Jabiru Aircraft
Pty Ltd
Instruction & Maintenance Manual
Jabiru 2200 Aircraft Engine
Hydraulic Valve Lifter Models
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REVISION
0
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9
Dated : June 2010
Issued By: DPS
Page: 3 of 116
L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx
5.8.7
New Engine Storage ................................................................................................................................. 26
5.8.8
Operation in Winter ................................................................................................................................... 26
5.8.9
Carburettor Icing ....................................................................................................................................... 26
5.8.9.1
Icing Due to Water in fuel ...................................................................................................................... 26
5.8.9.2
Icing Due to High Air Humidity. ............................................................................................................. 27
6
MAINTENANCE ..................................................................................................................... 28
6.1
L
UBRICATION
S
YSTEM
.......................................................................................................................... 28
6.2
A
IR
I
NTAKE
F
ILTER
............................................................................................................................... 28
6.3
C
ARBURETOR
A
DJUSTMENT
.................................................................................................................. 28
6.4
C
OMPRESSION
C
HECK
.......................................................................................................................... 29
6.4.1
Compression Gauge: ................................................................................................................................ 29
6.4.2
Pressure Differential Test: ......................................................................................................................... 29
6.5
I
GNITION
S
YSTEM
................................................................................................................................. 30
6.5.1
High-Tension Lead Connections ............................................................................................................... 30
6.5.2
Spark Plugs ............................................................................................................................................... 31
6.6
E
XHAUST
S
YSTEM
................................................................................................................................ 31
6.7
B
OLTS AND
N
UTS
................................................................................................................................. 31
6.8
T
APPET
A
DJUSTMENT
/
H
YDRAULIC
V
ALVE
L
IFTERS
............................................................................... 31
6.9
H
EAD
B
OLTS
........................................................................................................................................ 33
6.10
T
ACHOMETER AND
S
ENDER
............................................................................................................... 33
6.11
A
DDITIONAL
C
HECKS
–
P
OST
S
ERVICE
.............................................................................................. 33
6.11.1
Propeller .................................................................................................................................................... 34
6.11.2
Engine ....................................................................................................................................................... 34
6.11.3
Fuel System .............................................................................................................................................. 34
6.12
E
NGINE
I
NSPECTION
C
HART
.............................................................................................................. 35
7
SERVICE & REPAIR .............................................................................................................. 37
7.1
S
ERVICE
I
NTERVAL
T
OLERANCE
............................................................................................................ 37
7.2
E
NGINE
O
VERHAUL AND
TBO ............................................................................................................... 37
7.2.1
Full Overhaul ............................................................................................................................................. 37
7.2.2
Top End Overhaul ..................................................................................................................................... 38
7.3
E
NGINE
R
EMOVAL
P
ROCEDURE
............................................................................................................ 38
7.4
ENGINE
DISASSEMBLY.................................................................................................................... 39
7.5
2200
ENGINE
OVERHAUL ................................................................................................................ 42
7.5.1
Jabiru 2200 Component Inspection and Assembly Procedure ................................................................. 43
7.5.1.1
Sub-Assembly A - Crankshaft, Prop Mount and Con-Rods................................................................... 43
7.5.1.2
Sub-Assembly B
– Crankcase and Camshaft ....................................................................................... 45
7.5.1.3
Crankcase Decking / Machining ............................................................................................................ 48
7.5.1.4
Sub-Assembly C - Pistons, Cylinders and Cylinder Heads ................................................................... 48
7.5.1.5
Sub-Assembly D - Sump and Oil Pump ................................................................................................ 54
7.5.1.6
Sub-Assembly E
– Flywheel, Ignition Coils, Alternator & Alternator Operation ..................................... 55
7.5.1.7
Permanent Magnet Alternator (PMA) Operation ................................................................................... 58
7.5.1.8
Regulator ............................................................................................................................................... 59
7.5.1.9
Sub-Assembly F - Gear Case ............................................................................................................... 60
7.5.1.10
Sub-Assembly G - Fuel Pump, Carburetor and Carburetor Operation .............................................. 60
7.5.1.11
Sub-Assembly H - Final Assembly .................................................................................................... 65
7.5.1.12
Engine Run In ................................................................................................................................... 74
7.6
E
NGINE
I
NSTALLATION
.......................................................................................................................... 75
7.7
P
ROP
S
TRIKE
I
NSPECTION
.................................................................................................................... 76
7.8
S
TARTER
M
OTOR
O
VERHAUL
................................................................................................................ 77
7.8.1
Starter motor disassembly and inspection ................................................................................................ 77
7.8.2
Reassembly .............................................................................................................................................. 78
7.9
B
UILD
S
HEETS AND
R
UN
I
N
P
ROGRAMME
.............................................................................................. 78
8
NOTES BEFORE STARTING ENGINE .................................................................................. 79
9
SERVICE DOCUMENTATION ............................................................................................... 81
9.1
S
UBASSEMBLY
A
–
C
OMPONENT
A
SSEMBLY
P
ROCEDURE
...................................................................... 81
9.2
S
UBASSEMBLY
A
–
C
OMPONENT
R
EGISTER
&
P
ARTS
I
NSPECTION
R
ECORD
............................................ 82
9.3
S
UBASSEMBLY
B
–
C
OMPONENT
A
SSEMBLY
P
ROCEDURE
...................................................................... 83
9.4
S
UBASSEMBLY
B
–
C
OMPONENT
R
EGISTER
&
P
ARTS
I
NSPECTION
R
ECORD
............................................ 84
9.5
S
UBASSEMBLY
C
–
C
OMPONENT
A
SSEMBLY
P
ROCEDURE
...................................................................... 85
9.6
S
UBASSEMBLY
C
–
C
OMPONENT
R
EGISTER AND
P
ARTS
I
NSPECTION
R
ECORD
........................................ 86
