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Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
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ISSUE
1
2
3
4
5
6 7
Dated : 28/10/2014
Issued By: AS
Page: 64 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
5.10.1.4 Cleaning
Clean both crankcase halves thoroughly with kerosene. Remove the front and rear oil gallery NPT plugs
from the left hand case and flush the galleries through. Clean out all threaded holes with the correct
size UNC tap then wash and blow out all debris from the holes. Use a scraper made from Perspex or
similar material to remove any sealing compound from the jointing surfaces.
Blow through all oil galleries and take particular care that absolutely no dirt or debris remains in any part
of the cases. Use a piece of steel wire to push through all oil galleries to check for debris
– this is
particularly important if the case has been line bored.
5.10.1.5 Crankcase Inspection and repair
Figure 70
– Crankcase Fretting
Inspect the cases for fretting around the main bearing posts. If fretting can be detected (either by
observation and/or by feeling roughness against your fingernail across the affected area
– see Figure
70) then it must be corrected by having both case halves surface skimmed and the bearing tunnels
bored to the correct dimensions before return to service.
If fretting has occurred then a complete set of new crankcase studs must be purchased and fitted during
assembly, and the crankcase dowels must be shortened at one end by 0.5mm, then re-radiused / de-
burred. A detailed explanation of crankcase fretting is included in this manual in Section 12.3.
Clamp the case halves together using the old studs & nuts with 8mm packers under the nuts, torque to
the value given in Table 9 for through bolts (use the value appropriate to the through bolt thread on the
particular engine). Torque in 3 stages, working from the centre studs out to the front & rear studs.
Measure the main bearing and camshaft bore sizes horizontally and vertically as shown in Figure 71.
Figure 71
– Measuring Crankcase Bearing Tunnel
The main bearing tunnel and the camshaft tunnel must both measure within the limits of Table 10. If the
crankcase is not within these tolerances then both case halves must be surface skimmed and the
bearing tunnels line bored to the correct dimensions before the crankcase can be returned to service.
Again note that the target of these measurements is to get the crank
– bearing clearance in the target
range (Table 12). Depending on the measurements of the crank etc values outside those listed may
still be acceptable provided that the clearances are within tolerance. Crank-main bearing clearances
and cam-case clearances must be within the limits specified in Table 12.
Where cases have been skimmed the main bearing and cam tunnels must be line bored per Table 10
for correct bearing fit up. This job can only be done by competent machine shop operators.
“Pulled up” metal
Raised ridge