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Overhaul Manual Jabiru 2200 & 3300 Aircraft Engines

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Overhaul Manual Jabiru 2200 & 3300 Aircraft Engines OVERHAUL MANUAL FOR JABIRU 2200 & 3300 AIRCRAFT ENGINES DOCUMENT No. JEM0001-4 Date: 17th April 2013 This Manual has been prepared as a guide to correctly overhaul Jabiru 2200 & 3300 aero engines. It is the owner's responsibility to regularly check the Jabiru web site at www.jabiru.net.au for applicable Service Bulletins and have them implemented as soon as possible. Manuals are also updated periodically with the latest revisions available from the web site. Failure to maintain the engine or aircraft with current service information may render the aircraft un-airworthy and void Jabiru’s Limited, Express Warranty. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. Should you have any questions or doubts about the contents of this manual, please contact Jabiru Aircraft Pty Ltd. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 1 2 3 4 Dated : 17th April 2013 Issued By: DPS Page: 1 of 197 C:\Aero_Craft_Australia\Jabiru\Jabiru_Documents_Edited\Overhaul_Manual\Overhaul_Manual_Iss4\JEM0001-4_Overhaul_Manual.docx Engine Overhaul Manual Jabiru Aircraft Pty Ltd JEM0001-4 Jabiru 2200 & 3300 Aircraft Engines 1.1 TABLE OF FIGURES .................................................................................................................................................................. 7 1.2 TABLE OF TABLES.................................................................................................................................................................. 11 2 GENERAL INFORMATION .................................................................................................................................................. 12 2.1 LIST OF EFFECTIVE PAGES / ISSUE STATUS ................................................................................................................................. 12 2.2 INTRODUCTION .................................................................................................................................................................... 13 2.3 APPLICABILITY ...................................................................................................................................................................... 13 2.4 READING THIS MANUAL ........................................................................................................................................................ 13 2.5 DEGREE OF DIFFICULTY ......................................................................................................................................................... 13 2.6 MANUAL LAYOUT ................................................................................................................................................................. 14 2.7 ENGINE LIFE......................................................................................................................................................................... 14 2.8 COMPLETE OVERHAUL, TOP END OVERHAUL, WEAR TOLERANCES .................................................................................................... 14 2.9 MANDATORY UPDATES .......................................................................................................................................................... 14 2.10 MANDATORY REPLACEMENT OF PARTS ...................................................................................................................................... 14 2.11 RECORDING ......................................................................................................................................................................... 14 2.12 GENERAL DESCRIPTION .......................................................................................................................................................... 15 2.12.1 Engine identification ................................................................................................................................................................... 15 2.12.2 Build Configurations ................................................................................................................................................................... 15 2.12.3 Part Identification ....................................................................................................................................................................... 16 2.12.4 Cylinder Numbering Convention ................................................................................................................................................. 16 2.12.5 Cylinder heads ............................................................................................................................................................................ 16 2.12.6 Valves, valve guides and seats .................................................................................................................................................... 16 2.12.7 Cylinders ..................................................................................................................................................................................... 16 2.12.8 Pistons ........................................................................................................................................................................................ 16 2.12.9 Connecting rods .......................................................................................................................................................................... 16 2.12.10 Crankshaft .................................................................................................................................................................................. 17 2.12.11 Crankcase ................................................................................................................................................................................... 17 2.12.12 Camshaft .................................................................................................................................................................................... 17 2.12.13 Valve operating mechanism ....................................................................................................................................................... 17 2.12.14 Solid lifters .................................................................................................................................................................................. 17 2.12.15 Hydraulic lifters ........................................................................................................................................................................... 17 2.12.16 Roller Followers .......................................................................................................................................................................... 17 2.12.17 Lubricating system ...................................................................................................................................................................... 17 2.12.18 Cooling system ............................................................................................................................................................................ 17 2.12.19 Induction system ......................................................................................................................................................................... 17 2.12.20 Ignition system ........................................................................................................................................................................... 18 2.12.21 Electrical charging system .......................................................................................................................................................... 18 2.12.22 Starter motor .............................................................................................................................................................................. 18 2.12.23 Sump ........................................................................................................................................................................................... 18 2.13 ASSESSING AN ENGINE .......................................................................................................................................................... 18 3 GENERAL OVERHAUL PROCEDURES ................................................................................................................................. 19 3.1 MANUAL LAYOUT ................................................................................................................................................................. 19 3.2 DIRECTIONAL REFERENCES ..................................................................................................................................................... 19 3.3 TOP END OVERHAUL VS FULL OVERHAUL .................................................................................................................................. 19 3.4 SPECIAL CLASSES OF OVERHAUL .............................................................................................................................................. 19
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