Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
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ISSUE
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Dated : 28/10/2014
Issued By: AS
Page: 128 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
Figure 158
– Torque Seal Applied
Apply a small amount of Loctite 518 sealant to the cylinder base and the cylinder base O ring (Figure
154). Wipe excess sealant off the base face of the cylinder before fitting. Then offer the cylinder /
piston assembly up to the engine. Double-check the thrust direction of the piston now
– if necessary
rotate the piston in the bore to correct the orientation (Arrows / moulded lugs on propeller flange side of
the connecting rod). Insert the gudgeon pin and circlip, then fit the cylinder up against the crankcase.
Verify that the piston orientation is as shown in Figure 157: valve relief on the lower (sump side) of the
piston.
The orientation of the cylinder must also be double-checked
– make sure the cut-outs in the fins are
facing the sump
– these are to give clearance to the pushrod tubes. Figure 138 shows the cut-outs.
Fit the through-bolts to the engine.
Care must be taken to centre the through-bolts so that the
same amount of thread shows on both sides of the engine
. Refer to Table 6 for approved
configurations to be used at overhaul 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
– Hardware Configuration Summary
Size
Hardware Type
Washers Used
Loctite
3/8”
-
3/8” 12-point nut: reduced flange on cylinder
bases.
-
3/8” 12-point nut: full flange on front studs.
-
AN960-6 on front crankcase studs.
-
5/8” OD Hardened on cylinder
bases.
None.
7/16”
-
7/16” 12-point nut: reduced flange on cylinder
bases
-
7/16” 12-point nut: full flange on front studs
-
AN960-7 on front crankcase studs.
-
5/8” OD Hardened on cylinder
bases.
None.
Starting from the middle cylinders:
-
Remove both nuts from one through-bolt
-
Visually inspect the cylinder base for marks where the base of the nut has pressed against the lower
radius of the barrel.
-
Tighten all through bolts and studs to the value given in Table 9. Ensure even amounts of thread
are visible on both sides of the engine for through bolts. Apply torque wrench to nuts on both ends
of through-bolts.
-
Repeat for all through bolts and studs on the engine.
Mark the completed nuts with anti-tamper paint as shown in Figure 158. Note the torque seal applied to
the nut base / washer / cylinder flange to show if there is any movement in this location.
A special tool is available from Snap-On which speeds up the installation of the cylinder barrels
– P/No.
FU14B is a small universal joint with a built-
in 7/16” nut socket. This allows tensioning of the through-
bolts without a crowsfoot
– eliminating the need to make an allowance for the crowsfoot arm on the
torque setting.
FU16B is the equivalent tool with a ½” socket for use on 7/16” 12-point nuts.