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: 193 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
Figure 205
– Stripping Crankcases
Cases must be surfaced using a special machine. Care must be taken to not exceed the maximum
allowable amount. Operators must take the minimum material required to remove the fretting damage
–
usually removing less than 0.1mm of material is sufficient.
New crankcase through-bolts and studs must be fitted. The original parts must be discarded.
The original crankcase dowels can be re-used, however after the case has been surfaced 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 line boring the tunnels must be within the newly manufactured tolerance range
– main bearing
tunnel is 51.976 to 52.000mm and 20.00 to 20.01mm for the cam tunnel.
During line boring all crankcase dowels, studs and through-bolts must be fitted and correctly tensioned.
WARNING
ALL through bolts and crankcase studs must be replaced in a fretted case.
The same process which damages the cases also damages the bolts and studs and bolt failures are
likely if they are re-used.
After surfacing and line boring the case need to be thoroughly de-burred and cleaned. Studs must be
re-installed permanently using Loctite 620. Remember to fit the O-rings to the studs as required on
permanent assembly. Refer to the main body of the manual above for detailed instructions on how to
carry out this work.
Figure 206
– De-Burring Crankcase After Surfacing & Line Boring