Engine Maintenance Manual
Jabiru Aircraft
Pty Ltd
JEM0002-5
Jabiru 2200 & 3300 Aircraft Engines
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ISSUE
1
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5
Dated : 2nd June 2015
Issued By: AS
Page: 5 of 103
L:\files\Manuals_For_Products\Engine_Manuals\Engine Maintenance Manual 22 & 33\JEM0002-5.docx
1.1
Table of Figures
Figure 1
– Oil System Schematic .................................................................................................................... 18
Figure 2
– 2200 Engine Dimensions ............................................................................................................... 22
Figure 3
– 2200 Cylinder Denomination .......................................................................................................... 22
Figure 4
– 3300 Engine Dimensions ............................................................................................................... 23
Figure 5
– 3300 Cylinder Denomination .......................................................................................................... 23
Figure 6
– Distributor Cylinder Map ................................................................................................................. 24
Figure 7
– Power / Torque Curve – Typical 2200A Engine ............................................................................. 24
Figure 8
– Power Curve - Typical 2200C, 2200B, Engine ............................................................................... 25
Figure 9
– Power / Torque Curves – Typical 3300 Engine .............................................................................. 25
Figure 10
– Sealants, Compounds & Lubricants #1 ........................................................................................ 33
Figure 11
– Sealants, Compounds & Lubricants #2 ........................................................................................ 33
Figure 12
– Sealants, Compounds & Lubricants #4 ........................................................................................ 34
Figure 13 - Torque seal installed ..................................................................................................................... 34
Figure 14
– Sealants, Compounds & Lubricants #4 ........................................................................................ 34
Figure 15
– Sealants, Compounds & Lubricants #3 ........................................................................................ 35
Figure 16
– Valve Compressor / Lifter Bleed Tools ......................................................................................... 36
Figure 17
– Dimensional Details For Lifter Tool .............................................................................................. 36
Figure 18
– Valve Leakage Vacuum Tester .................................................................................................... 36
Figure 19
– Valve Spring Compressor / Collet Remover ................................................................................ 37
Figure 20
– Leak Down Tester ........................................................................................................................ 37
Figure 21
– Hand Press & Inserts ................................................................................................................... 37
Figure 22
– Optical Tachometer ...................................................................................................................... 37
Figure 23
– Supplementary Oil Pressure Gauge ............................................................................................ 38
Figure 24
– “Finger Bar” .................................................................................................................................. 38
Figure 25
– Carburettor Needle Seat Remover and Installer .......................................................................... 38
Figure 26
– “Crowsfoot” Adaptor ..................................................................................................................... 39
Figure 27
– Universal Joint tool FU14B ........................................................................................................... 39
Figure 28
– Safety Wire / Wire Pliers .............................................................................................................. 39
Figure 29
– Torque Wrench & Crowsfoot Adaptor Setting 1 ........................................................................... 39
Figure 30
– Torque Wrench & Crowsfoot Adaptor Setting 2 ........................................................................... 40
Figure 31
– Using A Crowsfoot Adaptor .......................................................................................................... 40
Figure 32
– Air Duct Hard Point Reinforcement .............................................................................................. 57
Figure 33
– Oil Pressure Relief Valve Assembly ............................................................................................. 59
Figure 34
– Adjusting High Tension Lead Caps .............................................................................................. 61
Figure 35
– Spark Plug Terminal Nut .............................................................................................................. 61
Figure 36
– Fuel Hose Assembly – Engine Bay .............................................................................................. 64
Figure 37
– Tacho Sender #1 .......................................................................................................................... 65
Figure 38
– Tacho Sender #2 .......................................................................................................................... 66
Figure 39
– Head Bolt Locations ..................................................................................................................... 67
Figure 40
– Washer Thickness Measurement ................................................................................................. 68
Figure 41
– Valve Clearance Adjustment (Solid Lifter) ................................................................................... 69
Figure 42
– Cam Identification Markings ......................................................................................................... 72
Figure 43
– Ignition Coil Tests ......................................................................................................................... 73
Figure 44
– Different Ignition Coil Models (Honda on Left, Jabiru on Right). .................................................. 73
Figure 45
– Safety Wire Details ....................................................................................................................... 76
Figure 46
– Safety Wire Installation Using a Twister/Pliers & By Hand .......................................................... 76
Figure 47
– Dial Indicator Position for Crankshaft & Prop Flange Run Out .................................................... 80
Figure 48
– Choke Schematic ......................................................................................................................... 87
