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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: 98 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
6 Assembly
– Top-End Overhaul
6.1 General
Those parts which must be replaced during a top end overhaul are detailed in Section 5.3
Those parts of an engine which have been disassembled for a Top-End overhaul are to be assembled
in accordance with the details given in the full overhaul assembly part of this manual.
Special top end overhaul build sheets are given in Section 9.
6.2 Engine Through-Bolts
As a pre-emptive test the engine through-bolts may be checked as detailed in Section 4.4.2. If fretting
is suspected it may be necessary to fully s
trip the engine to have the cases “decked” and line-bored.
Note that fretting can lead to failures of the engine through bolts and engine stoppage
– so suspected
case fretting must be taken seriously.
6.3 Fuel Pump
For a top end overhaul the fuel pump must be inspected.
Measure the push rod which drives the pump from the camshaft. Its length must be within the limits set
in Table 10 and the ends must be in good condition
– no excess wear, scoring etc.
Remove the cap of the pump and visually check that the internal parts are in good condition
– no tears
or cracking in the diaphragms or rust on the spring. Re-assemble.
Pre-lube the pushrod using a small amount of grease.
New gaskets must be used when re-fitting the pump. All joints must have 1 face coated with Loctite
515 sealant.
Apply Loctite 243 to the 5/16 x 1 1/4” cap screws and tighten to the value given in Table 9.
Assemble the connecting rods, cylinders, piston and cylinder head assemblies in accordance with the
full overhaul procedures detailed in Section 7 below.