Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
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Dated : 28/10/2014
Issued By: AS
Page: 138 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
7.8.7 Flywheel and Alternator Rotor
While the engine is still set at 25° before TDC (or as required to set the distributor timing) the flywheel
will fit onto the engine with its magnets aligned at the ignition pole positions. For the 2200 engine this
means the magnets are pointing to the left and right of the engine. For the 3300 the magnets are at the
1 o’clock, 5 o’clock and 9 o’clock positions. There is also a timing mark (a hole) drilled in the starfish (or
flywheel for non-starfish engines) which aligns to a corresponding hole in the crankshaft gear. Figure
174 refers.
Note that fitting dowels of some form or another is a mandatory update
– older engines which were not
originally equipped with dowels must be upgraded at overhaul.
Remove the temporary cap screw which was used to lock the gear to the crankshaft & preserve the
cam timing.
Once the timing marks are aligned and the temporary locking screw is removed, the flywheel can be
fitted to the engine.
Align the timing marks and then tap the dowels through the flywheel into the crank using a soft hammer.
The 6mm dowel pins (3 off) are fitted with a small amount of Loctite 620. Note that 20mm or 25mm
long dowels are required, depending on the configuration of the engine. The dowel holes in the
crankshaft are drilled to depth so the dowels are tapped in until they stop. After installation measure
how much dowel protrudes from the crank: approximately 18mm is required for non-starfish engines
and 12mm for starfish types. Excess length must be corrected as it will cause assembly problems.
Starfish engines use 5/16 x 1” or 3/8” x 1” screws, others 5/16 x 1 1/4”. All types must be fitted using
Loctite 620 and have a Belleville washer fitted. Apply a match-tip sized portion of Loctite to the threads
in the crankshaft and the same sized amount to the threads of the screws. Rub the threads of the
screws against each other to distribute the Loctite reasonably evenly over the first 3 threads. The
screws can now be fitted.
Torque them to the value specified in Table 9
– using a normal diagonal
pattern. Figure 175 refers. Work fast
– remember Loctite 620 can cure very quickly, especially when
cure accelerator spray (Loctite 7471) is used.
Figure 173
– Applying Loctite, Fitting Dowels.
