Jabiru J230 2009 User manual

Jabiru J230/430/250/450 Constructors Manual
Pre-Paint>Fuselage>Interior>Fuel system
1 of 5 Tuesday, January 20, 2009
Pre-Paint>Fuselage>Interior>Fuel system
Objectives of this task:
To fit the parts of the fuel system from the header tank to the firewall fitting.
Note that the fuel lines from the wing tanks to the header tank will be sized slightly over-
length and stored for later connection in the Post-Paint>Wings>Fit wings task.
This task is broken down into the following steps:
1. Fit the fuel header tank, fuel filter, electric fuel pump and all connecting fuel lines and
seal, size the fuel lines from the wing tanks to the header tank and store.
2. Install the fuel tap to the console, fit the fuel line from the electric fuel pump to the
fuel tap and fit the fuel line from the fuel tap to the firewall fitting and seal.
Materials required:
Fuel header tank
Card # J11A ‘Fuel Components Kit’
Blue fuel line, Black fuel line and clear fuel line sheathing
Lock wire
Epoxy Resin and Flock, 5-minute Araldite
Fit the fuel header tank
Position the fuel header tank under the rear cabin step with the quick drain fitting centred in
the hole in the fuselage (use a short length of plastic tubing around the quick drain fitting to
keep it centred during the header tank fitting operation) and oriented as shown on drawing
4A408AOD-1 (this drawing is shown full size on the next page of this task).
Cut four positioning brackets from fibreglass angle
and glue a rubber pad to one face of each bracket.
Mark the location for each bracket and then flock the
brackets to the fuselage in two stages: locate the front
and outside brackets first, flock them into place and
let them cure then put the header tank in place and
then flock the remaining two brackets into place
taking care that the header tank is firmly positioned
between the brackets.
When all of the flock has cured, remove the header
tank and attach the header tank securing strap brackets to the fuselage using flock and
countersunk screws. The left-hand bracket should be positioned about 150mm to the left of
the header tank and the right-hand bracket should be positioned about 50mm to the right of
the longitudinal rib. Each strap bracket is held in place with countersunk screws and
Tinnerman washers with Nyloc nuts on the bracket. Tighten the nuts to safety.
The securing strap should pass over the widest part of the header tank – refer to the drawing
on the next page for detail.
Using 5 minute Araldite, glue a rubber pad to the fuselage under the header tank taking care
that no part of the header tank can rub directly against the fibreglass of the fuselage or the
mounting brackets.
Brackets and rubber pad looking rearwards

Jabiru J230/430/250/450 Constructors Manual
Pre-Paint>Fuselage>Interior>Fuel system
2 of 5 Tuesday, January 20, 2009

Jabiru J230/430/250/450 Constructors Manual
Pre-Paint>Fuselage>Interior>Fuel system
3 of 5 Tuesday, January 20, 2009
Fit the fuel pump
Mount the electric fuel pump to the fuselage on the right of
the longitudinal rib as shown on the drawing on the
previous page, using countersunk screws and Tinnerman
washers and Nyloc nuts and tighten the nuts to safety.
The flow arrow on the pump should point towards the front
of the aircraft as shown at right.
Using an O-ring in the groove behind the nut and a small
drop of Loctite 577 Sealant on the threads, fit the finger
filter to the header tank outlet and tighten firmly.
Fit the fuel filter and electric fuel pump
Fit the fuel filter in place, taking care to orient the fuel flow line in the direction of flow,
which is away from the header tank and towards the
electric fuel pump.
Use two zip ties to secure the rubber sheet around the
filter body and another zip tie to secure the wrapped
filter to the locating bracket as shown at right.
Araldite a clip on the top of the lower longitudinal
rib to secure the fuel line from the fuel filter to the
electric fuel pump as shown below right.
Cut a short length of blue fuel line and connect the header tank to the filter, then cut a longer
length and connect the filter to the fuel pump. Secure each connection with hose clamps.
Size the fuel lines
Route one fuel line per side in from the upper conduit, above the side windows as shown
above and through the rear bulkhead conduit and then down to the header tank.
Route each fuel line around the front of the opening in the rear cabin step and leave enough
length to connect to the header tank fittings, leave 500mm of free length outside of the upper
fuselage. Remove the fuel lines and use each one as a measure to cut two more fuel lines of
each length for each side. Label the lines as “Left” or “Right” (the shorter lines will be the
“Left” set) and coil and store in a bag for later use.
Finger filter – header tank outlet

Jabiru J230/430/250/450 Constructors Manual
Pre-Paint>Fuselage>Interior>Fuel system
4 of 5 Tuesday, January 20, 2009
Fit the fuel tap and main fuel line
Remove the lever from the fuel tap and set it aside.
Mark a position on the left-hand side of the centre
console 50mm in front of the base of the armrest and
30mm below the forward section of the console as
shown at right:
Drill a 16mm hole at that position.
Working through the access hole in the right-hand
side of the console, hold the fuel tap in position
against the inside of the left-hand side of the console
and mark the positions for the alignment pin and
screw holes, which will be visible through the fibreglass, then remove the fuel tap and drill
the holes. Pre-fit the fuel tap with the two screws and then remove the tap and set it aside.
Cut a length of blue fuel hose of sufficient length to reach from the fuel tap to a position about
300mm aft of the electric fuel pump (under the rear cabin step), and a length of black fuel
hose of sufficient length to reach from the fuel tap down along the floor and back up to the
firewall fitting plus 100mm.
Fit both fuel hoses to the fuel tap and secure with the
supplied hose clips, first making sure that the flow
arrow on the face of the fuel tap is facing towards the
black fuel line.
Place a length of
fuel line sheathing
over the black fuel
line and secure with
lock wire to the boss on the fuel tap as shown at right.
Fit the fuel line and tap assembly: cover the ends of both
fuel lines to prevent foreign objects from entering by using
masking tape over the ends and then insert the blue fuel line
end into the console through the access hole in the right-
hand side and feed the blue fuel line down and back towards the rear of the fuselage and into
the lower longitudinal rib along the rear floor.
Keep feeding the fuel line back until it can be seen in the hole in the lower longitudinal rib
near the electric fuel pump under the rear cabin step, then, using a length of wire with a hook
in one end, lift the fuel line out of the lower longitudinal rib and run it past the electric fuel
pump. Keep feeding the fuel line back until the end of the black fuel line can be inserted into
the access hole in the console and then feed the black fuel line down and forwards until it can
be lifted out of the hole in the forward section of the lower console behind the rudder pedals.
Using a length of wire with a hook in one end, reach down into the console and lift the fuel
line assembly and move the fuel tap into position. Mount the fuel tap and secure to the
console with the two screws. Cut the end of the blue fuel line to the correct length and
connect it to the electric fuel pump with a supplied hose clip.
Cut the black fuel line and sheath to length to reach the firewall fitting. Cover the open end of
the fuel line to prevent dust or dirt from entering the fuel system. The fuel line will be
connected to the firewall fitting after the upholstery has been fitted.

Jabiru J230/430/250/450 Constructors Manual
Pre-Paint>Fuselage>Interior>Fuel system
5 of 5 Tuesday, January 20, 2009
Final check
At this stage you should have connected the fuel filter, the electric fuel pump, the fuel tap in
the console and the black fuel hose (which is now trimmed to length for the firewall fitting
and sealed) and sized the blue fuel lines from the upper fuselage conduits through to the fuel
header tank and stored the lines for later fitting.
Check that all the flow arrows on the fuel filter, the electric fuel pump and the fuel tap are
pointing in the correct direction, which is away from the header tank and towards the engine.
Check that the fuel lines are routed smoothly with absolutely no kinks and that there are no
rough edges anywhere nearby that could rub against the fuel lines, and then check that the
open ends of the fuel lines and the header tank input fittings are all covered so that no foreign
objects can enter.
This completes the Pre-Paint>Fuselage>Interior>Fuel system task.