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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: 124 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
7.8 Subassembly H
– Final assembly
Now that each Subassembly is ready the overhauled engine can be final assembled.
Note that the entire crankcase assembly process including the fitting of pistons and cylinders MUST be
completed in one continuous operation otherwise the Loctite 515 Sealant around the crankcase join can
dry before uniform pressure is applied to the crankcase join by the cylinder nuts, so make sure that you
have all parts ready for completion up to this stage (i.e. pistons and cylinders) before starting to fit the
crankcase halves to the crankshaft.
7.8.1 Crankcase Joining
During the joining process various sealants will be used which will cure quickly
– therefore it is essential
that the overhauler be thoroughly organised before starting this task and that they work efficiently and
quickly once they have begun. If too much time is taken the engine must be disassembled and re-
cleaned, ready for another attempt at joining.
Pre-Joining Checklist:
1. Ensure all tools, parts, sealants and compounds are available for the build and ready to be fitted.
Parts in particular must have been cleaned, inspected and had any necessary remedial work carried
out before beginning the final assembly.
2. Oil all bearings lightly.
3. Oil or grease (lightly) camshaft tunnel
4. Thrust bearings are installed correctly and oiled.
5. All required measurements have been taken
– cam end float, crank end float etc.
6. For solid lifter engines, ensure the valve lifters are fitted and lubricated.
7. Count all engine through bolts and place them close to hand.
8. Count all engine through bolt nuts, confirm they have been chamfered (per Section 7.3.2) and place
close to hand.
9. Confirm that all gudgeon pins are started into their pistons & are ready to go.
10. Count all piston circlips and place close to hand.
11. Check that suitable spanners are available
– torque wrench, special spanners for tightening the lock
nuts on the through-
bolts, “crowsfoot” adaptors etc.
12. Confirm the orientation of the cylinders and the pistons within the cylinders.
13. Confirm that the sump oil pickup and strainer, through bolt dowels and studs have been fitted to the
crankcase.
14. Confirm that the cam is assembled to its gears, ready to fit.
15. Apply a little grease to the cam and to the lifters.