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Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
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Dated : 28/10/2014
Issued By: AS
Page: 42 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
4.5 Engine Strip: Complete Overhaul
4.5.1 Accessories
Remove the spark plugs and exhaust system, followed by the carburettor, the machined inlet manifold
and induction tubes. Remove the starter motor. Remove the distributor caps and high-tension leads,
then the fuel pump, the ignition coils and finally the rear alternator bracing plate to expose the flywheel.
4.5.2 Cylinder Heads And Valve Gear
Remove the rocker covers.
Remove the NPT plug that covers the bottom cylinder head cap screw.
Figure 46
– Cylinder Head Disassembly
Where equipped, loosen the
hose clamps on the rubber oil line “T” connectors. Loosen and remove
each of the 6 cylinder head cap screws from the cylinder head.
The cylinder head should now be removed from the cylinder along with the pushrod tubes and pushrods
and placed on the workbench. Remove the cap screw from between the rockers and carefully drive the
rocker shaft out of the head, driving it from the non-slotted end.
Remove the rockers.
Using a valve spring tool, compress each valve spring and remove the collets and then remove the
valve springs, spring guides and valves.
Remove the O rings from the pushrod tube holes and the rocker shaft holes. Repeat for each cylinder
head.
4.5.3 Cam Followers, Rocker Oil Lines
Remove the pushrod adapters (hydraulic lifter models only) from the crankcase and use a small hooked
tool (an old dentist’s probe is very useful) to extract each hydraulic lifter.
Remove the cap screw that holds each rocker oil line to the side of the crankcase and remove each
rocker oil line. Remove the O rings from the pushrod and oil line holes.
Undo the retaining grub screw and extract the oil filler tube from between #1 and #3 cylinders.
Cap screw under the NPT plug
Remove the valves