Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
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Dated : 28/10/2014
Issued By: AS
Page: 113 of 201
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7.3.2 Cylinders
Each cylinder should be clearly marked with a number using permanent marker or similar
– these
numbers can be cleaned off at the end of the build using tool cleaner or similar. In the meantime the
numbers will allow the overhauler to easily identify cylinder head / piston / rod / cylinder sets. The
numbering system of the cylinders for the engines is given in Figure 3.
Figure 138
– Piston / Ring / Cylinder Assembly
If new cylinder heads are being used in the build then lapping the cylinder to the head is not required.
Otherwise the procedure noted in Section 7.3.4 must be followed.
Fit the rings to the piston. Orient 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 commercial ring compressor or a special tool per Figure 18) from
the underside (skirt side) of the cylinder. Do not push the piston far up into the cylinder as this makes
assembly difficult
– it should be left as shown, down near the cylinder skirt.
Ensure the piston is oriented correctly into the cylinder
– the side of the cylinder with the cut-out areas
in the fins faces the engine sump. Piston orientation is noted in Section 7.3.1. A good tip here is to
apply a temporary mark to the underside of the cylinder showing the front side, making later assembly
easier.
Start the gudgeon pin into the piston as shown in Figure 138 (left).
Fit the cylinder base O rings to the cylinder.
WARNING
Ensure that the thrust direction markings of the pistons are oriented correctly
Ensure that the cylinders are oriented correctly (top/bottom).
Note fin cut-outs
– these
face the sump when fitted
Optional tip: Apply temporary
mark (using a marker pen or
similar) to the underside of the
cylinder flange, in line with the
thrust marker on the piston.
