5.13 Front Seal & Oil Pump Housings .................................................................................................................................................47
4.5.14 Oil Return Manifolds...................................................................................................................................................................48
4.5.15 Roller Follower Locking Plate......................................................................................................................................................48
4.5.16 Crankcase ...................................................................................................................................................................................49
4.5.17 Oil Pickup Tube And Strainer.......................................................................................................................................................50
4.5.18 Camshaft And Cam Followers .....................................................................................................................................................50
4.5.19 Connecting rods ..........................................................................................................................................................................50
4.5.20 Crankshaft ..................................................................................................................................................................................51
4.5.21 Group The Parts..........................................................................................................................................................................51
4.6 ENGINE STRIP:TOP END OVERHAUL ........................................................................................................................................ 52
4.6.1 Accessories ......................................................................................................................................................................................52
4.6.2 Cylinder Heads And Valve Gear .......................................................................................................................................................52
4.6.3 Cylinders ..........................................................................................................................................................................................52
4.6.4 Pistons .............................................................................................................................................................................................52
4.6.5 Connecting Rods ..............................................................................................................................................................................52
4.6.6 Flywheel & Gear Case ......................................................................................................................................................................52
4.6.7 Propeller Flange...............................................................................................................................................................................52
4.6.8 Group The Parts...............................................................................................................................................................................52
5INSPECTION AND ASSESSMENT........................................................................................................................................ 53
5.1 MANDATORY REPLACEMENT ITEMS –MULTI-CYCLE PARTS .......................................................................................................... 53
5.2 MANDATORY REPLACEMENT ITEMS –FULL OVERHAUL................................................................................................................ 53
5.3 MANDATORY REPLACEMENT ITEMS –TOP END OVERHAUL .......................................................................................................... 54
5.4 GENERAL ............................................................................................................................................................................ 55
5.5 MANDATORY UPDATES .......................................................................................................................................................... 55
5.6 MANDATORY DISCARD .......................................................................................................................................................... 55
5.7 CLEANING ........................................................................................................................................................................... 56
5.7.1 Materials and Processes ..................................................................................................................................................................56
5.7.2 Degreasing.......................................................................................................................................................................................56
5.7.3 Removal of hard carbon ..................................................................................................................................................................56
5.8 INSPECTION......................................................................................................................................................................... 57
5.8.1 Return to service repair work ..........................................................................................................................................................57
5.8.2 High temperature operation............................................................................................................................................................57
5.8.3 Bearing surfaces ..............................................................................................................................................................................57

Engine Overhaul Manual
Jabiru Aircraft Pty Ltd
JEM0001-7
Jabiru 2200 & 3300 Aircraft Engines
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5.8.4 Gears ...............................................................................................................................................................................................57
5.8.5 Corrosion on stressed areas.............................................................................................................................................................57
5.8.6 Magnetic particle inspection (MPI)..................................................................................................................................................58
5.8.7 Damaged parts................................................................................................................................................................................58
5.8.8 Replacement of studs or broken cap screws....................................................................................................................................58
5.9 SUBASSEMBLY A–CRANKSHAFT,PROPELLER FLANGE AND CONNECTING RODS ................................................................................. 59
5.9.1 Crankshaft and propeller flange......................................................................................................................................................59
5.9.2 Connecting rods...............................................................................................................................................................................61
5.10 SUBASSEMBLY B–CRANKCASE,CAMSHAFT AND OIL PUMP........................................................................................................... 63
5.10.1 Crankcase ...................................................................................................................................................................................63
5.10.2 Hydraulic Valve Lifters ................................................................................................................................................................66
5.10.3 Camshaft ....................................................................................................................................................................................67
5.10.4 Oil pump .....................................................................................................................................................................................69
5.10.5 Oil Pressure Relief Valve .............................................................................................................................................................70
5.11 SUBASSEMBLY C–PISTONS,CYLINDERS AND CYLINDER HEADS....................................................................................................... 72
5.11.1 Pistons and cylinders ..................................................................................................................................................................72
5.11.2 Cylinder heads ............................................................................................................................................................................74
5.11.3 Valves .........................................................................................................................................................................................75
5.11.4 Valve guides................................................................................................................................................................................77
5.11.5 Valve seats..................................................................................................................................................................................79
5.11.6 Cylinder Head –Cylinder Seal .....................................................................................................................................................81
5.11.7 Valve Springs, Spring Washers & Pushrods.................................................................................................................................81
5.11.8 Rockers .......................................................................................................................................................................................83
5.12 SUBASSEMBLY D–SUMP &INDUCTION MANIFOLD.................................................................................................................... 84
5.12.1 Sump...........................................................................................................................................................................................84
5.12.2 Induction Manifold .....................................................................................................................................................................86
5.13 SUBASSEMBLY E–FLYWHEEL,IGNITION COILS,STARTER MOTOR AND ALTERNATOR ........................................................................ 87
5.13.1 Ignition Coils & Alternator ..........................................................................................................................................................87
5.13.2 Flywheel/Starfish Attachment ....................................................................................................................................................88
5.13.3 Starter Motor..............................................................................................................................................................................88
5.13.4 Engine Mount Plate ....................................................................................................................................................................90
5.14 SUBASSEMBLY F–GEAR CASE AND DISTRIBUTORS....................................................................................................................... 91
5.14.1 Gear Case & Distributors ............................................................................................................................................................91
5.15 SUBASSEMBLY G–FUEL PUMP AND CARBURETTOR.................................................................................................................... 93
5.15.1 Carburettor .................................................................................................................................................................................93
5.15.2 Fuel Pump ...................................................................................................................................................................................96
5.16 SUBASSEMBLY H–FINAL ASSEMBLY ........................................................................................................................................ 97
5.16.1 Exhaust System...........................................................................................................................................................................97
6ASSEMBLY –TOP-END OVERHAUL ................................................................................................................................... 98
6.1 GENERAL ............................................................................................................................................................................ 98
6.2 ENGINE THROUGH-BOLTS ...................................................................................................................................................... 98
6.3 FUEL PUMP......................................................................................................................................................................... 98
7ASSEMBLY –FULL OVERHAUL .......................................................................................................................................... 99
7.1 SUBASSEMBLY A–CRANKSHAFT,PROPELLER FLANGE AND CONNECTING RODS ............................................................................... 100
7.1.1 Crankshaft, propeller flange ..........................................................................................................................................................100
7.1.2 Connecting rods.............................................................................................................................................................................101
7.1.3 Assemble .......................................................................................................................................................................................102
7.2 SUBASSEMBLY B–CRANKCASE AND CAMSHAFT........................................................................................................................ 104
7.2.1 Crankcase ......................................................................................................................................................................................104
7.2.2 Camshaft .......................................................................................................................................................................................107
7.3 SUBASSEMBLY C–PISTONS,CYLINDERS AND CYLINDER HEADS..................................................................................................... 108
7.3.1 Pistons ...........................................................................................................................................................................................108
7.3.2 Cylinders ........................................................................................................................................................................................113
7.3.3 Through-Bolt Nuts .........................................................................................................................................................................114
7.3.4 Cylinder heads ...............................................................................................................................................................................115
7.4 SUBASSEMBLY D–SUMP..................................................................................................................................................... 117
7.5 SUBASSEMBLY E–FLYWHEEL,IGNITION COILS,STARTER MOTOR AND ALTERNATOR ...................................................................... 118
7.5.1 Ignition Coils ..................................................................................................................................................................................118
7.5.2 Alternator ......................................................................................................................................................................................118
7.5.3 Flywheel.........................................................................................................................................................................................118

Engine Overhaul Manual
Jabiru Aircraft 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.
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7.5.4 Starter Motor.................................................................................................................................................................................119
7.6 SUBASSEMBLY F–GEAR CASE AND DISTRIBUTORS..................................................................................................................... 120
7.6.1 Engine Mount Plate & Tacho Pickup..............................................................................................................................................120
7.6.2 Distributor Case & Distributor Mounts ..........................................................................................................................................121
7.7 SUBASSEMBLY G–FUEL PUMP AND CARBURETTOR.................................................................................................................. 123
7.7.1 Carburettor....................................................................................................................................................................................123
7.7.2 Fuel Pump......................................................................................................................................................................................123
7.8 SUBASSEMBLY H–FINAL ASSEMBLY....................................................................................................................................... 124
7.8.1 Crankcase Joining ..........................................................................................................................................................................124
7.8.2 Option –Fitting Oil Pump ..............................................................................................................................................................129
7.8.3 Setting Cam Timing .......................................................................................................................................................................130
7.8.4 Sump..............................................................................................................................................................................................132
7.8.5 Engine Mount Plate .......................................................................................................................................................................134
7.8.6 Distributor drives ...........................................................................................................................................................................136
7.8.7 Flywheel and Alternator Rotor ......................................................................................................................................................138
7.8.8 Ignition Posts & Alternator Stator .................................................................................................................................................140
7.8.9 Distributor Caps.............................................................................................................................................................................141
7.8.10 Cylinder Heads ..........................................................................................................................................................................142
7.8.11 Induction Plenum & Tubes ........................................................................................................................................................146
7.8.12 Exhaust Pipes............................................................................................................................................................................148
7.8.13 Carburettor ...............................................................................................................................................................................148
7.8.14 High-Tension Leads & Spark Plugs............................................................................................................................................148
7.8.15 Front Crankshaft Seal Housing..................................................................................................................................................149
7.8.16 Propeller Flange........................................................................................................................................................................150
7.8.17 Oil pump ...................................................................................................................................................................................152
7.8.18 Oil Pressure Relief Valve ...........................................................................................................................................................153
8POST-ASSEMBLY ............................................................................................................................................................ 155
8.1 OILS................................................................................................................................................................................. 155
8.2 BEFORE FIRST START ........................................................................................................................................................... 155
8.3 GROUND RUN-IN &TEST PROCEDURES .................................................................................................................................. 156
8.4 FINAL TASKS...................................................................................................................................................................... 157
8.5 TROUBLESHOOTING ............................................................................................................................................................ 158
9APPENDIX A - BUILD SHEETS & TEST CARDS –APPROVED SECTION................................................................................ 160
9.1 TORQUE SETTINGS.............................................................................................................................................................. 160
9.1.1 Table of Torque Specifications.......................................................................................................................................................160
9.2 BUILD TOLERANCES............................................................................................................................................................. 161
9.3 MULTI-CYCLE ITEMS ........................................................................................................................................................... 162
9.4 COMPOUNDS &SEALANTS ................................................................................................................................................... 162
9.5 MAXIMUM ALLOWABLE CLEARANCES (WEAR LIMITS) ............................................................................................................... 163
9.5.1 Oil Pump Clearance Measurement: ...............................................................................................................................................164
9.6 ELECTRICAL SYSTEM SPECIFICATIONS ...................................................................................................................................... 164
9.7 DISASSEMBLY RECORD SHEET ............................................................................................................................................... 166
9.7.1 Engine Details................................................................................................................................................................................166
9.7.2 Engine Disassembly Record Sheet .................................................................................................................................................166
9.8 SAMPLE COMPLETED BUILD SHEET ........................................................................................................................................ 167
9.9 JABIRU ENGINE BUILD BOOKLET ............................................................................................................................................ 167
9.9.1 Engine Details................................................................................................................................................................................167
9.9.2 Subassembly A Build Sheet –Crankshaft, Propeller Mount Flange and Conrods ..........................................................................168
9.9.3 Subassembly B Build Sheet –Crankcase and Camshaft Assembly .................................................................................................169
9.9.4 Subassembly C Build Sheet –Pistons, Cylinders and Cylinder Heads .............................................................................................170
9.9.5 Subassembly D Build Sheet –Sump ...............................................................................................................................................171
9.9.6 Subassembly E Build Sheet –Flywheel, Ignition Coils, Starter Motor And Alternator....................................................................171
9.9.7 Subassembly F Build Sheet –Gear Case.........................................................................................................................................172
9.9.8 Subassembly G –Fuel Pump and Carburettor ...............................................................................................................................173
9.9.9 Subassembly H –Final Assembly ...................................................................................................................................................174
9.9.10 Ground Run-In Procedure .........................................................................................................................................................175
9.9.11 Engine Post Run Procedure –Stage J ........................................................................................................................................177
9.9.12 Jabiru Engine Build: Parts Measure and Clearance Record Sheet.............................................................................................178
9.10 TOP END OVERHAUL BOOKLET.............................................................................................................................................. 179
9.10.1 Engine Details ...........................................................................................................................................................................179

Engine Overhaul Manual
Jabiru Aircraft 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.
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9.10.2 Top End Subassembly A Build Sheet –Conrods.........................................................................................................................179
9.10.3 Top End Subassembly C Build Sheet –Pistons, Cylinders and Cylinder Heads...........................................................................180
9.10.4 Top End Subassembly E Build Sheet –Starter Motor ................................................................................................................180
9.10.5 Top End Subassembly F Build Sheet –Gear Case ......................................................................................................................181
9.10.6 Top End Subassembly G –Fuel Pump and Carburettor.............................................................................................................182
9.10.7 Top End Subassembly H –Final Assembly.................................................................................................................................183
9.10.8 Top End –Engine Ground Run-In Procedure .............................................................................................................................183
9.10.9 Top End –Engine Post Run Procedure –Stage J .......................................................................................................................183
9.10.10 Parts Measure and Clearance Record Sheet .............................................................................................................................184
10 APPENDIX B –OTHER DOCUMENTATION ....................................................................................................................... 185
10.1 JOB TRAVELLER .................................................................................................................................................................. 185
10.2 SUMMARY OF PARTS USED................................................................................................................................................... 186
10.2.1 Bulk Strip Checklist....................................................................................................................................................................187
10.3 JOB SUMMARY SHEET ......................................................................................................................................................... 188
11 APPENDIX C - WEAR FACTORS........................................................................................................................................ 189
11.1 WEAR FACTORS ................................................................................................................................................................. 189
12 APPENDIX D - MANDATORY REPLACEMENT PARTS ........................................................................................................ 190
12.1 GENERAL .......................................................................................................................................................................... 190
12.2 CAMSHAFT........................................................................................................................................................................ 191
12.3 CRANKCASE....................................................................................................................................................................... 191
12.3.1 Maximum Surfacing / Decking Limit.........................................................................................................................................191
12.3.2 Fretting General Information....................................................................................................................................................192
12.3.3 Fretted Crankcase Repair..........................................................................................................................................................192
12.4 CRANKSHAFT ..................................................................................................................................................................... 194
12.4.1 Maximum Time In Service.........................................................................................................................................................194
12.4.2 Dowel Pins ................................................................................................................................................................................194
13 APPENDIX E –HISTORY OF UPDATES.............................................................................................................................. 199
13.1 ENGINE SERIAL NUMBER DECODE.......................................................................................................................................... 199
13.2 UPDATE HISTORY TABLE ...................................................................................................................................................... 199

Engine Overhaul Manual
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JEM0001-7
Jabiru 2200 & 3300 Aircraft Engines
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1.1 Table of Figures
Figure 1 –2200 Engine...................................................................................................................................................16
Figure 2 –3300 Engine...................................................................................................................................................16
Figure 3 –Cylinder Numbering Convention....................................................................................................................17
Figure 4 –Sealants, Compounds & Lubricants #1 .........................................................................................................25
Figure 5 –Sealants, Compounds & Lubricants #2 .........................................................................................................25
Figure 6 –Sealants, Compounds & Lubricants #4 .........................................................................................................26
Figure 7 –Sealants, Compounds & Lubricants #4 .........................................................................................................26
Figure 8 –Sealants, Compounds & Lubricants #3 .........................................................................................................27
Figure 9 –Safety Wire / Wire Pliers................................................................................................................................28
Figure 10 –Valve Compressor / Lifter Bleed Tools........................................................................................................28
Figure 11 –Dimensional Details For Lifter Tool..............................................................................................................28
Figure 12 –Valve Leakage Vacuum Tester....................................................................................................................29
Figure 13 –Valve Spring Compressor / Collet Remover................................................................................................29
Figure 14 –Solid Valve Lifter –Rocker Adjustment Tool ...............................................................................................29
Figure 15 –Valve Guide Size Gauges............................................................................................................................29
Figure 16 –Leak Down Tester........................................................................................................................................30
Figure 17 –Hand Press & Inserts...................................................................................................................................30
Figure 18 –Piston & Ring Installer .................................................................................................................................30
Figure 19 –Cylinder Hone Helper ..................................................................................................................................30
Figure 20 –Piston Circlip Remover and Installer............................................................................................................31
Figure 21 –Standard Circlip Pliers .................................................................................................................................31
Figure 22 –Optical Tachometer......................................................................................................................................31
Figure 23 –Crankshaft / Flywheel Drilling Jig (for Dowels)............................................................................................31
Figure 24 –Degree Wheel..............................................................................................................................................32
Figure 25 –Supplementary Oil Pressure Gauge............................................................................................................32
Figure 26 –Crankshaft Run-Out Test Bed .....................................................................................................................32
Figure 27 –Ignition Coil Tester.......................................................................................................................................32
Figure 28 –“Finger Bar”..................................................................................................................................................33
Figure 29 –Cam Timing Tool (Hydraulic Lifter)..............................................................................................................33
Figure 30 –Carburettor Needle Seat Remover and Installer .........................................................................................33
Figure 31 –“Crowsfoot” Adaptors ...................................................................................................................................34
Figure 32 –Crankcase Dry Fit Through-Bolts and Nuts.................................................................................................34
Figure 33 –TDC Locator.................................................................................................................................................34
Figure 34 –Crankcase Stud Remover............................................................................................................................34
Figure 35 –Crankcase Dowel Remover.........................................................................................................................35
Figure 36 –Crankshaft Welch Plug Installer / Remover.................................................................................................35
Figure 37 –Die-Grinder Flapper Wheel For Little End ...................................................................................................35
Figure 38 –Universal Joint tool FU14B ..........................................................................................................................35
Figure 39 –Torque Wrench & Crowsfoot Adaptor Setting 1 ..........................................................................................36
Figure 40 –Torque Wrench & Crowsfoot Adaptor Setting 2 ..........................................................................................36
Figure 41 –Using A Crowsfoot Adaptor .........................................................................................................................37
Figure 42 –Safety Wire Details ......................................................................................................................................39
Figure 43 –Safety Wire Installation Using a Twister/Pliers & By Hand..........................................................................39
Figure 44 –Engine Stand ...............................................................................................................................................40
Figure 45 –Measuring Propeller Flange & Crank Run-Out............................................................................................41
Figure 46 –Cylinder Head Disassembly.........................................................................................................................42
Figure 47 –Removing Flywheel Cap Screws & Distributor Drive Housings...................................................................43
Figure 48 –Removing Flywheel......................................................................................................................................44
Figure 49 –Remove Timing Gearbox Case ...................................................................................................................44
Figure 50 –Hidden Sump Screws ..................................................................................................................................45
Figure 51 –Starter Motor Disassembly ..........................................................................................................................45
Figure 52 –Removing Crankshaft Timing Gear & Dowels.............................................................................................46
Figure 53 –Remove Cylinders........................................................................................................................................46
Figure 54 –Remove Pistons...........................................................................................................................................47
Figure 55 –Front Seal & Oil Pump Removal..................................................................................................................47
Figure 56 –Oil Return Manifolds ....................................................................................................................................48
Figure 57 –Crankcase & Locking Plate..........................................................................................................................48
Figure 58 –Split Crankcase............................................................................................................................................49
Figure 59 –Remove Oil Strainer.....................................................................................................................................50
Figure 60 –Remove Con-Rods ......................................................................................................................................50

Engine Overhaul Manual
Jabiru Aircraft Pty Ltd
JEM0001-7
Jabiru 2200 & 3300 Aircraft Engines
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Figure 61 –Welch Plug & Propeller Flange Removal From Crankshaft ........................................................................51
Figure 62 –Stud & Broken Cap Screw Removal............................................................................................................58
Figure 63 –Crankshaft End Detail (Dowel Holes)..........................................................................................................59
Figure 64 –Starfish Flywheel..........................................................................................................................................60
Figure 65 –Crankshaft Measurement ............................................................................................................................61
Figure 66 –Radius Crank Centre Holes.........................................................................................................................61
Figure 67 –Steel Con-Rod .............................................................................................................................................61
Figure 68 –Rear Cam Journal Oil Feed.........................................................................................................................63
Figure 69 –Fuel Pump Oil Drain.....................................................................................................................................63
Figure 70 –Crankcase Fretting.......................................................................................................................................64
Figure 71 –Measuring Crankcase Bearing Tunnel ........................................................................................................64
Figure 72 –Removing Studs and Dowels from Crankcase............................................................................................65
Figure 73 –Main Bearings..............................................................................................................................................66
Figure 74 –Hydraulic Lifter (top left), Solid Lifter (lower left), Roller Follower (right).....................................................67
Figure 75 –Hydraulic Lifter Inspection ...........................................................................................................................67
Figure 76 –2-Ring Camshaft..........................................................................................................................................68
Figure 77 –Roller Cam Lobe..........................................................................................................................................68
Figure 78 –Port Plate Evolution .....................................................................................................................................69
Figure 79 –Modified Port Details....................................................................................................................................69
Figure 80 –Inspecting Oil Pump.....................................................................................................................................70
Figure 81 –Oil Pressure Relief Valve.............................................................................................................................70
Figure 82 –Measuring Cylinder Length..........................................................................................................................72
Figure 83 –Measuring Cylinders & Pistons....................................................................................................................73
Figure 84 –Cylinder hone Pattern..................................................................................................................................74
Figure 85 –Cracking Between Valves, Recessed Cylinder Spigot ................................................................................75
Figure 86 –Valve Measuring..........................................................................................................................................75
Figure 87 –Valve Damage .............................................................................................................................................76
Figure 88 –Valve Guides................................................................................................................................................77
Figure 89 –Measure Guide Wear (Telescopic Gauge Left & Middle, Go-No-Go Gauge Right)....................................77
Figure 90 –Valve Seat Geometry...................................................................................................................................79
Figure 91 –Recessed Valve Seat, Valve Being Cut ......................................................................................................79
Figure 92 –Vacuum Test Rig .........................................................................................................................................80
Figure 93 –Valves Assembly, Cylinder Head / Cylinder Lapping ..................................................................................81
Figure 94 –Valve Springs, Pushrods .............................................................................................................................82
Figure 95 –Valve Spring Washer Thickness..................................................................................................................82
Figure 96 –Pushrod Tube End.......................................................................................................................................82
Figure 97 –Fitting Rocker Bush......................................................................................................................................83
Figure 98 –Solid VS Hollow Valve Rockers...................................................................................................................84
Figure 99 –2200 Engine Sumps ....................................................................................................................................84
Figure 100 –3300 Engine Sumps...................................................................................................................................85
Figure 101 –Different Ignition Coil Models (Honda on Left, Jabiru on Right). ...............................................................87
Figure 102 –Damaged Flywheel “Starfish” ....................................................................................................................88
Figure 103 –Starter Motor Old & New............................................................................................................................89
Figure 104 –Typical Disassembled Starter Motor..........................................................................................................89
Figure 105 –Starter Motor Overhauling .........................................................................................................................90
Figure 106 –Checking Engine Mount Plate Trueness ...................................................................................................90
Figure 107 –Distributor Gears & Case...........................................................................................................................91
Figure 108 –Adjusting High Tension Lead Caps ...........................................................................................................92
Figure 109 –Carburettor Updates ..................................................................................................................................94
Figure 110 –Carburettor Schematic...............................................................................................................................94
Figure 111 –Disassembling Carburettor #1...................................................................................................................95
Figure 112 –Disassembling Carburettor #2...................................................................................................................95
Figure 113 –Fitting New Float Needle Seat...................................................................................................................96
Figure 114 –Carburettor Jets & Diaphragm...................................................................................................................96
Figure 115 –Fuel Pumps (Type 1 on Left, Type 2 on Right)..........................................................................................97
Figure 116 –Crankshaft Painting, Degree Wheel ........................................................................................................100
Figure 117 –Blueing Bearings, Assembling Rods........................................................................................................101
Figure 118 –Measuring Connecting Rods ...................................................................................................................101
Figure 119 –Polishing Little End ..................................................................................................................................102
Figure 120 –Fit Connecting Rods ................................................................................................................................102
Figure 121 –Crankcase Assembly Preparation ...........................................................................................................104

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Figure 122 –Crankcase Dowels...................................................................................................................................104
Figure 123 –Crankcase Clamping Preparation............................................................................................................105
Figure 124 –Fitting Thrust Bearings.............................................................................................................................105
Figure 125 –Fitting Oil Pickup Tube.............................................................................................................................106
Figure 126 –Checking Crankshaft End Float, Installing Solid Lifters...........................................................................106
Figure 127 –Cam Timing Gear Assembly....................................................................................................................107
Figure 128 –Assembling Cam & Fitting to Crankcase.................................................................................................107
Figure 129 –Thrust Direction Markings For Pistons ....................................................................................................108
Figure 130 –Installation of Pistons With Valve Relief ..................................................................................................108
Figure 131 –Fitting Circlip to Piston.............................................................................................................................109
Figure 132 –Fitting Wire-Type Piston Circlips..............................................................................................................109
Figure 133 –The Two Sides of Circlips........................................................................................................................110
Figure 134 –Clip Installation Detail ..............................................................................................................................110
Figure 135 –Over-Compressed and New Clips ...........................................................................................................111
Figure 136 –Checking Piston Ring Gap.......................................................................................................................111
Figure 137 –Compression Ring Cross Section............................................................................................................112
Figure 138 –Piston / Ring / Cylinder Assembly............................................................................................................113
Figure 139 –Through Bolt Nut Installation Detail.........................................................................................................114
Figure 140 –12-Point Nuts, 7/16” Hardware (on right).................................................................................................114
Figure 141 –Cylinder Head Comparison (2200 head on left, 3300 on right)...............................................................115
Figure 142 –Fitting Valves to Head, Fitting Bushes to Rockers ..................................................................................116
Figure 143 –Cylinder Head Welch Plug & Lube Tube Installation...............................................................................116
Figure 144 –Ignition Coil Insulating Washer, Alternator Stator Thickness ..................................................................118
Figure 145 –Flywheel Assembly..................................................................................................................................119
Figure 146 –Installation of Oil Feed Tubes & Tacho Pickup Post ...............................................................................120
Figure 147 –Hall affect Tacho Sender .........................................................................................................................120
Figure 148 –Installation of Seals & Assembly..............................................................................................................121
Figure 149 –New Distributor Shaft Bush Fitted –nopic x 1.........................................................................................121
Figure 150 –Assembling Distributor Gear to shaft.......................................................................................................122
Figure 151 –Applying Sealant to Case, Fitting to Crank..............................................................................................125
Figure 152 –Fitting The Second Case Half..................................................................................................................125
Figure 153 –Tightening The Front Crankcase Studs...................................................................................................126
Figure 154 –Applying Sealant and O-Ring to Cylinder Base.......................................................................................126
Figure 155 –Fitting Gudgeon Pin.................................................................................................................................127
Figure 156 –Fitting Cylinder, Inserting & Tightening Through-Bolts............................................................................127
Figure 157 –Piston Orientation ....................................................................................................................................127
Figure 158 –Torque Seal Applied ................................................................................................................................128
Figure 159 –Universal Joint tool FU14B (FU16B for ½” Socket) .................................................................................129
Figure 160 –Measuring Top Dead Centre ...................................................................................................................130
Figure 161 –Setting Cam Timing .................................................................................................................................131
Figure 162 –Checking Cam Timing #1 ........................................................................................................................131
Figure 163 –Checking Cam Timing #2 ........................................................................................................................132
Figure 164 –Fitting Sump.............................................................................................................................................133
Figure 165 –Oil Filler Tube Installation ........................................................................................................................133
Figure 166 –Sealing Engine Mount Plate ....................................................................................................................134
Figure 167 –Fitting Engine Mount Plate.......................................................................................................................134
Figure 168 –Engine Mount Plate Screw Locations......................................................................................................135
Figure 169 –Fitting Distributor Case & Setting Timing.................................................................................................136
Figure 170 –Setting Distributors, Checking Rotor Position..........................................................................................136
Figure 171 –Checking Rotors, Tightening Distributor Case ........................................................................................137
Figure 172 –Gearbox Installation.................................................................................................................................137
Figure 173 –Applying Loctite, Fitting Dowels...............................................................................................................138
Figure 174 –Flywheel & Crank Timing Marks..............................................................................................................139
Figure 175 –Fitting & Tightening Flywheel Cap Screws..............................................................................................139
Figure 176 –Ignition Post & Alternator Stator Installation............................................................................................140
Figure 177 –Distributor Cap Installation.......................................................................................................................141
Figure 178 –Fitting Hydraulic Lifter To Crankcase.......................................................................................................143
Figure 179 –Crankcase & Locking Plate......................................................................................................................143
Figure 180 –Oil Return Manifold Fitted........................................................................................................................143
Figure 181 –Applying Thread Lubricant & Tightening Lower Head Screw..................................................................144
Figure 182 –Fitting Rockers #1....................................................................................................................................144

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Figure 183 –Fitting Rockers #2....................................................................................................................................144
Figure 184 –Fitting Rockers #3....................................................................................................................................145
Figure 185 –Rocker Lube (Left) & Crankcase Oil Port Blanking Plug.........................................................................145
Figure 186 –Valve Clearance Adjustment (Solid Lifter)...............................................................................................146
Figure 187 –Induction Manifold Installation .................................................................................................................146
Figure 188 –Fitting Induction Pipes to Plenum Chamber ............................................................................................147
Figure 189 –Fitting Carburettor....................................................................................................................................147
Figure 190 –Exhaust Installation..................................................................................................................................148
Figure 191 –Firing Order of Distributor Caps...............................................................................................................148
Figure 192 –HT Leads Fitted To Engine......................................................................................................................149
Figure 193 –Fitting Seal To Housing ...........................................................................................................................149
Figure 194 –Front Seal Housing Ready To Fit ............................................................................................................150
Figure 195 –Preparing To Fit Propeller Flange............................................................................................................150
Figure 196 –Tightening Screws With Torque Wrench.................................................................................................152
Figure 197 –Fitting Oil Pump & Port Plate...................................................................................................................152
Figure 198 –Engine Turning Tool, Installed Oil Pump.................................................................................................153
Figure 199 –Lapping Oil Pressure Relief Valve...........................................................................................................153
Figure 200 –Oil Pressure Relief Valve Assembly........................................................................................................154
Figure 201 –Engine Ground Running Rig....................................................................................................................156
Figure 202 –Oil Pump Details......................................................................................................................................164
Figure 203 –Magnet Tests...........................................................................................................................................165
Figure 204 –Crankcase Fretting...................................................................................................................................192
Figure 205 –Stripping Crankcases...............................................................................................................................193
Figure 206 –De-Burring Crankcase After Surfacing & Line Boring..............................................................................193
Figure 207 –Drilling Fixture –Crankshaft Side on Left, Flywheel Side On Right .......................................................194
Figure 208 –15/64” Drill (Left), 6mm Ream (Centre), UNF Cap Screws (Right) .........................................................195
Figure 209 –Guide positioned on crankshaft...............................................................................................................195
Figure 210 –Drilling & Reaming Crankshaft –ILLUSTRATION ONLY........................................................................196
Figure 211 –Aligning Guide & Fitting To Flywheel.......................................................................................................196
Figure 212 –Drilling & Reaming Flywheel –ILLUSTRATION ONLY...........................................................................197
Figure 213 –Flywheel to crankshaft assembly drawing...............................................................................................198

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1.2 Table of Tables
Table 1 –List of Approved Revisions .............................................................................................................................12
Table 2 –The Spanner Scale .........................................................................................................................................14
Table 3 –Mandatory Replacement Items –Full Overhaul .............................................................................................53
Table 4 –Mandatory Replacement Items –Top End Overhaul......................................................................................54
Table 5 –Carburettor Tuning..........................................................................................................................................93
Table 6 –Hardware Configuration Summary................................................................................................................128
Table 7 –Oil Recommendations for Run-In..................................................................................................................155
Table 8 - Troubleshooting .............................................................................................................................................158
Table 9 –Torque Specifications....................................................................................................................................160
Table 10 –Build Tolerances .........................................................................................................................................161
Table 11 –Mandatory Replacement Items –Multi-Cycle Parts....................................................................................162
Table 12 –Clearance and Wear Limits.........................................................................................................................163
Table 14 –Electrical System Specifications .................................................................................................................164
Table 15 –Engine Disassembly....................................................................................................................................166
Table 16 –Build Sheet A (EXAMPLE)..........................................................................................................................167
Table 17 –Build Sheet A ..............................................................................................................................................168
Table 18 –Build Sheet B ..............................................................................................................................................169
Table 19 –Build Sheet C..............................................................................................................................................170
Table 20 –Build Sheet D..............................................................................................................................................171
Table 21 –Build Sheet E ..............................................................................................................................................171
Table 22 –Build Sheet F...............................................................................................................................................172
Table 23 –Build Sheet G..............................................................................................................................................173
Table 24 –Build Sheet H..............................................................................................................................................174
Table 25 –Ground Run-In Procedure...........................................................................................................................175
Table 26 –Sheet J –Post Run Inspection....................................................................................................................177
Table 27 –Measure & Clearance Record Sheet..........................................................................................................178
Table 28 –Top End Build Sheet A................................................................................................................................179
Table 29 –Top End Build Sheet C ...............................................................................................................................180
Table 30 - Top End Build Sheet E ................................................................................................................................180
Table 31 –Top End Build Sheet F................................................................................................................................181
Table 32 –Top End Build Sheet G ...............................................................................................................................182
Table 33 –Top End Build Sheet H ...............................................................................................................................183
Table 34 –Top End Measure & Clearance Record Sheet ...........................................................................................184
Table 35 –Job Traveller ...............................................................................................................................................185
Table 36 –Summary of Parts Used..............................................................................................................................186
Table 37 –Bulk Strip Checklist.....................................................................................................................................187
Table 38 –Job Summary Sheet....................................................................................................................................188
Table 39 –Wear Factors...............................................................................................................................................189
Table 40 –Mandatory Updates.....................................................................................................................................190
Table 41 –Update History ............................................................................................................................................199

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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 aircraft
engines. These engines are intended to be installed in accordance with the details given in the
appropriate Jabiru Engine Installation Manual. 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 Jabiru Engine Installation Manual. Any non-compliant
installation may render the aircraft un-airworthy and will void any warranty issued by Jabiru.
The Jabiru Aircraft Engines are designed to be operated and maintained only in strict accordance
with the appropriate Instruction and 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 these manuals 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 an 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.
2.1 List of Effective Pages / Issue Status
This manual is revised as a whole. All pages retain the revision status of the overall document.
Altered text is shown in red.
In cases where the data contained in Appendix A is altered and the information in the main body of the
manual is not an additional issue suffix will be applied: Issue 4-A1 indicates Issue 4 of the manual and
Revision 1 of Appendix A. Whenever the main manual is updated this suffix is re-set
Table 1 –List of Approved Revisions
Issue
Reason for Issue
1
Initial Issue
2
Added notes re crankcase dowel fit, general update
3
2: Reading this manual section added. 3.6: Tool & gauge notes expanded. 4: Inspect before cleaning,
7/16” bolt details, oil return manifolds. 5.8: engine cooling notes added. 5.9: notes re flywheel screws.
5.10: oil return manifold notes. 5.11: barrel length notes, valve vacuum unit correction, pushrod length
notes, hollow pushrod & rocker details. 5.15.2: new notes re fuel pump. 7.3: circlip notes, alternator
installation notes.
4
Alter header. Add safety wire, hardware notes. Alter build book format. Create standard tables of
torques, dimensions and clearances. Roller follower references added. Loctite 518 references added.
Top valve spring washer inspection notes added. Rocker arm length note added. Flywheel dowel fit
notes added. Reciprocating part weight limits added. 12-point 7/16” nuts added. Valve seat details
altered.

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Issue
Reason for Issue
5
Appendix A Tables Altered. Parts table updated. Table 13: spark plug gap removed. Pushrod cover
circlip installation details added (Section 7.3.4 & Figure 184). Add certification basis notes (Section
2.4). Con rod installation altered (Section 7.1.3). Allowable compression side ring clearance altered
(Table 12). Through bolt installation detail updated (Section 7.8, 7.3.3). Add details for series-wound
alternator (Table 13). Update propeller flange installation details (Section 7.8.16 and 5.9.1.3). Add
details for pistons with valve relief (Section 7.3.1, 7.8)
7
Ground run-in procedure checklist updated (Section 9.9.10)
Corrections made to Mandatory check and Mandatory replacement items (Section 5.2)
Corrections made to Mandatory Replacement Parts table (Appendix D)
Firing order of distributor caps changed to be looking from flywheel end (Figure 191)
Correction of upper limit main bearing clearance Table 12
Correction of build order for crankcase camshaft assembly 9.9.3 B Build Sheet
Correction –Torque flywheel bolts in one step to value specified in Table 9
2.2 Introduction
This Engine Overhaul Manual has been written to cover the 4-cylinder 2200 and 6-cylinder 3300 Jabiru
engines. Many engine components are common to both engines, for example the cylinders, pistons,
connecting rods etc, as well as many accessories and consequentially the procedures in this Manual
apply equally to both engines.
Before attempting an overhaul the technician must be fully conversant with the appropriate Engine
Instruction & 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 .
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 Applicability
This manual is applicable to all 2200 and 3300 engine models and variants.
2.4 Certification Basis
The 2200C engine is type Certified to the CS-22 Subpart H standard. Various 2200 and 3300 engine
models also comply with the requirements of ASTM F2339.
These standards are not equivalent to FAR 33 or CS-E: CS-22 Subpart H and ASTM F2339 are
simplified engine design standards designed to be suitable for small aircraft with up to two seats
certified using CS-22, CS-VLA or similar design standards.
In all cases, participants in these categories accept that the aircraft, engines and propellers are not
manufactured to the same standards as aircraft in normal categories and that different reliability
expectations apply.
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 5.9” –then you can click on
the “5.9” and automatically skip to that page. Similarly, if Figures or Tables are referenced.

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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 overhaulers 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.
Table 2 –The Spanner Scale
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 Manual layout
This Manual suggests that an engine overhaul will be conducted in three stages: Disassembly,
Inspection and assessment, and Assembly. The intention is that an engine will initially be stripped and
the mandatory replacement parts will be discarded. The remaining parts will be inspected and assessed
for return to service and a single parts order will then be placed.
Final assembly can take place once all the required parts are present.
2.8 Engine life
Engine life is expressed here in cycles, with 1 cycle being nominally in the vicinity of 1,000 hours, the
actual number of hours achieved being heavily dependant on the use of correct operating and
maintenance procedures and, to a lesser degree, operating conditions.
The expected life (expressed as time between complete overhauls) of a correctly operated and
maintained Jabiru engine is 2 cycles, with a top end overhaul taking place at 1 cycle.
Various components of the engine have a service life which is determined “on condition” – that is the
overhauler must examine the part and make a judgement as to the part’s suitability for re-use. Other
parts are evaluated both on condition and by a fixed maximum life –for example valves which are
replaced around 1,000 hours (See Sections 5.1, 5.2 and 5.3).
Engine life is measured via direct tachometer hour meters or “Hobbs” meters. Air switches or scaled
hour readings based on cumulative power output are not to be used to determine when overhauls or
services are due.
2.9 Complete overhaul, top end overhaul, wear tolerances
While the overall thrust of this Manual is complete overhaul, distinction must be made between a
complete overhaul and top end overhaul: the objective of a complete overhaul is to return the engine to
a condition where it can be reasonably expected to achieve 2 cycles, while the objective of a top end
overhaul is to return the top end of the engine (i.e. big ends, cylinders, pistons and cylinder heads) to a
condition where it can be reasonably expected to achieve 1 cycle to take the engine to the next
complete overhaul.
Consequentially the allowable wear tolerances for a top end overhaul, which is intended to achieve 1
cycle, will be different to the allowable wear tolerances for a complete overhaul, which is intended to
achieve 2 cycles.

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2.10 Mandatory updates
Jabiru has been producing engines for many years, and over that time we have made some
improvements to our engine designs in light of operating experience. As a result we have compiled a list
of mandatory updates that must be made to older engines during overhaul.
During the Inspection and assessment stage these modifications will be addressed for each
Subassembly.
The requirements of these modifications must be taken into account when ordering parts.
Section 10 refers.
2.11 Mandatory replacement of parts
During overhaul (either complete or top end) some parts must be replaced regardless of condition: for
example all bolts, all seals, O-rings, etc. Detailed listings will be found in the Inspection and assessment
stage.
2.12 Recording
Careful records of all overhauling work must be completed. It is strongly recommended that the
overhauler print out the build sheets given as a part of this manual and use them to record all the details
of the job.
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.

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2.13 General Description
The engines covered in this manual are all direct drive four and six cylinder, horizontally opposed, air-
cooled models.
Figure 1 –2200 Engine
Figure 2 –3300 Engine
2.13.1 Engine identification
Engine serial numbers are located on the engine number plate that is affixed to the right rear top of the
crankcase. An explanation of the cross-reference of engine numbers may be found in Section 13.1.
2.13.2 Build Configurations
At many places in this manual a serial number range will be referenced with respect to an aspect of the
engine build –i.e. S/No. 200 –250 use a triple-flexed widget while engines outside that range have
double-flexed widgets.

Engine Overhaul Manual
Jabiru Aircraft Pty Ltd
JEM0001-7
Jabiru 2200 & 3300 Aircraft Engines
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In all cases this information refers to the configuration of the engine when it was originally built.
In many cases this information will be changed –such as if the engine is upgraded to a newer
configuration at overhaul. The overhauler must be aware of the potential for these changes and confirm
the engine configuration before beginning re-assembly.
2.13.3 Part Identification
Several components of the engines have been revised since the engines entered production. In some
cases important differences between parts cannot be distinguished easily by inspection. In these cases
identification markings have been applied to the parts. Where applicable, these markings will be shown
and explained in the body of the manual below.
2.13.4 Cylinder Numbering Convention
Figure 3 –Cylinder Numbering Convention
2.13.5 Cylinder heads
The cylinder heads are machined from solid aluminium billet and are fitted to the cylinders by means of
6 retaining cap screws per head.
2.13.6 Valves, valve guides and seats
Stainless steel valves run in press fitted aluminium/bronze valve guides and seat against nickel steel
valve seats that have been shrunk fit into the cylinder heads.
2.13.7 Cylinders
Cylinders are machined in one piece from solid bar 4140 chrome molybdenum alloy steel, with the
pistons running directly in the steel bores.
2.13.8 Pistons
The pistons are machined from aluminium castings and have 3 rings, the top 2 rings being cast iron to
compliment the chrome molybdenum cylinder bores. The gudgeon pin (wrist pin) is of the full floating
type and is retained by a circlip at each end.
2.13.9 Connecting rods
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

Engine Overhaul Manual
Jabiru Aircraft Pty Ltd
JEM0001-7
Jabiru 2200 & 3300 Aircraft Engines
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ends) are machined to fit the gudgeon pin. The big end bearing end caps are fixed to the connecting
rod by two Allen head cap screws through the rod into the end cap.
2.13.10 Crankshaft
The crankshaft is machined from solid bar 4140 chrome molybdenum alloy steel and is stress relieved
using a heat treatment process. The journals are precision ground prior to being inspected by the MPI
(Magnetic Particle Inspection) method.
2.13.11 Crankcase
The crankcase is machined from solid aluminium billet and consists of two halves divided along the
vertical centreline and fastened together by the studs and nuts that retain the cylinders. The mating
surfaces of the crankcase halves are joined without the use of a gasket, and the main bearing bores are
machined for the use of automotive slipper type bearings. Thrust bearings are located fore and aft of
the front double main bearing. The crankcase forms the bearings for the camshaft.
2.13.12 Camshaft
The camshaft is machined from solid bar 4140 chrome molybdenum alloy steel and is hardened using a
nitriding process.
2.13.13 Valve operating mechanism
The camshaft is gear driven from the crankshaft. The camshaft operates cam followers that operate the
valves though pushrods and valve rocker arms. The valve rocker arms are made from steel, induction
hardened and mounted in the cylinder heads on steel shafts through low friction bronze/steel bushes.
2.13.14 Solid lifters
2200 and 3300 engines earlier than serial number [22A-2068] or [33A-961] utilise solid lifters driven by
a 330° camshaft.
2.13.15 Hydraulic lifters
2200 and 3300 engines from serial number [22A-2068] or [33A-961] use hydraulic lifters.
2.13.16 Roller Followers
2200 and 3300 engines from serial number [22A-3596] or [33A-2539] use hydraulic lifters with roller
bases.
2.13.17 Lubricating system
All engines employ a full pressure wet sump lubrication system. A positive-displacement pump driven
from the front of the camshaft provides oil pressure, and oil is circulated to the oil galleries through a
spin-on automotive type oil filter. An adaptor fitted beneath the oil filter feeds oil to the oil cooler.
The primary lubrication sections of the engine –crankshaft, big ends etc –use this full pressure
lubrication system. Secondary lubrication sections of the engine such as the cylinder heads and
gearbox use low pressure lubrication systems while tertiary lubrication sections such as piston/bore
lubrication uses splash lubrication.
2.13.18 Cooling system
Cooling is provided by air pressure that is built up above the cylinder heads in the ram air ducts and
discharged, with an accompanying pressure drop, down through the cooling fins on the cylinder heads
and cylinders and out of the lower rear of the engine cowling.
2.13.19 Induction system
All engines are equipped with a BING brand pressure compensating float type carburettor. The inlet
manifold is mounted in direct contact with the engine oil sump, thus providing a relatively constant
temperature in the manifold for more uniform vaporisation of fuel.
Fuel-air mix is distributed from the manifold to the cylinder heads by individual tubes.

Engine Overhaul Manual
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JEM0001-7
Jabiru 2200 & 3300 Aircraft Engines
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2.13.20 Ignition system
Dual transistorised ignition is provided by two flywheel mounted rare earth magnets that energise two
fixed coils mounted adjacent to the flywheel. The resulting high-voltage current is distributed to the
spark plugs by two gear driven distributors and associated high tension leads. The ignition system has
fixed timing and is fully redundant, self-generating, and does not depend on battery power for operation.
Spark is not generated below 275rpm crankshaft speed.
2.13.21 Electrical charging system
An integral alternator, using rare earth magnets, provides alternating current for battery charging and
powering electrical accessories. The alternator is attached to the flywheel and is driven directly by the
crankshaft. The alternating current goes to a firewall-mounted regulator and thence to the aircraft
electrical system.
2.13.22 Starter motor
The 1.5kw starter motor is mounted to the engine mounting plate at the left rear of the engine with the
drive gear positioned above and ahead of the flywheel when not engaged.
2.13.23 Sump
The engines are equipped with a wet sump lubrication system. The sump is a cast aluminium item
fitted to the underside of the engine and also provides the mounting points for the induction system and
oil cooler.
2.14 Assessing An Engine
While not intended as a complete guide, the overhauler must be aware that the following factors will
affect the service life of an engine. With familiarity the overhauler will be able to look at an engine on
receipt, assess it and have an excellent idea of what will need to be done and what has caused any
issues. For example:
1. Overheating causes higher than normal oil consumption.
2. Hydraulic engines prior to oil fed rockers (hollow pushrods) have higher wear in rocker bushes.
3. Non adherence to published bulletins will shorten engine life. It is essential that operators keep up-
to-date with all updated Jabiru Service information.
4. Operation with defective valves (partially sealing valves) will end with structural failures and
expensive repairs.
5. Operation with poor quality or incorrect fuel will cause problems.
6. Oil/fuel additives are not to be used; some have proven to have highly detrimental effects on
engines.
7. Incorrect load (propellers) will shorten engine life.
8. The installation and matching of the engine and propeller to the aircraft are absolutely essential for
getting the best out of Jabiru Engines. Guidance material is available in the Jabiru Engine
Installation Manuals and Instruction & Maintenance Manuals.

Engine Overhaul Manual
Jabiru Aircraft Pty Ltd
JEM0001-7
Jabiru 2200 & 3300 Aircraft Engines
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3 General overhaul procedures
3.1 Manual layout
This manual is intended for use by experienced technicians and 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 an overhaul.
The sections of the Manual are arranged in the stages in which work will be performed: the engine is
stripped, all components are either discarded (mandatory replacement items) or cleaned then inspected
and assessed for return to service and parts are ordered then the engine is assembled and finally
tested and run-in.
This Manual will describe the overhaul procedures by individual Subassembly of the engine, thus
dividing the manual, for all practical purposes, into a series of individual handbooks dealing with each
Subassembly in turn.
The disassembly stage will be described in a slightly different sequence from the Subassemblies used
in the Inspection and assessment and Assembly stages.
Many of the photographs throughout this Manual are of a 2200 engine –the procedures used are
common across Jabiru 4 and 6 cylinder engines, the only difference being the number of cylinders.
Since there are various overhaul practices and instructions of a non-specific nature, such as cleaning
and inspection, which apply equally to all basic engine components, these general instructions will be
grouped together where possible, to avoid repetition.
3.2 Directional References
In all references to orientation such as “the front of the engine” it will be assumed that the engine has
been installed in a tractor configuration and “front” refers to the propeller end of the engine while “rear”
refers to the flywheel end of the engine. “Left hand” and “right hand” refer to the same orientation when
standing behind the engine facing towards the front of the engine.
3.3 Top End Overhaul vs Full Overhaul
While the overall thrust of this Manual is complete overhaul some sections can also be applied to a top
end overhaul.
A top end overhaul means overhauling only the “top end” of the engine: big ends, cylinders, pistons and
cylinder heads. If a top end overhaul is being conducted then only those items listed in Section 5.3
should be removed from the engine during the engine strip procedure.
Note that greater wear tolerances may be used for a top end overhaul than would be used for a
complete overhaul as a top end overhaul is only required to achieve a life of 1 cycle, taking the engine
through to the next complete overhaul, whereas a complete overhaul is intended to return the engine to
a state where it can be expected to achieve a life of 2 cycles.
As for disassembly, on assembly only certain sections of this manual are relevant for a top end
overhaul. These are detailed in Section 6.
3.4 Special Classes of Overhaul
The following section discusses unusual cases, where an engine is presented to the overhauler where
something other than normal operation has taken place.
In general the procedures for dealing with these are the same as those for a normal overhaul, however
the overhauler must be particularly alert and vigilant for unusual features within the engine. For
example, during a severe prop strike the engine mount plate is often bent –sometimes only slightly –
and this sort of damage may be missed if the inspection process is in any way lax.
3.4.1 Bulk Strip
A Bulk Strip is a special class of procedure where an engine is pulled apart, inspected and then put
back together again –generally using all the same components. It is generally called for when
something has happened to put the internal condition of the engine into doubt –such as a propeller
strike, in-flight failure or improper long term storage.
In its purest form a bulk strip will not affect the life of the engine –so an engine which has a bulk strip at
a time in service of 700 hours will still only have 300 hours left to run after the bulk strip has been