Engine Maintenance Manual
Jabiru Aircraft
Pty Ltd
JEM0002-5
Jabiru 2200 & 3300 Aircraft Engines
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Dated : 2nd June 2015
Issued By: AS
Page: 51 of 103
L:\files\Manuals_For_Products\Engine_Manuals\Engine Maintenance Manual 22 & 33\JEM0002-5.docx
Note: On the Bing carburettor best power is delivered when the throttle butterfly is not
quite parallel with the carburettor throat (i.e. not quite fully open). The full power throttle
stop has accordingly been set at the factory for best power output and normally does not
require adjustment in service.
27. Carburettor: Inspect for damage or wear. Remove the bowl and check for contamination.
Inspect the carburettor mount / coupling to check for cracking or degradation.
28. Oil system tubes and hoses: check for condition and replace any which are hard, cracked
or softened.
Note mandatory replacement requirements of Section 8.3.
29. Firewall: Inspect for damage & cleanliness. Particularly check that the electrical
connections to the firewall (master earth tag, starter solenoid etc) are clean.
30. Oil Collector Bottle on Firewall: Measure volume of oil inside then empty. Excess oil in the
bottle can indicate several engine issues
– see troubleshooting section for details.
31. Exhaust system
– including muffler: Inspect for damage or wear. Check for appropriate
tension on exhaust flange screws.
32. Cylinder Head bolt tension: Check as noted in Section 9.15.
33. Inspect valve springs & rockers: Check as noted in Section 9.16.
34. Valve clearance check (solid lifter engines only): Check as noted in Section 9.16.
35. Hydraulic Lifter & Rocker Inspection: Check as noted in Section 9.20
36. Oil & filter change: Carry out as detailed in Section 9.5
37. SCAT hose condition: Check for damage or wear. Ensure that where the hose connects to
the carburettor there is minimum bunching
– a rough surface here from bunched hose can
adversely affect the function of the carburettor.
38. Engine Post-Inspection Test Run as detailed in Section 9.1.
8.9
Fuel System
– Inspection Details
1. Fuel filter(s): Change filter at the interval noted in Table 13.
2. Fuel drain valves, carburettor bowl: Inspect for wear or damage.
3. Electronic fuel boost pump and fittings: Inspect for wear or damage.
4. Fuel lines, taps and connectors: Check flexible lines for condition and replace any which
are hard, cracked or softened. Inspect for fittings for wear or damage. Verify correct
function of tap(s) and that correct fuel tap placards are fitted.
Note mandatory replacement requirements of Section 8.3.
5. Fire sleeves: Check for wear and correct fitment per Figure 36.
6. Fuel flow rate: Check as detailed in Section 9.19
8.10
Special Maintenance - Check after initial 5 Hours
– Solid Lifter Only
For a new aircraft or one equipped with a new or overhauled engine the first few hours of
operation are critical. During this time the engine must be monitored carefully in operation and
during scheduled maintenance.
The following list requirements for mandatory maintenance and inspection recommendations
for engines in their first 5 hours in service or since overhaul / major engine maintenance.
As all possible circumstances cannot be listed here, the following is provided as guidance only.
A critical, trained eye is required and inspections should include, but not be limited to, the
following:
1. Remove engine cowlings
2. Check engine mounts.
3. Thoroughly check engine for missing or loose bolts, nuts, pins, etc.
4. Check fit of cooling air ducts & baffles. Check the engine (including oil cooler) for signs of
abrasion against cowls and ducts.
5. Check induction and exhaust flange for loose bolts.
6. Check safety wires, ignition wiring & hose connections.
7. Re-torque cylinder head bolts to the setting noted in Table 10 in a diagonal pattern (see
Section 9.15).
8. Check & adjust valve clearances.