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Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
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ISSUE
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Dated : 28/10/2014
Issued By: AS
Page: 43 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
4.5.4 Flywheel Cap Screws
Now the cap screws that hold the flywheel to the crankshaft must be removed.
These cap screws are held in place with Loctite 620, which is very strong, and they will be very difficult
to undo. Great care must be taken not to break any of them or round the drive sockets of the cap
screws. Due to the high stress on the screws and tools the Allen key must be i
n “as-new” condition with
no wear to its drive faces.
Apply heat to the area around the cap screws, shielding the magnets in the alternator from direct heat,
and then try to crack each cap screw loose using an Allen key and a 3/8” breaker bar.
As excess heat can de-magnetise the alternator magnets overhaulers may prefer to remove the magnet
ring before attempting to remove the flywheel.
This step can take an hour or more and it may involve heating the flywheel (thus the end of the
crankshaft) several times until you can safely undo each cap screw.
Do NOT apply heat directly to the cap screws as this can weaken the screw material. Instead, apply
the heat to the area around the cap screws. This is particularly important because you will need to apply
considerable turning force to undo each cap screw.
It is good practise to wear leather gloves during this task to protect your hands from the heated items
such as the heat shield and the flywheel.
WARNING
Used flywheel cap screws must be discarded and replaced with new items.
Figure 47
– Removing Flywheel Cap Screws & Distributor Drive Housings
4.5.5 Distributor Drive Housings
Carefully lever each distributor rotor off of the distributor shaft
– the rotors are held in place with 5-
Minute Araldite and flock so you will need to work each one off gently.
Undo the Allen head cap screws and remove the 2 machined distributor gear drive housings from the
timing case as shown in Figure 47.
Drive the oil seals out of the drive housings.
Heat shield
Heat the area around the cap screws
Remove distributor drive housings