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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: 57 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
5.8 Inspection
The inspection of engine parts during overhaul is divided into three categories, visual, dimensional and
structural. The first and last categories deal with the structural defects in parts while the second is
concerned with the size, shape and fit.
Visual
inspection should precede all other inspection procedures.
Dimensional
inspections should be carried out in accordance with the measurements and tolerances
detailed in the Table of Limits.
Structural
integrity of steel components must be determined by MPI (Magnetic Particle Inspection).
5.8.1 Return to service repair work
Some components will require repair work in order to be returned to service and this work will be
performed as part of the Inspection and assessment stage.
5.8.2 High temperature operation
The insides of pistons and the crankcase should be visually inspected during disassembly for burnt-on
oil deposits that would indicate overheating and/or operation in extreme conditions.
If such evidence of overheating is seen then the engine cooling arrangement must be inspected and
possibly modified for greater cooling airflow before the overhauled engine is refitted. The Jabiru Engine
Installation Manuals refer.
5.8.3 Bearing surfaces
All bearing surfaces should be examined for scoring, galling and wear.
Some scratching and light scoring of aluminium bearing surfaces in the engine will do no harm and
should not be considered cause for rejection of the part, provided it falls within the tolerances set forth
in the Table of Limits. Even though the part may come within specified limits it should not be
reassembled into the engine unless inspection shows it to be free of other serious defects.
All journal surfaces should be checked for galling, scores, misalignment and out-of-round condition.
Shafts, pins etc, should be checked for straightness. This may be done in most cases by using vee
blocks and a dial indicator.
5.8.4 Gears
All gears should be examined for evidence of pitting and excessive wear. Bearing surfaces of all gears
should be free from deep scratches. However, minor abrasions may be dressed out with a fine abrasive
cloth. In particular the starter ring gear and the matching gear from the starter clutch are susceptible to
damage and must be checked carefully.
5.8.5 Corrosion on stressed areas
Pitted surfaces in highly stressed areas resulting from corrosion can lead to ultimate failure of the part.
The following areas should be carefully examined for evidence of such corrosion: the fillets at the edges
of crankshaft main and journal surfaces, connecting rods and the camshaft.
If pitting exists on any of the surfaces mentioned to the extent that it cannot be removed by polishing
with crocus cloth or other mild abrasive, the part must be rejected.