Jabiru Aircraft
Pty Ltd
Instruction & Maintenance Manual
Jabiru 2200 Aircraft Engine
Hydraulic Valve Lifter Models
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REVISION
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Dated : June 2010
Issued By: DPS
Page: 37 of 116
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7
SERVICE & REPAIR
7.1
Service Interval Tolerance
A tolerance of plus or minus 3 hours is allowable on all of the service intervals given
within this manual.
7.2
Engine Overhaul and TBO
These are carried out only by the manufacturer, Jabiru Aircraft Pty Ltd or by a
specifically approved Jabiru Engine Service Centre (contact Jabiru for details).
The engine must be sent in a complete state, with logbook, to Jabiru (or the Approved
Service Centre) after reaching the TBO limit.
Changes to the TBO due to operational experience will be advised by Jabiru through
Service Bulletins.
Engines have full overhauls at 2000 hours with a Top End being done at around 1000
hours. This is also subject to certain conditions. Overhauls are influenced by condition.
7.2.1
Full Overhaul
During an overhaul or Top End, particular attention must be paid to Section 12 -
Torque Specifications, Prescribed sealants, Tolerances and Maximum Allowable
Clearances.
MPI testing is carried out on the crankshaft, camshaft, prop drive and conrods. Any
necessary upgrades to represent as close as possible a current engine must be
undertaken.
All parts are cleaned, measured, inspected and recorded in the prescribed build sheets
in the manual. Engine assembled according to maintenance section and build sheet
directions.
Parts that are
replaced during a full overhaul include:- Pistons, gudgeons and circlips,
rings, main bearings, conrod bearings, thrust bearings, conrod bolts, all orings gaskets
and seals, fuel pump, valves, induction hoses, rubber oil feed tees, spark plugs, rotors,
head bolts, intake/exhaust studs, fuel hose, oil filter, oil hoses, flywheel bolts, prop
flange bolts, woodruff key (oil pump), crankcase through-bolts and crankcase studs.
Cylinder, heads and dizzy shafts are usually replaced at a full overhaul.
The RUN IN procedure also to be used as outlined in this section.
If the run in is
performed on the ground large air cooling ducts and a large oil cooler must be
used.
Engine can be run in, in the aircraft in the air with caution, using the run in
program as the guide. Section 13.1
Early Operation
of an engine must be understood.
Initial performance data must be recorded.
