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: 77 of 103
L:\files\Manuals_For_Products\Engine_Manuals\Engine Maintenance Manual 22 & 33\JEM0002-5.docx
9.25
Engine Overhaul and TBO
These are carried out only by the manufacturer, Jabiru Aircraft Pty Ltd or by a specifically
approved Jabiru Engine Service Centre (contact Jabiru for details).
The engine must be sent in a complete state, with logbook, to Jabiru (or the Approved Service
Centre) after reaching the TBO limit. In some cases a questionnaire may be supplied
regarding the service life of the engine so far. In these cases the questionnaire must be filled
out as completely as possible & returned with the engine.
Changes to TBO due to operational experience will be advised by Jabiru via Service Bulletin
Engines have full overhauls at 2000 hours with a Top End being done at around 1000 hours.
This is also subject to certain conditions: overhauls are influenced by condition.
9.25.1 Full Overhaul
Full overhauls must be carried out as detailed in the latest approved revision of the Jabiru
Engine Overhaul Manual.
During a full overhaul all parts are cleaned, measured, inspected and recorded in the
prescribed build sheets in the manual. Parts that are
replaced during a full overhaul include:-
Pistons, gudgeons and circlips, rings, main bearings, conrod bearings, thrust bearings, conrod
bolts, all orings gaskets and seals, fuel pump, valves, induction hoses, rubber oil feed tees,
spark plugs, rotors, head bolts, intake/exhaust studs, fuel hose, oil filter, oil hoses, flywheel
bolts, prop flange bolts, woodruff key (oil pump), crankcase through-bolts and crankcase studs.
Cylinder, heads and dizzy shafts are usually replaced at a full overhaul, depending on
condition.
As a part of the overhaul process the engine must be run-in. Again, the procedure given in the
Jabiru Engine Overhaul Manual must be used. Details are given in that manual, however note
that
if the run in is performed on the ground large air cooling ducts and a large oil cooler
must be used
. The engine can also be run-in, in the aircraft in the air with caution, using the
run in program as the guide. Section 5.10 Early Operation of an engine must be understood.
Initial performance data must be recorded. New engines and engines overhauled by Jabiru
Aircraft (Australia) are dispatched already run-in
– no further running-in is required.
9.25.2 Top End Overhaul
Top End Overhauls must be carried out as detailed in the latest approved revision of the Jabiru
Engine Overhaul Manual.
Parts replaced include:- Conrod bearings, pistons, gudgeon pins and circlips, rings, valves, all
relevant O rings and gaskets, head bolts, spark plugs, induction hose joiners, rotors, relevant
cap screws and fuel line. Other parts for inspection, measure and clean or replace are oil
pump, starter, alternator, fuel pump, coils, ignition leads, oil seals, induction and exhaust
capscrews, carby, heads and barrels.
As a part of the overhaul process the engine must be run-in. Again, the procedure given in the
Jabiru Engine Overhaul Manual must be used. Details are given in that manual, however note
that
if the run in is performed on the ground large air cooling ducts and a large oil cooler
must be used
. The engine can also be run-in, in the aircraft in the air with caution, using the
run in program as the guide. Section 5.10 Early Operation of an engine must be understood.
Initial performance data must be recorded. New engines and engines overhauled by Jabiru
Aircraft (Australia) are dispatched already run-in
– no further running-in is required.
