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Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
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Dated : 28/10/2014
Issued By: AS
Page: 40 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
4 Disassembly Procedure
As each part is removed from the engine it should be set aside for later evaluation
– in our factory
engine workshop we use disposable plastic containers to keep all of the smaller components (cap
screws, bolts, nuts, washers, etc) separate during disassembly.
4.1 Preliminary Cleaning
Inspect engines carefully before cleaning. The patterns of dirt, oil etc can indicate damage or wear and
provide valuable information of which tasks should be added to the overhaul or inspection process.
The engine must be cleaned externally before it is removed from the aircraft. A stiff-bristled brush,
solvent (de-greaser), water and some compressed air will usually be adequate for this task.
4.2 Remove The Engine From The Aircraft
Remove the cowlings and the spinner. Remove the propeller. Disconnect both cables from the battery
and remove the battery from the aircraft. Disconnect the earth cable and free the starter motor power
cable from the wiring loom.
Remove the muffler and then remove the oil drain plug and drain the oil from the engine. Remove the
ram air ducts. Disconnect all engine control cabling and disconnect the air intake duct from the
carburettor. Remove the oil filter, the oil filter adapter and oil cooler.
Disconnect and remove all engine wiring: the signal wiring from the oil pressure and temperature
senders and fuel pressure sender (if fitted), the low-tension ignition wiring and the alternator wiring.
Remove the oil pump from the front of the engine and undo the cap screws that hold the front oil seal
around the crankshaft.
Remove the engine from the airframe and place it onto the engine stand, holding it in place with 3 bolts
through the propeller flange.
4.3 Engine Stand
We recommend that an engine stand be used to hold the engine vertically during all workshop
procedures.
In our engine workshop we use a spare propeller flange bolted to the workbench. The propeller flange
on the engine is then bolted to that flange so that the engine is held in an upright position as shown in
Figure 44.
You may find it convenient to simply bolt the propeller flange of the engine directly to the workbench
using 3 suitable bolts.
Note that for a top end overhaul the engine can remain in the aircraft, although the use of an engine
stand may be more convenient and is usually faster.
Figure 44
– Engine Stand