![background image](http://html1.mh-extra.com/html/jabiru/2200/2200_overhaul-manual_3122313074.webp)
Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.
ISSUE
1
2
3
4
5
6 7
Dated : 28/10/2014
Issued By: AS
Page: 74 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
If returning the cylinders to service, bead blast the outer cylinder area (fins and cylinder base) to
remove all old paint and rust, then etch prime and paint with a high-temperature paint.
Figure 84
– Cylinder hone Pattern
5.11.1.4 Weighing
Weigh piston / connecting rod / gudgeon pin / circlip / piston ring assemblies.
Verify that each assembly falls within the limits given in Table 10.
5.11.2 Cylinder heads
Complete Overhaul:
mandatory replacement of cylinder head bolts, valves and collets.
Top End Overhaul:
mandatory replacement of cylinder head bolts and valve collets.
5.11.2.1 Mandatory updates
Top end Overhaul:
Older cylinder heads should be upgraded to the current “fine fin” model.
5.11.2.2 Cleaning
Top End Overhaul:
Run a 12mm tap through the spark plug threads.
Clean the cylinder heads: bead blast the combustion chambers and valve seats.
5.11.2.3 Inspection and repair
Top End Overhaul:
Check for cracks between the valve seats and for movement of the valve seats in
the cylinder head. Also check for cracking around the exhaust manifold stud threads. Dye penetrant
testing may be required.
Figure 85 (right) is a cylinder head in which the cylinder has crushed into the cylinder head. This can
be caused by over-tensioning or operating the engine with too-
high CHT’s. This is not acceptable for
re-use as it alters the engines compression ratio.
The bores must then be lightly honed with a Sunnen
brand MM33-J58 stone or equivalent so that a 30-40°
crosshatch pattern is visible in the bore as shown in
the drawing at right.
This will allow the new rings to bed in quickly and
minimise oil consumption for the rest of the cycle.
Run a 5/16” UNF tap through the head bolt threads to
clean any debris out that might cause incorrect torque
readings.
Wash the cylinder thoroughly with kerosene and then
hot soapy water, rinse, dry and coat the bore with
engine oil or other corrosion protection immediately.