AEROVEE 2.1 $35.00 ASSEMBLY and INSTALLATION ACV-R02 Rev AE. 04/27/2021 Applies to AeroVee s/n 0440 and up. Includes top-mounted oil cooler. Photo for illustration only and does not represent the specific contents of your kit. A Product Line of Sonex Aircraft LLC AeroVee 2.1 Rev AE. 04/27/2021 TABLE of CONTENTS Contents Trigger Shaft Installation ........................................... 34 Your feedback is welcome and encouraged as we continue to Spark Plug Installation ............................................... 35 improve this manual. Please send comments to tech@aerocon- versions.com. Comments will be reviewed and considered for Intake Manifold Installation ....................................... 36 inclusion in future revisions of this manual. Alternator Installation ................................................ 37 Your success is important to us. If you have any questions Firewall Preparation ................................................... 38 while assembling your engine do not hesitate to seek technical Voltage Regulator Installation ............................................................38 support by emailing [email protected]. Secondary Ignition Coil Installation ..................................................38 Table of Contents ......................................................... 2 Mounting the Engine .................................................. 39 Mount Bushings .................................................................................39 IMPORTANT! ................................................................. 4 Lifting the Engine ..............................................................................39 AeroVee Engine Kit Documentation ...................................................4 Mount Pin Detail Drawing and Typical Installation ..........................40 AeroVee Serial Number .......................................................................4 Magnatron Ignition Wiring ......................................... 41 Assembly / Service Resources ................................... 4 Other AeroConversion Resources ........................................................4 Electronic Ignition Wiring .......................................... 43 AeroConversions' Service Bulletins ....................................................4 Additional Resources ...........................................................................4 Spark Plug Wires ........................................................ 44 Electronic Ignition Timing ......................................... 45 Specifications ............................................................... 5 Weights and Dimensions ......................................................................5 Alternator / Regulator Wiring .................................... 47 Mount Dimensions ...............................................................................5 Prop Hub Bolt Pattern ..........................................................................5 Starter Installation / Wiring ........................................ 48 General Specifications .........................................................................6 Oil Breather Tube ........................................................ 49 Cylinder Identification, Engine Orientation, Firing Order ...................6 Operating Limitations ..........................................................................6 Oil Cooler Installation Options .................................. 50 Oil Cooler - Bottom Mount.................................................... 51 Before You Begin... .................................................... 7 Oil Cooler - Top Mount ......................................................... 52 Crankshaft Assembly ................................................... 8 Oil Cooler Removal / Bypass ................................................ 55 Cam Assembly ............................................................ 10 Exhaust Installation.................................................... 56 Installing EGT Probes ............................................................ 60 Connecting Rod Assembly ........................................ 11 Crank Case Preparation ............................................. 12 Fuel Supply ................................................................. 57 Crank Case Assembly ................................................ 16 Engine Cooling Baffles .............................................. 59 Piston and Cylinder Assembly .................................. 20 Engine Oil .................................................................... 60 Compression Ratio Chart ....................................................... 21 Approved Oils - Break-in Period ........................................... 60 Approved Oils - Post Break-in ............................................... 60 Cylinder Head Installation ......................................... 22 Priming the Engine and Setting the Oil Level ....................... 60 Rocker Shaft Installation ........................................... 23 Oil Changes During Break-in Period ..................................... 60 Oil Screen Installation ................................................ 25 Start-up and Break In ................................................. 61 Oil Pump Installation .................................................. 26 Maintenance ................................................................ 62 Oil Cooler Installation ............................................................ 26 Minimum Maintenance Interval ............................................ 62 Operation Without an Oil Cooler ........................................... 26 When to Rebuild Your AeroVee ............................................. 62 Torque Values ......................................................................... 62 Oil Seal Installation .................................................... 27 Troubleshooting ......................................................... 63 Prop Drive Lug Installation ........................................ 28 Electrical Schematics................................................. 65 Valve Adjustment ........................................................ 29 Block-off Plates and Plugs ........................................ 30 APPENDIX A: Sonex Cowl Openings ....................... 66 Details the installation of an AeroVee on a Sonex, Waiex, or Flywheel Installation .................................................. 31 Xenos airframe. Flywheel Magnet Orientation Check ..................................... 32 Revision Log ............................................................... 69 Accessory Plate Installation ...................................... 33 Part Numbers and Packing Lists .............................. 71 Sonex Aircraft LLC © 2018 All Rights Reserved 2 AeroVee 2.1 Rev AE. 04/27/2021 IMPORTANT! Disclaimer and Limited Warranty AeroVee Engine Kit Documentation THE EXPERIMENtal AEROVEE ENGINE KIT IS This manual is your primary document for the assembly and SOLd “AS IS”. NO WARRANTY IS EXPRESSED OR operation of your Experimental AeroVee Engine Kit. The in- IMPLIED! cluded assembly DVD is an additional aide, but when there is a discrepancy between this manual and the DVD, the informa- Sonex Aircraft LLC makes every effort to assure the supplied tion in this manual takes precedence. components of the AeroVee Engine Kit meet high quality and durability standards, and warrants to the original purchaser The manuals provided with the AeroVee kit are important that these components are free of defects in material and documents and should be kept with your aircraft's documents. workmanship for the period of one year from the date of pur- Keep Your Packing Lists chase. This warranty does not apply to damage due directly or The packing list provided with each AeroVee kit lists the indirectly to improper assembly, misuse, abuse, negligence or specific parts provided for that specific engine. Please refer- accidents, repairs or alteration outside our facilities, or lack of ence your packing list for correct part numbers when ordering maintenance. Due to the experimental nature of the AeroVee maintenance and repair parts for your particular engine. Engine Kit, the end user is solely responsible for determining suitability of application, assembly, installation and operation. In addition to the packing list secured to the outside of the engine kit boxes, a duplicate packing list has been attached to Sonex Aircraft LLC and its agents will in no event be liable the back of the physical manual supplied with that engine. for death, injuries to person or property, or incidental, contin- gent, special, or consequential damages arising from the use of Copies of (most) packing lists are archived by Sonex Aircraft our product. and you may request an electronic (PDF) copy. To get a copy, provide evidence you own the engine for which you are re- Sonex Aircraft LLC and its agents will not be responsible questing the original packing list as well as the engine's serial for any incidental or consequential damage including direct number. or indirect labor, repair, medical, or legal expense in any way attributable to the use of any AeroConversions, Inc. product Engine Serial Number or to the delay or inconvenience caused by the necessity of The engine's serial number is stamped on the rear of the acces- replacing or repairing any such item. sory plate, above the starter. It is also recorded on your