Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
This 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: 12 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
2 General Information
WARNING:
Jabiru Aircraft Pty Ltd has devoted significant resources and testing to develop the Jabiru aircraft
engines. These engines are intended to be installed in accordance with the details given in the
appropriate Jabiru Engine Installation Manual. Any other uses or applications may be extremely
hazardous, leading to property damage, or injury or death of persons on or in the vicinity of the
vehicle. Jabiru Aircraft Pty Ltd does not support the use of this engine in any applications which do
not meet the requirements of the appropriate Jabiru Engine Installation Manual. Any non-compliant
installation may render the aircraft un-airworthy and will void any warranty issued by Jabiru.
The Jabiru Aircraft Engines are designed to be operated and maintained only in strict accordance
with the appropriate Instruction and Maintenance Manual. Any variation of any kind, including
alteration to any component at all, whether replacement, relocation, modification or otherwise
which is not strictly in accordance with these manuals may lead to dramatic changes in the
performance of the engine and may cause unexpected engine stoppage, engine damage or harm to
other parts of the aircraft to which it may be fitted and may lead to injury or death. Jabiru Aircraft
Pty Ltd does not support any modifications to an engine, its parts, or components. Any such
actions may render the aircraft un-airworthy and will void any warranty issued by Jabiru.
Maintenance and modification cannot be supervised by the manufacturer. Maintenance requires
extreme cleanliness, exact parts, precise workmanship 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 lives rely on precise and accurate following
of instructions in this manual.
In exchange for the engine manual provided by Jabiru Aircraft Pty. Ltd. (“Jabiru”) I hereby agree to
waive, release, and hold Jabiru harmless from any injury, loss, damage, or mishap that I, my
spouse, heirs, or next of kin may suffer as a result of my use of any Jabiru product, except to the
extent due to gross negligence or willful misconduct by Jabiru. I understand that proper skills and
training are essential to minimize the unavoidable risks of property damage, serious bodily injury
and death that arise from the use of Jabiru products.
2.1 List of Effective Pages / Issue Status
This manual is revised as a whole. All pages retain the revision status of the overall document.
Altered text is shown in red.
In cases where the data contained in Appendix A is altered and the information in the main body of the
manual is not an additional issue suffix will be applied: Issue 4-A1 indicates Issue 4 of the manual and
Revision 1 of Appendix A. Whenever the main manual is updated this suffix is re-set
Table 1
– List of Approved Revisions
Issue
Reason for Issue
1
Initial Issue
2
Added notes re crankcase dowel fit, general update
3
2: Reading this manual section added. 3.6: Tool & gauge notes expanded. 4: Inspect before cleaning,
7/16” bolt details, oil return manifolds. 5.8: engine cooling notes added. 5.9: notes re flywheel screws.
5.10: oil return manifold notes. 5.11: barrel length notes, valve vacuum unit correction, pushrod length
notes, hollow pushrod & rocker details. 5.15.2: new notes re fuel pump. 7.3: circlip notes, alternator
installation notes.
4
Alter header. Add safety wire, hardware notes. Alter build book format. Create standard tables of
torques, dimensions and clearances. Roller follower references added. Loctite 518 references added.
Top valve spring washer inspection notes added. Rocker arm length note added. Flywheel dowel fit
notes added. Reciprocating part weight limits added. 12-
point 7/16” nuts added. Valve seat details
altered.