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
This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.
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Dated : 28/10/2014
Issued By: AS
Page: 8 of 201
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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

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.
ISSUE
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Dated : 28/10/2014
Issued By: AS
Page: 9 of 201
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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

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.
ISSUE
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2
3
4
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7
Dated : 28/10/2014
Issued By: AS
Page: 10 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
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