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OVERHAUL MANUAL

FOR

JABIRU 2200 & 3300 AIRCRAFT ENGINES

DOCUMENT No. JEM0001-7

Date: 28

October 2014

This Manual has been prepared as a guide to correctly overhaul Jabiru 2200 & 3300 aero engines.

It is the owner's responsibility to regularly check the Jabiru web site at www.jabiru.net.au for

applicable Service Bulletins and have them implemented as soon as possible. Manuals are also

updated periodically with the latest revisions available from the web site. Failure to maintain the

engine or aircraft with current service information may render the aircraft un-airworthy and void

Jabiru’s Limited, Express Warranty.

This document is controlled while it remains on the Jabiru server. Once this no longer applies the

document becomes uncontrolled.

Should you have any questions or doubts about the contents of this manual, please contact Jabiru

Aircraft Pty Ltd.

Summary of Contents for 2200

Page 1: ...aero engines It is the owner s responsibility to regularly check the Jabiru web site at www jabiru net au for applicable Service Bulletins and have them implemented as soon as possible Manuals are al...

Page 2: ...s 16 2 13 3 Part Identification 17 2 13 4 Cylinder Numbering Convention 17 2 13 5 Cylinder heads 17 2 13 6 Valves valve guides and seats 17 2 13 7 Cylinders 17 2 13 8 Pistons 17 2 13 9 Connecting rods...

Page 3: ...5 4 Flywheel Cap Screws 43 4 5 5 Distributor Drive Housings 43 4 5 6 Flywheel 44 4 5 7 Timing Case 44 4 5 8 Engine Mount Plate And Sump 45 4 5 9 Starter Motor 45 4 5 10 Crankshaft Gear 46 4 5 11 Cyli...

Page 4: ...nder Seal 81 5 11 7 Valve Springs Spring Washers Pushrods 81 5 11 8 Rockers 83 5 12 SUBASSEMBLY D SUMP INDUCTION MANIFOLD 84 5 12 1 Sump 84 5 12 2 Induction Manifold 86 5 13 SUBASSEMBLY E FLYWHEEL IGN...

Page 5: ...l Pressure Relief Valve 153 8 POST ASSEMBLY 155 8 1 OILS 155 8 2 BEFORE FIRST START 155 8 3 GROUND RUN IN TEST PROCEDURES 156 8 4 FINAL TASKS 157 8 5 TROUBLESHOOTING 158 9 APPENDIX A BUILD SHEETS TEST...

Page 6: ...Subassembly G Fuel Pump and Carburettor 182 9 10 7 Top End Subassembly H Final Assembly 183 9 10 8 Top End Engine Ground Run In Procedure 183 9 10 9 Top End Engine Post Run Procedure Stage J 183 9 10...

Page 7: ...ling Jig for Dowels 31 Figure 24 Degree Wheel 32 Figure 25 Supplementary Oil Pressure Gauge 32 Figure 26 Crankshaft Run Out Test Bed 32 Figure 27 Ignition Coil Tester 32 Figure 28 Finger Bar 33 Figure...

Page 8: ...5 Cracking Between Valves Recessed Cylinder Spigot 75 Figure 86 Valve Measuring 75 Figure 87 Valve Damage 76 Figure 88 Valve Guides 77 Figure 89 Measure Guide Wear Telescopic Gauge Left Middle Go No G...

Page 9: ...sembly 119 Figure 146 Installation of Oil Feed Tubes Tacho Pickup Post 120 Figure 147 Hall affect Tacho Sender 120 Figure 148 Installation of Seals Assembly 121 Figure 149 New Distributor Shaft Bush F...

Page 10: ...9 Figure 193 Fitting Seal To Housing 149 Figure 194 Front Seal Housing Ready To Fit 150 Figure 195 Preparing To Fit Propeller Flange 150 Figure 196 Tightening Screws With Torque Wrench 152 Figure 197...

Page 11: ...tory Replacement Items Multi Cycle Parts 162 Table 12 Clearance and Wear Limits 163 Table 14 Electrical System Specifications 164 Table 15 Engine Disassembly 166 Table 16 Build Sheet A EXAMPLE 167 Tab...

Page 12: ...manship and proper consumables It is your responsibility to ensure absolute attention to detail no matter who may become involved in work on this engine Your safety your life and your passenger s live...

Page 13: ...e Letters or other manufacturer s data Current information is available from the Jabiru Aircraft Australia web site www jabiru net au Overhauls must only be carried out by an approved person Depending...

Page 14: ...and assessed for return to service and a single parts order will then be placed Final assembly can take place once all the required parts are present 2 8 Engine life Engine life is expressed here in...

Page 15: ...nes during overhaul During the Inspection and assessment stage these modifications will be addressed for each Subassembly The requirements of these modifications must be taken into account when orderi...

Page 16: ...covered in this manual are all direct drive four and six cylinder horizontally opposed air cooled models Figure 1 2200 Engine Figure 2 3300 Engine 2 13 1 Engine identification Engine serial numbers a...

Page 17: ...rkings have been applied to the parts Where applicable these markings will be shown and explained in the body of the manual below 2 13 4 Cylinder Numbering Convention Figure 3 Cylinder Numbering Conve...

Page 18: ...cker arms are made from steel induction hardened and mounted in the cylinder heads on steel shafts through low friction bronze steel bushes 2 13 14 Solid lifters 2200 and 3300 engines earlier than ser...

Page 19: ...e with the drive gear positioned above and ahead of the flywheel when not engaged 2 13 23 Sump The engines are equipped with a wet sump lubrication system The sump is a cast aluminium item fitted to t...

Page 20: ...of the engine while rear refers to the flywheel end of the engine Left hand and right hand refer to the same orientation when standing behind the engine facing towards the front of the engine 3 3 Top...

Page 21: ...test the propeller flange crankshaft and connecting rods Replace all screws used in the propeller flange flywheel and connecting rod attachments Replace O rings and gaskets as required Replace piston...

Page 22: ...crankshaft and MPI inspect the connecting rods Check and carry out any mandatory updates 3 4 3 Abrupt Engine Stoppage An abrupt engine stoppage may be caused by a number of different failures within t...

Page 23: ...Total Overhauls Bulk Strips and other heavy maintenance 3 7 Overhaul Tools Equipment 3 7 1 Tool Gauge Control Tool and gauge control is an important part of aviation maintenance systems Tools and gau...

Page 24: ...with a soft pencil flame Micrometer and internal measuring tools must read up to 100mm Multimeter or an ohmmeter Spring scale must read up to 2 5kg in 0 1kg increments Thread taps 1 4 5 16 3 8 UNF an...

Page 25: ...arts in storage Loctite 7471 Cure Accelerator Loctite 7471 is used where increased cure speed of Loctite anaerobic products is required 7471 is particularly recommended when prevailing temperature is...

Page 26: ...and cylinder head screws Loctite Nickel Anti Seize is copper free Recommended for stainless steel and other metal fittings For preventing corrosion seizing and galling in harsh chemical environments a...

Page 27: ...e than a minute is not recommended particularly if cure accelerator spray Loctite 7471 is used Only use as much as required specified Excess compound can make it nearly impossible to disassemble the p...

Page 28: ..._For_Products Engine_Manuals Overhaul_Manual JEM0001 7_Overhaul_Manual_DRAFT_ 29_10_14 docx 3 8 1 Special Tools Special tools can simplify the process and are shown in the photos below Figure 9 Safety...

Page 29: ...eat See Section 5 11 5 for details of use Figure 13 Valve Spring Compressor Collet Remover Modified sash clamp shown commercial types are also available Used to compress the valve spring to allow the...

Page 30: ...ushes distributor shaft and crankshaft seals Inserts are made for the press to suit the parts Figure 18 Piston Ring Installer Simplifies compressing the piston rings to allow installation of the pisto...

Page 31: ...to the piston Figure 21 Standard Circlip Pliers Standard internal circlip pliers are required Such pliers may be modified by brazing a washer to one leg as shown in Figure 21 right The washer is filed...

Page 32: ...RAFT_ 29_10_14 docx Figure 24 Degree Wheel Figure 25 Supplementary Oil Pressure Gauge Figure 26 Crankshaft Run Out Test Bed A test bed to simplify measuring crankshaft and propeller flange run out Thi...

Page 33: ...sily while tightening or loosening propeller flange or flywheel screws Figure 29 Cam Timing Tool Hydraulic Lifter A piece of material Nylon has been used here machined to fit neatly into a hydraulic l...

Page 34: ...Manual_DRAFT_ 29_10_14 docx Figure 31 Crowsfoot Adaptors Commercially available tool designed for high torque applications on small nuts Figure 32 Crankcase Dry Fit Through Bolts and Nuts A set of eng...

Page 35: ...aft Welch Plug Installer Remover Figure 37 Die Grinder Flapper Wheel For Little End Figure 38 Universal Joint tool FU14B Snap On tool FU14B a universal joint with inbuilt 7 16 nut drive Used for chang...

Page 36: ...a way which is traceable to a NATA standard laboratory A Crowsfoot extension as shown in Figure 31 is also necessary it allows high torque settings to be used on small nuts without damaging them The c...

Page 37: ...rate bolt torque reading is going to be obtained Firstly the nut must be tightened smoothly Any jerks or bumps can cause the torque reading to be obtained prematurely The torque must be obtained while...

Page 38: ...when being twisted and maintain a light tension when secured Figure 43 f Safety wire ends must be bent under and inward toward the part to avoid sharp or projecting ends which might present a safety h...

Page 39: ...ils Figure 43 Safety Wire Installation Using a Twister Pliers By Hand 3 10 Hardware Certain applications on the Jabiru Engine must use particular grades of hardware Propeller flange attach screws flyw...

Page 40: ...rcraft Disconnect the earth cable and free the starter motor power cable from the wiring loom Remove the muffler and then remove the oil drain plug and drain the oil from the engine Remove the ram air...

Page 41: ...on dial indicator onto prop flange as shown above eliminate end float by either pulling or pushing flange when rotating Rotate prop flange to measure the face run out 0 02 0 06 mm is normal but if run...

Page 42: ...e rubber oil line T connectors Loosen and remove each of the 6 cylinder head cap screws from the cylinder head The cylinder head should now be removed from the cylinder along with the pushrod tubes an...

Page 43: ...overhaulers may prefer to remove the magnet ring before attempting to remove the flywheel This step can take an hour or more and it may involve heating the flywheel thus the end of the crankshaft sev...

Page 44: ...rs are placed under the flywheel on the tops of opposing timing case cap screws and then moved evenly up to provide leverage to remove the flywheel from the crankshaft 4 5 7 Timing Case Remove the cap...

Page 45: ...ews can only be accessed by removing the timing gearbox Note that these screws have been omitted on later model engines to allow the sump to be removed without first removing the gearbox Figure 50 Hid...

Page 46: ...working from side to side Figure 52 Removing Crankshaft Timing Gear Dowels Extract the 3 dowels from the end of the crankshaft use a suitable collet type extractor a commercially available tool that h...

Page 47: ...side load as shown above right and carefully extract the gudgeon pin out of the piston Remove the piston from the connecting rod Take care not to put any side load on the connecting rods while removi...

Page 48: ...les Manuals_For_Products Engine_Manuals Overhaul_Manual JEM0001 7_Overhaul_Manual_DRAFT_ 29_10_14 docx 4 5 14 Oil Return Manifolds Figure 56 Oil Return Manifolds 4 5 15 Roller Follower Locking Plate F...

Page 49: ...nuts from the retained studs and then set about carefully tapping each retained stud located at the front and back of the case with a suitable soft hammer until the case halves start to separate Caref...

Page 50: ...lifter engine only remove the cam followers from each crankcase half 4 5 19 Connecting rods Figure 60 Remove Con Rods Remove each connecting rod from the crankshaft in the following matter heat the b...

Page 51: ...throws Figure 61 shows the plug emerging preceded by some sludge Figure 61 Welch Plug Propeller Flange Removal From Crankshaft Remove the crankshaft from the stand clamp it between the heavily padded...

Page 52: ...e After measuring they may be honed lightly 4 6 4 Pistons As for complete overhaul disassembly 4 6 5 Connecting Rods As for complete overhaul disassembly Remove the rod and end cap and remove the bear...

Page 53: ...All O rings gaskets seals Connecting rods Pistons piston gudgeon pins and circlips Propeller flange Piston rings Engine mount plate engine back plate Intake and exhaust valves collets Starter motor an...

Page 54: ...for solid lifter engines Intake and exhaust valves Rocker shafts Pistons piston gudgeon pins and circlips Pushrods Piston rings Pushrod tubes Cylinder base O rings Rocker bushes Spark plugs Cylinders...

Page 55: ...c Structural MPI Magnetic Particle Inspection on steel parts At the end of this process a single parts order can be placed with your local Jabiru dealer 5 5 Mandatory updates All engines must be check...

Page 56: ...mpounds or soap Such compounds in addition to being potentially harmful to aluminium may become impregnated in the pores of the metal and cause oil foaming when the engine is returned to service 5 7 3...

Page 57: ...for greater cooling airflow before the overhauled engine is refitted The Jabiru Engine Installation Manuals refer 5 8 3 Bearing surfaces All bearing surfaces should be examined for scoring galling an...

Page 58: ...tapped threads NPT must not be tapped deeper in order to clean them up because this practice will invariably result in an oversized tapped hole Following any repairs of this type the part should be ca...

Page 59: ...d flywheel must be modified before return to service and a new crankshaft timing gear must be purchased Details of the process are given in Section 12 4 2 If the drilling and dowelling modification is...

Page 60: ...al indicator on a magnetic base to check that the runout as measured at the very front of the crankshaft is within the range 0 01 to 0 05mm Upper limits for crank run out are given in Table 10 Now mou...

Page 61: ...eck around the centre holes in the crank web for a radius once again there must be no sharp edges that could form a stress point anywhere on the crankshaft Older engines are more susceptible to this b...

Page 62: ...make fitting the gudgeon pin difficult This can be done by hand using fine emery paper or using a fine grade flapper wheel on a die grinder or Dremel Only oil deposits must be removed not metal Wash...

Page 63: ...t overhaul this may also require fitting a new oil pump pickup tube 5 10 1 2 Optional Updates For hydraulic lifter engines the oil return manifolds shown in Figure 56 can be retrofitted These parts im...

Page 64: ...ions before return to service If fretting has occurred then a complete set of new crankcase studs must be purchased and fitted during assembly and the crankcase dowels must be shortened at one end by...

Page 65: ...ion of heat will assist the removal as shown above Extract the dowels from the lower stud holes in Figure 72 an expanding puller is being used to pull the dowels out of the case Clean the stud holes w...

Page 66: ...r extreme care is needed to make sure that each lifter is re assembled correctly The lifters contain many small parts which must be oriented correctly for the valving of the lifter to work Note also t...

Page 67: ...y other adverse wear of the lifter base such as galling or pitting of the working surface Before installation all hydraulic lifters must be polished around their base as shown below to remove any burr...

Page 68: ...e 76 2 Ring Camshaft Figure 77 Roller Cam Lobe 5 10 3 2 Cleaning Clean out the 4 threaded holes in the rear flange with a 1 4 UNF tap Clean the camshaft with kerosene and dry Coat with engine oil or o...

Page 69: ...he outlet port and at the bottom of both ports there are small tapered indentations Some versions of this plate will only have the larger indentation at the top of the outlet port and not the pair at...

Page 70: ...surfaces Visually inspect the woodruff key which drives the pump It is normal for there to be some light marking on this part however significantly marked keys must be replaced Measure the clearances...

Page 71: ...with kerosene and dry 5 10 5 3 Inspection Visually inspect the poppet for wear If it has a significant worn ring where it has been sitting against the washer then the marks must be polished out or the...

Page 72: ...st be within the limits given in Table 10 when measured from the base flange to the top of the bore as shown above Shorter cylinders must be replaced with longer cylinders Alternatively 1 00mm or 0 50...

Page 73: ...further use if operated and maintained correctly After measuring check carefully for signs of ovality measure at 3 equally spaced intervals around the bore Measure the piston diameter and calculate th...

Page 74: ...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 Inspec...

Page 75: ...seats scoring of the stem or necking of the stem This is a useful check as it will indicate very poor maintenance Valves are replaced at both top end and full overhauls Check that the heads of the va...

Page 76: ...shown 2 A valve showing burnt residue on the valve seal face and rust on the valve stem from incorrect long term storage 3 A non sealing valve 4 A badly burnt valve this has run for many hours allowin...

Page 77: ...ection arrow in Figure 88 movement in the head of the valve Check each valve in this manner Use a micrometer to measure the valve stems and the valve guide bores and calculate the clearance it must be...

Page 78: ...g an oven or other uniform heat source until the old guides can be driven out easily If the head is not heated sufficiently it is possible that some metal may be picked up when the old guides are driv...

Page 79: ...n in Figure 90 then the seats will need to be cut and the valves may also need to be refaced Valve seats are cut at 45 degrees for the actual seat and then under and over cut at 30 and 60 degrees as r...

Page 80: ...curate The unit pictured below used compressed air to generate a vacuum and is manufactured by SMC P No ZH13B Figure 92 Vacuum Test Rig If the valve seats are badly worn or recessed into the cylinder...

Page 81: ...mount of material After lapping the valves or head must be cleaned thoroughly to make sure all the grinding paste has been removed 5 11 7 Valve Springs Spring Washers Pushrods Complete Overhaul mandat...

Page 82: ...d on the right Replace any bent or damaged pushrods Pushrod length limits are given in Table 10 For hydraulic lifter engines the 215mm type is recommended for standard use as it allows greater toleran...

Page 83: ...s shown in Figure 97 right If this hole is not present rapid wear of the bush will occur Push the new bushes completely into each rocker the width of the bush determines the amount of end float for th...

Page 84: ...controlled ISSUE 1 2 3 4 5 6 7 Dated 28 10 2014 Issued By AS Page 84 of 201 L files Manuals_For_Products Engine_Manuals Overhaul_Manual JEM0001 7_Overhaul_Manual_DRAFT_ 29_10_14 docx Figure 98 Solid V...

Page 85: ...urrent model larger sump This will reduce crankcase pressure and excessive blow by of engine oil into the overflow bottle Either sump may be used on a solid lifter engine Note that although the sump v...

Page 86: ...urettor at overhaul 3300 engines Most 3300 engines are equipped with a bolt on induction manifold assembly similar in appearance to the 2200 engine part shown in Figure 187 note the shape of the diffu...

Page 87: ...drive gear and the flywheel ring gear for chipped teeth if any teeth are chipped or missing then a new gear must be ordered The ring gear may have either 99 or 101 teeth you must specify the exact to...

Page 88: ...t where the parts can be assembled by light hammer taps is the minimum acceptable fit Where equipped assess the fit of the dowels into the flywheel spacer vacuum pump drive a slip fit where the parts...

Page 89: ...rying solvent Figure 105 left 5 13 3 3 Inspection And Repair Check commutator for wear if you are not experienced in this field then seek a suitable qualified person to check the commutator for servic...

Page 90: ...datory Updates As noted above engine mount plates are specific to the flywheel ring gear used there are 99 and 101 tooth versions of the plate to suit the different gears Parts must be matched on asse...

Page 91: ...to the shafts as shown above right and replace any that are loose with new 3 16 x 5 16 Monel rivets taking care to drive the pin out of the centre of the rivet on completion of fitting Check gears and...

Page 92: ...d 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 92 of 201 L files Manuals_For_Products Engi...

Page 93: ...replacement parts required to achieve current carburettor tuning standards Refer also to Jabiru Service Bulletin JSB018 In some applications non standard jets will be required and are acceptable if t...

Page 94: ...he engine and will warn the overhauler to check thoroughly for wear on parts like cylinders The carburettor exterior can be cleaned using kerosene then washed with water and air dried The carburettor...

Page 95: ...rong light and carefully stretching each section in turn If any leaks are found then a new diaphragm must be ordered Lift the slide and diaphragm assembly out of the carburettor body remove the needle...

Page 96: ...in jet are installed in the correct orientation and correct order as shown in Figure 114 left Also ensure that the tag on the diaphragm is aligned and fitted correctly to the socket in the carburettor...

Page 97: ...h pumps are driven by pushrods acting from a special lobe of the camshaft however the Type 2 pump requires a different length pushrod to the Type 1 refer to Table 10 for lengths Wherever a Type 1 pump...

Page 98: ...4 4 2 If fretting is suspected it may be necessary to fully strip the engine to have the cases decked and line bored Note that fretting can lead to failures of the engine through bolts and engine sto...

Page 99: ...mbly Section 7 8 where each of the subassemblies will be combined to form the complete overhauled engine Remember that for a Jabiru Engine it is required that at certain stages of the assembly a secon...

Page 100: ...e main bearing driving the plug in from the rear then the rear 7 8 plug at the back of the crankshaft and finally the 28mm front plug located at the very front of the crankshaft tap each plug squarely...

Page 101: ...be corrected by carefully sanding the ends of the bearing shells on a sheet of 600 grit sandpaper laid on a flat surface and then rechecking Remember that altering bearing crush will also alter the b...

Page 102: ...5 11 1 4 Extra care must be taken if a partial set of pistons are to be fitted i e 1 new piston to an engine In this case the weight of the new piston must be compared to to the weight of the existin...

Page 103: ...lbs then to the final value given in Table 9 Perform a final check for ease of rotation the connecting rod should move smoothly around the big end journal If it does not rotate freely then the rod sh...

Page 104: ...and 97mm free length above the crankcase join Fit the hollow dowels to one crankcase half in the positions arrowed above It is vital that poorly fitted dowels are not used at the crankcase join if the...

Page 105: ...tages working from the centre studs out to the front and rear studs Measure the main bearing bore size with the new main bearing shells in place The bore size with the new main bearing shells in place...

Page 106: ...using moly grease or cam honey This prevents damage during initial starting of the engine Hydraulic lifters will be fitted later in the final assembly process as they can be fitted from outside the c...

Page 107: ...the cam flange threads with Loctite 7471 cure accelerator align the inner gear so that the alignment hole on the camshaft flange aligns with the hole in the inner gear Hold that position and fit the s...

Page 108: ...4 cylinder engine during maintenance In this case the overhauler must accurately weigh reciprocating part assemblies per Section 5 11 1 4 For in service maintenance purposes it is acceptable practice...

Page 109: ...llation of that type of clip is shown in Figure 132 The circlip has a lot of tension and as a result installation can be tricky Overhaulers must roll the clip into the groove they must never be levere...

Page 110: ...which was over compressed lying on top of a brand new clip Note how the clip on top has been bent to a smaller size compared to the one underneath This damage to the clip reduces the force it can app...

Page 111: ...stons and cylinders using engine oil One at a time fit the compression rings the first and second ring of each piston into their cylinder Use a piston to press the rings down into the bore this will p...

Page 112: ...piston crown The compression ring with the cut out section fits in the next groove down see Figure 137 Some compression rings are marked with a dot or an R Compression rings with either of these mark...

Page 113: ...rient the ring gaps at 120 intervals around the piston so that it is unlikely that the gaps will ever line up The rings must also be oiled for assembly Fit the piston to the cylinder using a commercia...

Page 114: ...ult in the nut hitting on the radius at the cylinder base To avoid this it is necessary to use a Small flange nut per Figure 139 left or a nut which has been modified the diameter of the nut base can...

Page 115: ...piston rod cylinder sets The numbering system of the cylinders for the engines is given in Figure 3 Note that the 2200 engine uses two different cylinder heads one for cylinders 1 4 and another for 2...

Page 116: ...cker arms if needed A special tool and a hand press as shown in Figure 142 simplifies this job Orient the new bushes so that the joint in the bush is pointing away from the crankshaft Additional detai...

Page 117: ...r If the crankcases have been surfaced and line bored it is possible that the sump dowel pins may not align correctly After the crankcases have been joined the sump must be dry fitted to confirm that...

Page 118: ...is used on these screws 7 5 3 Flywheel If the engine is being updated to a Starfish style flywheel then the alternator rotor and the ignition magnets must be fitted otherwise these parts are left undi...

Page 119: ...body Figure 145 Flywheel Assembly 7 5 4 Starter Motor Assemble motor and starter housing and include the earth wire refer to JSL 005 1 service bulletin for details if the earth wire connection was not...

Page 120: ...scussed in Section 5 13 4 for each engine there are 2 different engine mount plates available one to suit the 99 tooth ring gear and another to suit the 101 tooth ring gear It is not mandatory for the...

Page 121: ...erous lubrication now will greatly reduce wear of these parts The distributor posts shafts and mount plates can be fitted to the distributor case now Loctite 515 sealant is used on all mating surfaces...

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Page 123: ...Overhaul_Manual JEM0001 7_Overhaul_Manual_DRAFT_ 29_10_14 docx 7 7 Subassembly G Fuel Pump And Carburettor 7 7 1 Carburettor Pre fit the carburettor to the rubber mount ready to be fitted to the engin...

Page 124: ...egun If too much time is taken the engine must be disassembled and re cleaned ready for another attempt at joining Pre Joining Checklist 1 Ensure all tools parts sealants and compounds are available f...

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Page 126: ...igure 153 Tightening The Front Crankcase Studs Apply a light coating of Loctite 515 sealant to one crankcase joining face Ensure that all oil galleries and feeds are free an excess of sealant can bloc...

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Page 128: ...or maintenance Note that the front studs of the engine use a nut washer combination different to the other studs Tighten all through bolts and studs to 20lb ft without locking compound Table 6 Hardwa...

Page 129: ...l result ALL BOLT TORQUE SETTINGS IN THIS MANUAL ARE DRY UNLESS STATED OTHERWISE Correct tightening procedures must be used See Section 3 8 3 Fitting cylinders through bolts is a critical operation mu...

Page 130: ...ent to point at 0 Care must be taken from now on not to bend the wire Double check this position by repeating the above procedure twisting to the left then to the right Rotate the cam until the two ti...

Page 131: ...31 of 201 L files Manuals_For_Products Engine_Manuals Overhaul_Manual JEM0001 7_Overhaul_Manual_DRAFT_ 29_10_14 docx Figure 161 Setting Cam Timing Figure 162 Checking Cam Timing 1 Timing marks on cran...

Page 132: ...apply the sealant to the sump than to the crankcase Fit the sump using cap screws and locating pins as shown in Figure 164 Note that on early engines the length of the screw which is in line with the...

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Page 135: ...nt Plate Screw Locations Apply Loctite 515 sealant to the rear of the crankcase and sump as shown in Figure 166 The cam drive gears should also be lubricated with oil now before the gear cover is fitt...

Page 136: ...nd crankshaft timing marks lining up as shown in Figure 169 Both distributor rotors must point to the timing mark engraved on the distributor mount plate use a ruler to check that they are nearly para...

Page 137: ...nuals Overhaul_Manual JEM0001 7_Overhaul_Manual_DRAFT_ 29_10_14 docx Figure 171 Checking Rotors Tightening Distributor Case Figure 172 Gearbox Installation Tighten the screws holding the gearbox to th...

Page 138: ...preserve the cam timing Once the timing marks are aligned and the temporary locking screw is removed the flywheel can be fitted to the engine Align the timing marks and then tap the dowels through the...

Page 139: ...he 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 139 of 201 L files Manuals_For_Products Engine_Manuals Overhaul_Ma...

Page 140: ...he simplest method is to use a large 0 010 feeler gauge lie this gauge against one of the magnet poles of the flywheel the magnetism will keep it in place Then rotate the engine until this pole lies b...

Page 141: ...Overhaul_Manual JEM0001 7_Overhaul_Manual_DRAFT_ 29_10_14 docx 7 8 9 Distributor Caps Figure 177 Distributor Cap Installation Fit the distributor cap to the mount plate using the clamps cap screws Not...

Page 142: ...e heads are fitted For later specification engines which use the pushrod tubes to feed oil to the rocker gear this step is omitted Note that if an engine has been converted from the external oil feed...

Page 143: ...EM0001 7_Overhaul_Manual_DRAFT_ 29_10_14 docx 17 For engines using an external oil feed tube for the rocker gear the rubber T pipes can be centred between each head and the clamps tightened now 18 For...

Page 144: ...201 L files Manuals_For_Products Engine_Manuals Overhaul_Manual JEM0001 7_Overhaul_Manual_DRAFT_ 29_10_14 docx Figure 181 Applying Thread Lubricant Tightening Lower Head Screw Figure 182 Fitting Rock...

Page 145: ...For a solid lifter engine to adjust the valve clearances use the following procedure 1 Start with the top valve in the top head Rotate the engine on the work stand to the point where the valve is ful...

Page 146: ...own using Loctite 515 sealant between the halves Once assembled by hand the plenum chamber can be fitted to the engine Insert new O rings into the plenum chamber as shown In this application the O rin...

Page 147: ...urettor mount is sealed to the rear face of the plenum chamber using Loctite 515 and attached using cap screws as shown in Figure 189 Apply Loctite 243 to these screws The carburettor coupling and car...

Page 148: ...port of the head for these engines there is no seal and no shake proof washers needed Loosely fit the exhaust pipes to the engine Each pipe will have 3 for gasket type or 2 metal seat type cap screws...

Page 149: ...they are equivalent to the D9EA in all respects Note that Resistor type plugs are not recommended as they reduce the spark strength and can contribute to difficult starting and that Iridium plugs are...

Page 150: ...ion of the housing Use 4 off 5 16 cap screws with Loctite 243 on the threads Note that earlier engines used 1 4 screws Either type assembly is acceptable 7 8 16 Propeller Flange Figure 195 Preparing T...

Page 151: ...hat there is no paint Loctite or other contaminants on the internal face of the propeller flange where the mounting screws and washers seat Because the retaining compound sets quickly it is recommende...

Page 152: ...not rotate while tightening these screws Figure 195 left shows a screwdriver being used to hold the ring gear on the flywheel locking the crank Alternatively a finger bar Figure 28 may be used The sec...

Page 153: ...am or pump gears This can be done by placing a piece of 600 grit wet and dry emery paper on a flat surface and rubbing the key against it The fit needs to be snug however do not remove too much materi...

Page 154: ...JEM0001 7_Overhaul_Manual_DRAFT_ 29_10_14 docx Fit the components of the valve as shown in Figure 200 Ensure the circlip is fitted with the flat face outwards and the curved face inwards and that it s...

Page 155: ...to the Jabiru Instruction Maintenance Manual appropriate to the engine Table 7 Oil Recommendations for Run In Oil Weight 80 100 120 Outside Air Temperature 17 C to 25 C 1 to 77 F 15 C to 35 C 59 to 9...

Page 156: ...ted to the aircraft and run While the very first runs may take place on the ground in an airframe any further testing must be carried out in the air to ensure sufficient airflow for engine cooling The...

Page 157: ...ery susceptible to corrosion and so must be inhibited immediately that post run checks have been completed Details are included in Section 9 9 11 Thoroughly clean engine Apply caps to all engine openi...

Page 158: ...t See Jabiru Engine Installation Manual 3 Valves not seating adjust 4 Tuning incorrect 5 Propeller sizing wrong engine overloaded High oil usage 1 Worn valve guides 2 Worn or stuck piston rings 3 Worn...

Page 159: ...d 28 10 2014 Issued By AS Page 159 of 201 L files Manuals_For_Products Engine_Manuals Overhaul_Manual JEM0001 7_Overhaul_Manual_DRAFT_ 29_10_14 docx Symptom Suggestion 3 Cam lifter face wear Pushrod w...

Page 160: ...case front studs 3 8 7 16 40 47 30 35 Propeller flange cap screws 3 8 40 30 Cylinder head cap screws 5 16 34 24 Engine mount plate bolts 1 4 14 10 Engine mount plate bolts 5 16 16 12 Flywheel crank ca...

Page 161: ...m bearing bores 20 000 20 020 N A Per New Build Crankcase Cam thrust face 14 95 15 10 N A Per New Build Crankcase Lifter stems solid lifter 8 965 8 990 N A Per New Build Crankcase Lifter bores solid l...

Page 162: ...New Build Per New Build 2200 New Sump Dipstick length from top of cap to markings Full Mark 314 316 Low Mark 329 331 Per New Build Per New Build 3300 Sump Dipstick length from top of cap to markings F...

Page 163: ...o crankcase 0 15 N A Per New Build Hydraulic Lifter to Case 0 19 N A Per New Build Piston to cylinder 0 08 0 13 0 08 0 15 Per New Build Piston compression ring end gap 0 40 1 20 N A Per New Build Pist...

Page 164: ...Coils Strong continuous spark required with 8mm gap when tested using coil tester Figure 27 Coil to flywheel gap 0 27mm to 0 30mm Ignition harness resistance 6 7 K per 300mm length Ignition magnet St...

Page 165: ...7 Dated 28 10 2014 Issued By AS Page 165 of 201 L files Manuals_For_Products Engine_Manuals Overhaul_Manual JEM0001 7_Overhaul_Manual_DRAFT_ 29_10_14 docx Figure 203 Magnet Tests Magneto and alternat...

Page 166: ...overhaul as detailed Disassembly for top end overhaul may substitute Sections 9 10 2 to 9 10 7 in Table 14 Table 14 Engine Disassembly No Details Initials Checked By Date Z1 Disassembly Reverse proces...

Page 167: ...opeller Mount Flange includes flange run out 0 0 XYZ 1 1 13 A5 Inspect and measure Conrods includes bearing crush bearing clearance 0 0 XYZ 1 1 13 A6 Temporarily Mount Propeller Mount Flange to Cranks...

Page 168: ...ert Welch Plugs 5 9 7 1 A3 Measure Crankshaft dimensions Includes crank run out 5 9 A4 Inspect and measure Propeller Mount Flange includes flange run out 5 9 A5 Inspect and measure Conrods includes be...

Page 169: ...uds Use Loctite 620 on threads 7 2 B4 Fit crankcase dowls 7 2 B5 Blue and fit bearing shells 7 2 B6 Assemble and torque 7 2 B7 Measure main bearings 7 2 B8 Measure Cam Follower Bores 7 2 B9 Disassembl...

Page 170: ...springs washers and circlips 7 3 C3 Check valve seats fit spring retainers install valves 7 3 C4 Complete rocker shaft and rocker assemblies 7 3 C5 Fit cylinder base O rings 7 3 C6 Measure and fit fro...

Page 171: ...ify that the above subassembly has been assembled in accordance with the applicable Jabiru Pty Ltd Instructions and Maintenance procedures Signed Date for Jabiru Aircraft Pty Ltd 9 9 6 Subassembly E B...

Page 172: ...e shaft post internal diameters and the distributor shaft diameters 5 14 F3 Using loctite 515 fit the shaft posts to the gear housing 5 14 F4 Fit the distributor shaft seals and rear crankshaft seal 7...

Page 173: ...Check Size Para Initials Checked By Date G1 Main Jet 5 15 G2 Needle Jet 5 15 G3 Idle Jet 5 15 G4 Needle 5 15 G5 Float seat ___ mm dia 5 15 G6 Gravity Feed Valve 47 969 5 15 G7 Air Bleed 1 6mm 5 15 G8...

Page 174: ...8 H9 Stage H2 Stage Inspection of Assembly H10 Tension the cylinder base studs bolts 7 8 H11 Fit pushrods and valve gear Set gap per Table 12 solid lifter engines 7 8 H12 Apply Loctite 515 to sump se...

Page 175: ...Power 2600 2 Mid Power 2000 2 75 Power 2800 2 Mid Power 2200 2 85 Power 3000 2 Cooling Run 2000 4 75 Power 2800 2 Mid Power 2000 2 85 Power 3000 3 60 Power 2400 4 85 Power 3000 3 50 Power 2400 3 Takeo...

Page 176: ...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 176 of 201 L files Man...

Page 177: ...or oil leaks and or any modifications made oil pressure leaks etc J5 Check voltage output of alternator Volts J6 Leak Down Test Results 1 2 3 4 5 6 80 80 80 80 80 J7 Check all paper work J8 Drain fuel...

Page 178: ...haft Journals 1 2 3 4 5 6 7 8 Camshaft Tunnel 1 2 3 4 5 6 7 8 Clearances 1 2 3 4 5 6 7 8 Head 1 P No Batch Item Comments Head 2 P No Batch Item Comments Head 3 P No Batch Item Comments Head 4 P No Bat...

Page 179: ...heet Conrods Table 27 Top End Build Sheet A No Details Para Initials Checked By Date A1 Clean Conrods 5 9 A2 Inspect and measure Conrods includes bearing crush bearing clearance 5 9 7 1 A3 Fit the Con...

Page 180: ...end gaps fit rings to pistons 7 3 C8 Fit cylinders to heads Torque per Table 9 7 3 C9 Install piston assembly to cylinder just clear of the oil ring 7 3 C10 Record measurements clearances in build re...

Page 181: ...t internal diameters and the distributor shaft diameters 5 14 F3 Fit new crankshaft timing gear 7 6 F4 Using loctite 515 fit the shaft posts to the gear housing 5 14 F5 Fit the distributor shaft seals...

Page 182: ...heet G No Check Size Para Initials Checked By Date G1 Main Jet 5 15 G2 Needle Jet 5 15 G3 Idle Jet 5 15 G4 Needle 5 15 G5 Float seat ___ mm dia 5 15 G6 Gravity Feed Valve 47 969 5 15 G7 Air Bleed 1 6m...

Page 183: ...valve gear Set gap per Table 12 solid lifter engines 7 8 H7 Apply Loctite 515 to sump sealing faces fit to cases 7 8 H8 Apply Loctite 515 to induction manifold sealing faces Assemble and fit to sump...

Page 184: ...h Item Comments Head 5 P No Batch Item Comments Head 6 P No Batch Item Comments In Valve Guides 1 2 3 4 5 6 Ex Valve Guides 1 2 3 4 5 6 In Valves 1 2 3 4 5 6 Ex Valves 1 2 3 4 5 6 In Clearances 1 2 3...

Page 185: ...to be filed Copy of ARC Jabiru Engine Job Traveller Copy of all job sheets Copy of specialist inspection reports MPI etc Report to owner Copy of log book entry Job book completed Parts Shipped To Jabi...

Page 186: ...e O Rings Pick Up Stainer Collets Oil Pressure Switch Valve Oil Pressure Sender Springs Oil Cooler Fitting Adjustors Valve Lifters Solid Pushrods Tacho Pick up Pushrod Tubes Oil Feed To Heads Rocker C...

Page 187: ...strike No Details Initials Checked By Date 1 Disassemble engine per Section 4 2 Original Prop Flange Engraving Measure Original Prop Flange Run Out mm Limits per Table 10 Serviceable Unserviceable 3 W...

Page 188: ...op End Overhaul Full Overhaul Engine Run In Table 24 Ground Run Record attached Table 25 Post ground run check sheet attached Parts Used Table 35 Summary of parts used attached Bulk Strip Checklist Ta...

Page 189: ...cycle Parts which are unlikely to survive in service for another full cycle must be replaced Table 38 Wear Factors Part Typical Wear for 1 Cycle 1000 hours Crankshaft end thrust 0 02 Crankshaft Main B...

Page 190: ...pgraded or replaced to use 5 16 or 3 8 flywheel screws 6mm dowels Oil Pumps New port plate must be fitted or existing part modified to match current porting specs Details in body of this manual Oil Pr...

Page 191: ...0 engine uses P No 4533064 Conrods Alloy rods must be replaced with steel items Oil Feed To Rockers Solid lifter engine must use external oil feed pipe Hydraulic lifter engines external oil feed pipe...

Page 192: ...gine stoppage The main causes of crankcase fretting in the Jabiru Engines are a Pre ignition or detonation due to lean running incorrect fuel low octane fuel contaminated fuels or combinations b Incor...

Page 193: ...ced they need to be shortened slightly 0 5mm and radiused de burred on the modified end After surfacing the cases must be bolted together and line bored along the crankshaft and camshaft tunnels After...

Page 194: ...crank which has not exceeded its maximum Time In Service and which uses 5 16 flywheel mounting cap screws may be re worked as detailed in Jabiru Procedure AVDALSR038 Details of this procedure are repr...

Page 195: ...ained supported as noted below The photographs used in this procedure were taken on a bench to give an idea of the procedure involved In practice a good quality drill press must be used The engine cra...

Page 196: ...try for the ream The first time the jig is used the ream will be quite tight in the holes Minimum ream depth into the crankshaft is 6 5mm but due to the use of hand tools reaming to 7 8mm depth is rec...

Page 197: ...DRAFT_ 29_10_14 docx Figure 212 Drilling Reaming Flywheel ILLUSTRATION ONLY 12 4 2 6 Assembly Once the dowel holes have been drilled and before the engine is assembled dowels and a new vacuum pump dri...

Page 198: ...ile 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 198 of 201 L files Manuals_For_Products Engine_...

Page 199: ...t of configuration changes 13 2 Update History Table Table 40 Update History Component 2200 S No 3300 S No Details Cylinders 01 106 Head gasket type 107 127 Spigot type 105 5mm long 128 831 01 153 Spi...

Page 200: ...wheel screws 3499 Current 2446 Current Dowels added tween prop flange crank Camshaft 01 377 Cast cam 21mm between profiles 378 603 Cast cam 23mm between profiles 604 2849 01 1683 Machined billet steel...

Page 201: ...es suit 99 tooth ring gear 2087 Current 857 Current Plates suit 101 tooth ring gear Distributor Rotors 01 139 Red rotors 140 Current Black rotors GB73 Distributor Plates 01 208 Std type posts 209 Curr...

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