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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: 52 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
4.6 Engine Strip: Top End Overhaul
4.6.1 Accessories
Remove the spark plugs and the exhaust system, followed by the carburettor, the machined inlet
manifold and induction tubes. Remove the distributor caps and high-tension leads.
4.6.2 Cylinder Heads And Valve Gear
As for complete overhaul disassembly.
4.6.3 Cylinders
As for complete overhaul disassembly. Coat the bore of each cylinder with engine oil or a similar
corrosion preventative. After measuring they may be honed lightly.
4.6.4 Pistons
As for complete overhaul disassembly.
4.6.5 Connecting Rods
As for complete overhaul disassembly. Remove the rod and end cap and remove the bearing shells,
taking care not to drop any parts into the crankcase.
4.6.6 Flywheel & Gear Case
As for complete overhaul disassembly: Remove the flywheel. Use pliers or similar to remove the rear
seal and replace crank timing gear. Note that it may be necessary to withdraw the dowels from the
crankshaft to allow the gear to be removed. On re-assembly check ignition and cam timing as detailed
below.
4.6.7 Propeller Flange
As for complete overhaul disassembly. Remove the propeller flange and replace the mounting screws.
4.6.8 Group The Parts
This completes the top end overhaul disassembly stage. All parts can now be separated into 2 groups:
the discard group, which will contain all of the parts that are subject to mandatory replacement; and the
inspection group, which will be cleaned and inspected prior to being returned to service.