Engine Maintenance Manual
Jabiru Aircraft
Pty Ltd
JEM0002-5
Jabiru 2200 & 3300 Aircraft Engines
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ISSUE
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Dated : 2nd June 2015
Issued By: AS
Page: 50 of 103
L:\files\Manuals_For_Products\Engine_Manuals\Engine Maintenance Manual 22 & 33\JEM0002-5.docx
ducts being lifted from the engine by air pressure, pulling plug leads off spark plugs and
resulting in engine stoppage. If necessary, fit baffle hard points as shown in Figure 32.
Check for correct fitting and signs of abrasion between engine and ducts or between ducts
and cowlings.
10. Cylinders: Inspect for excess oil leakage at the base, cracks, overheating (shown by
discolouration) and other damage or wear.
11. Crankcase & front crankcase seal: Check for leaks.
Note: A leaking front crankcase seal can be an early indicator of unacceptable propeller
vibrations.
12. Fuel hoses, lines and fittings: check for condition and replace any which are hard, cracked
or softened.
Note mandatory replacement requirements of Section 8.3.
13. Intake and exhaust systems: Inspect for signs of damage or wear. In particular, inspect the
sealant between the induction pipes and the induction manifold. Cracking here can result in
air leakage, lean mixture and engine damage. Check for loose or missing bolts at the
intake / exhaust flanges. Ensure that the carburettor heat muff is in good condition and
fitted / connected correctly. Inspect all exhaust springs for condition & security.
14. Ignition harness, distributor caps & rotors: Inspect for signs of damage or wear. Check for
chafing where the leads have rubbed against projections in the engine bay. Check that all
caps are secure on the distributors and are fitting securely to the spark plugs. If any high
tension caps are found to be a loose fit they can be adjusted as shown in Section 9.9.
Inspect the condition of rotors & rotor buttons. Check for leakage from the distributor shaft
seal.
15. Spark plugs: Adjust the spark plug gap to within the limits set in Section 3.4. It is
recommended to set the gaps at the minimum limit during winter for easier starting.
16. Spark plugs: Replace at the intervals specified in Table 13. Adjust the gap of the new plugs
to within the limits set in Section 3.4. It is recommended to set the gaps at the minimum
limit during winter for easier starting.
17. Compression check or leak-down check: Check in accordance with Section 9.18.
18. Electrical wiring: Check wires for damage and wear, including chaffing, burning, dirty or
loose connections. In particular, the connectors for the voltage regulator and the alternator
must be inspected for corrosion, loose connections or damage.
19. Engine-Driven Fuel pump: Inspect for leakage, damage & security of connections.
20. Engine controls and linkages: Inspect for damage and wear. Verify that all controls are
moving smoothly through their full range, that the stops are correctly adjusted and that the
item being controlled is moving through its correct arc
– i.e. when the choke is fully ON or
OFF in the cabin the choke arm on the carburettor moves to the fully ON or OFF position
respectively.
21. Engine mounts, mount structure: Inspect for damage, corrosion and wear including dents,
scratches, rust, cracks etc. Inspect engine rubbers for cracking, bulging, softening or other
signs of deterioration.
22. Safety Wires: Check safety wires are in place and correct.
23. Starter, solenoid and electrical connections: Inspect connections. Ensure they are clean
and tight.
24. Coils and electrical connections: Check the ignition coil gap is set correctly per Section 3.4
& 9.21
25. Carburettor heat system: Inspect for damage and wear. Verify that the control is moving
smoothly through its full range and that the carburettor heat flap is moving through its
correct arc
– i.e. when carby heat is selected as fully ON or OFF in the cabin, the flap in the
air box moves to the fully ON or OFF position respectively.
26. Throttle and linkage: Inspect for damage and wear. Verify that throttle is moving smoothly
through its full range, that the stops are correctly adjusted and that the throttle arm on the
carburettor is moving through its correct arc
– i.e. when the throttle is fully OPEN or
CLOSED in the cabin the arm on the carburettor moves to the fully OPEN or CLOSED
position respectively.