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Jabiru Aircraft
Pty Ltd
Instruction & Maintenance Manual
Jabiru 2200 Aircraft Engine
Hydraulic Valve Lifter Models
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REVISION
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Dated : June 2010
Issued By: DPS
Page: 43 of 116
L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx
7.5.1
Jabiru 2200 Component Inspection and Assembly Procedure
7.5.1.1
Sub-Assembly A - Crankshaft, Prop Mount and Con-Rods
A1
1. Remove welsh plugs from crankshaft
2. Clean conrods and crankshaft
Note - Make sure all old loctite is removed from threads
3. Strip paint off prop flange and crankshaft.
4. Magnetic particle inspect crankshaft , prop flange, cam and conrods
A2
Measure crankshaft and record in Build Sheet
A3
Inspect Oil Holes for Cleanliness and insert new front welsh plugs (2 off) and rear
welsh plug.
A4
Inspect prop flange. Paint prop flange and end of crankshaft to prevent rusting
A5
1) Magnetic Particle Inspect conrods for cracks.
2) Fit bearings with a light smear of bearing blue on back of shells.
3) Torque Caps to 18 lbs (with new bolts)
4) Measure Big End Bearings. Record in Build Sheet.
5) Measure Piston Pin Bore. Record in Build Sheet. Check CRUSH.
6) Remove caps and check bearing back contact (Must be at least 90%)
7) Remove all blue and thoroughly clean surfaces. Refit bearing shells.
8) Clearance as close to 0.05mm is recommended.
A6
Temporarily mount prop flange to crankshaft and mount to stand vertically.
(Flange is removed later to fit front oil seal)
A7
1) Spray conrod bolts and conrod bolt threads with Loctite 7471 primer and
allow to dry.
2) Mount conrods to crankshaft. Use plenty of oil on journals. Closest to prop
flange is number 1. Use Loctite 620 on rods and bolts torque up to 24.0 NM
(18 ft/lbs)
3) Wipe off excess locktite at bases of cap screws on the end cap