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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: 73 of 116
L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx
Oil Pump
H15 1. Put loctite 515 on back face of oil pump backing plate and fit.
2. Fit woodruff key
3. Fit inner gear to camshaft.
4. Fit outer gear to housing and fill with oil.
5. Fit O Ring
6. Fit Oil pump on. Use loctite 242 on cap screws.
Note: Before torquing up, rotate engine carefully to ensure oil pump is not binding.
If oil pump binds it can sheer the end of camshaft.
H16 Fit exhaust system. Use shake proof washers.
Note: There are no gaskets. When fitting the muffler the front exhaust pipes may
need to be loosened to seat at the correct angle and ensure a good fit in the
muffler. Re-tighten once muffler has been fitted.
H17
Front Seal & Prop Flange
CAUTION: This is a critical operation in the process of assembling the engine
and must be only carried out by a suitably qualified competent person, with
suitable calibrated tools.
1. Remove from vertical stand and mount on engine mount stand
2. Remove prop flange.
3. Clean oil from sealing surfaces of front seal.
4. Fit seal to seal housing.
5. Apply Loctite 515 on crankshaft seal housing - crank face joint. Put a little
grease on seal lip and install seal and seal housing assembly to crankcase.
Apply Loctite to cap screws and torque to 20Nm (15 ft lbs)
6. Before fitting the prop flange check that the screws protrude through the prop
flange by 11 - 12 mm for correct engagement in the crankshaft. The screws
used to fit the original flange may be re-used provided they are the correct
length and are not visibly damaged. If the screws are replaced then high-
strength cap screws must be used
– “Unbrako 1960” type or equivalent.
7. Visually inspect the front face of the crankshaft and the mating face of the
propeller flange are clean, free from burrs, rust and defects and fit together with
minimal radial clearance.
8. If the screws are to be re-used their threads must be cleaned with a wire brush
and primed with Loctite 7471 activator and allowed to air dry.
9.
The crankshaft threads must be cleaned using a 3/8” UNF tap to remove
leftover retaining compound in the threads. Care must be taken to not cross-
thread the tap as it will damage the thread in the crankshaft. Blow out the holes
using dry compressed air and prime with Loctite 7471 activator and air dry.
10. Apply a small amount
– approximately the size of a large match head – of
Loctite 620 retaining compound to the flange screws and threads in the
crankshaft.
11. Fit the flange to the crankshaft & fit the screws by hand, then tension the
screws using a calibrated torque wrench
immediately
. Tension the screws in a
standard diagonal tightening pattern. Torque all screws first to 27 Nm (20 lb.ft),