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: 72 of 201
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5.11 Subassembly C
– Pistons, cylinders and cylinder heads
5.11.1 Pistons and cylinders
Complete overhaul: mandatory replacement of pistons, piston rings, gudgeon pins and piston circlips.
Cylinders may require replacement as after honing if they do not have enough wear left to complete
another cycle. Note that a light, quick hone is generally all that is required.
Top end overhaul: mandatory replacement of pistons, piston rings and piston circlips.
5.11.1.1 Mandatory updates
Figure 82
– Measuring Cylinder Length
Top end overhaul: measure the length of the cylinders and any shims fitted
– combined cylinder/shim
length must be within the limits given in Table 10 when measured from the base flange to the top of the
bore as shown above.
Shorter cylinders must be replaced with longer cylinders. Alternatively 1.00mm or 0.50mm shims may
be cut to suit the base of the cylinder and fitted between the cylinder and the crankcase. Note that only
1 shim can be fitted to any barrel
– for example fitting 2 off 0.5mm shims to increase the barrel
assembly length by 1mm is not acceptable. This distance is used to set the compression ratio of the
engine and short cylinders give higher compression with reduced detonation tolerance.
WARNING
On no account may cylinders or cylinder / shim assemblies shorter than the minimum length given
in Table 10 be used.
5.11.1.2 Cleaning
Top End Overhaul / Full Overhaul:
Pistons are to be replaced.
If conducting maintenance: clean the pistons in a decarbonising solution. Clean the ring lands out
carefully using a non-metallic scraper
– a piece of Perspex is often useful for this task. A piece of
broken piston ring can be used with extreme care but is not recommended because of the damage to
the piston which may result
– any other type of metal scraper is discouraged for the same reasons.
Cylinder Length
