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: 48 of 116
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7.5.1.3
Crankcase Decking / Machining
NOTE:
This is an advanced procedure which must only be carried out by suitable
workshops. It is recommended that this work be done through Jabiru Aircraft or
our locally approved representative.
In some cases the crankcase may need to be machined
– “decked” – to repair damage
to the crankcase mating surfaces. A maximum of 0.15mm may be taken from each
case half over its life.
If the case is machined, line-boring may be required to re-size the crankshaft and
camshaft bores to within the approved dimensional limits.
If the case is machined, a continuous shim of 0.5mm metal shim material must be
fitted beneath the cylinder bases to prevent an increase in the compression ratio.
7.5.1.4
Sub-Assembly C - Pistons, Cylinders and Cylinder Heads
C1
1. Clean oil off heads
2. Dip heads in a cold dip solvent (i.e. Redik dkt Degreaser - Decarboniser -
Paint stripper) as per manufactures instructions to remove all carbon
deposits.
3. Note: The heads can be bead blasted, but care must be taken.
4. Wire buff valves
5. Clean all other parts
C2
Cylinder Head Inspection and Repair
1. Inspect cylinder head for flatness. If sealing surface show signs of leakage
it may need refacing. When refacing, remove only the minimum to clean
up.
2. Measure valve guide wear
3. If wear is excessive remove guides. Measure valve guide bore in the head.
The new guide must have at least 0.05mm (0.002") interference on the
outside diameter.
Note - The standard guide has no dimples in top (P.N.4518064) In
(P.N. 4519064) Ex
0.05mm (0.002") has one dimple
0.05mm (0.004") has two dimples
0.05mm (0.006") has three dimples
4. Press guides back in.
Note - Oil hole must go up
5. Special Note Guides: Guides are installed at 7.045 - 7.050mm bore
diameter. Guides from 7.08mm can cause oil usage in the engine (max.
valve stem to guide clearance is 0.12mm).
Note: Valve guides and valve seats are installed to a specific program. Valve
guide replacement is relatively straightforward. Valve seat replacement requires
special tools and techniques and it is strongly recommended that valve seats are
not replaced. Advice is available on request.
6. Mount head up and cut seats as per drawing