INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...

Jabiru Aircraft Pty LtdInstruction & Maintenance ManualJabiru 2200 Aircraft EngineHydraulic Valve Lifter Models7 SERVICE & REPAIR7.1 Service Interval ToleranceA tolerance of plus or minus 3 hours is allowable on all of the service intervals givenwithin this manual.7.2 Engine Overhaul and TBOThese are carried out only by the manufacturer, Jabiru Aircraft Pty Ltd or by aspecifically approved Jabiru Engine Service Centre (contact Jabiru for details).The engine must be sent in a complete state, with logbook, to Jabiru (or the ApprovedService Centre) after reaching the TBO limit.Changes to the TBO due to operational experience will be advised by Jabiru throughService Bulletins. Engines have full overhauls at 2000 hours with a Top End being done at around 1000hours. 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 AllowableClearances.MPI testing is carried out on the crankshaft, camshaft, prop drive and conrods. Anynecessary upgrades to represent as close as possible a current engine must beundertaken.All parts are cleaned, measured, inspected and recorded in the prescribed build sheetsin the manual. Engine assembled according to maintenance section and build sheetdirections.Parts that are replaced during a full overhaul include:- Pistons, gudgeons and circlips,rings, main bearings, conrod bearings, thrust bearings, conrod bolts, all orings gasketsand 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, propflange 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 isperformed on the ground large air cooling ducts and a large oil cooler must beused. Engine can be run in, in the aircraft in the air with caution, using the run inprogram as the guide. Section 13.1 Early Operation of an engine must be understood.Initial performance data must be recorded.This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.REVISION 0 1 2 3 4 5 6 7 8 9 Dated : June 2010 Issued By: DPS Page: 37 of 116L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx