Sonex Aircraft Aerovee 2.1 Assembly And Installation Manual Download Page 1

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AEROVEE 2.1

ASSEMBLY and INSTALLATION

ACV-R02 Rev Z. 01/14/2015 Applies to AeroVee s/n 0440 and up. Includes top-mounted oil cooler.

A Product Line of Sonex Aircraft LLC

Photo for illustration only and does not represent the specific contents of your kit.

$35.00

Summary of Contents for Aerovee 2.1

Page 1: ...ALLATION ACV R02 Rev Z 01 14 2015 Applies to AeroVee s n 0440 and up Includes top mounted oil cooler A Product Line of Sonex Aircraft LLC Photo for illustration only and does not represent the specifi...

Page 2: ...d Oils Break in Period 60 Approved Oils Post Break in 60 Priming the Engine and Setting the Oil Level 60 Oil Changes During Break in Period 60 Start up and Break In 61 Maintenance 62 Minimum Maintenan...

Page 3: ...ir medical or legal expense in any way attributable to the use of any AeroConversions Inc product or to the delay or inconvenience caused by the necessity of replacing or repairing any such item Engin...

Page 4: ...which we feel must be corrected for the continued use of your engine Upon compliance of the Required Service Bulletin an entry must be made in your engine log book Required Service Bulletins are post...

Page 5: ...Hub Bolt Pattern 9 16 Dia Drive Lug Hole Typical 6 places 5 O D Drive Lugs Centered on 4 Dia Bolt Circle Weights and Dimensions Weight Less Oil and Exhaust with Standard Pistons and Barrels 160 lbs Le...

Page 6: ...ing to ASTM D 910 Electrical System Battery Required minimum 12v 20 amp Starter Geared Alternator 20 amp Propeller Drive Propeller Drive Direct 1 1 Prop Bolt Pattern 6 holes 9 16 dia on 4 dia center P...

Page 7: ...k Smartly Parts should never be forced into position If excess effort seems to be needed to assemble parts STOP and investigate the problem NEVER apply concentrated heat such as with a torch to assemb...

Page 8: ...ly clean the crankshaft with Mineral Spirits Re install the hex plugs with Locktite 242 __ 4 Test fit the prop hub The prop hub should NOT slide onto the crankshaft __ 5 Place the cleaned crankshaft i...

Page 9: ...stalled in the crankshaft and tap the prop hub into place using a mallet and block of wood The prop hub must be tight against the oil slinger __10 After the prop hub cools to room temperature remove t...

Page 10: ...include either Cam Bolts with integral lock washers Cam bolts and wavy spring washers Cam bolts and tab lock washers Note While not common slight interference between the cam and the connecting rods...

Page 11: ...oto below with the stamped numbers facing up Be sure to re assemble the connecting rods as matched parts 4 __5 ACV P06 33 Rods Only with starred bolt and nut Apply Moly Lube to each rod bolt and insta...

Page 12: ...ngs only ACV P01 57 __ Cam Bearings ACV P01 58 __ Gasket Set ACV P02 15 Preparation __ 1 Separate the case halves and thoroughly clean them with mineral spirits Remove all traces of metal chips and du...

Page 13: ...a retaining plug and screw the plug into the relief port __7 Insert the non grooved plunger lightly lubri cated with motor oil solid end first into the oil pressure relief port in the bottom of the c...

Page 14: ...ide with very fine emery cloth After test fitting liber ally lubricate each lifter with white lithium grease and install them in their guides The cam bearings are installed in the right case half as s...

Page 15: ...ain Bearing Set ACV P01 57 into the middle journal of each case half carefully aligning the recess in the bear ing with the dowel pin in the journal A light tap may be required to properly seat each b...

Page 16: ...fully set the crank shaft assembly into right case half Make sure dowel pin hole in each bearing is aligned with the dowel pins in the case half and the crankshaft assembly is fully seated in the case...

Page 17: ...ve __12 Select any combination of three to five shims which most closely equals the Shim Thickness determined in step 10 Shim Chart Complete this chart to determine the total thick ness of shims requi...

Page 18: ...y sparingly __17 Note While assem bling the case halves the lifters in the left half will want to slide out This can be mini mized by giving them each a heavy coat of white lithium grease Assemble the...

Page 19: ...ut in each of the three through holes which serve to join to two case halves Minimal thread en gagement is normal Nuts will be flush with ends of screws 25 __27 Torque the two cam nuts from step 24 to...

Page 20: ...shims so they match the reliefs in the cylinder for the case studs __ 9 Apply Permatex Aviation Form A Gasket No 3 Sealant to the shims and base of cylinder Assembly Instructions IMPORTANT Pistons an...

Page 21: ...ult in high tempera tures detonation and damage to the engine Measured Deck Height 005 0 08 to 0 10 0 05 to 0 07 0 01 to 0 04 0 00 to 0 01 0 02 to 0 03 0 04 to 0 05 0 06 to 0 07 0 08 to 0 10 Head Gask...

Page 22: ...d stud kit onto the head studs Tighten in sequence shown in drawings A and B below Torque sequence must be used to prevent the head from warping First Tighten 7 10 Ft Lbs Final Torque 18 Ft Lbs __5 Pe...

Page 23: ...The rocker blocks are installed so their gaps are toward the cupped end of the rocker arms GAP IN ROCKER BLOCKS Two different swivel pads exist The one on the right is a large swiveling pad the one o...

Page 24: ...arms and mounting blocks must be distributed as needed to get each swivel pad cor rectly aligned with each valve stem It is acceptable to have no spacer between components if that will achieve the pr...

Page 25: ...rovided 6mm copper washers and acorn nuts You may also use the elastic stop nuts from the Shakeproof nut kit instead of the acorn nuts __ 5 Install the oil drain plug and included metal copper gaskets...

Page 26: ...stallation of an oil cooler is described in the Appendix of this manual All oil cooler installations must use threaded AN fittings and high quality 06 hose Operation Without an Oil Cooler To operate y...

Page 27: ...t number and thickness of end shims was determined in Crank Case Assembly page 17 __1 Clean the oil seal bore of excessive sealant particularly around near the case parting lines __2 Install the end s...

Page 28: ...5 16 Washer not supplied in kit __ 5 8 Socket Parts Required __ Prop Drive Bushings ACV H01 11 Assembly Instructions __1 Insert a prop drive bushing into the prop hub __2 Insert the bolt through a dr...

Page 29: ...er gauge moves smoothly between the valve and the swivel foot __ 4 Lock the adjustment screw in place by torquing the locking nut to 14 foot pounds __ 5 Recheck the valve setting with the 006 feeler g...

Page 30: ...t Set Note If your engine requires the use of this plate it can be drilled and tapped for an optional M14 x 1 5 oil temperature probe Fuel pump block off plate A and oil fill plug B A B __ 5 Slide the...

Page 31: ...e dowel pin area of the flywheel and place a small bead 1 8 diameter in the groove near the dowel pin area of the flywheel Note The engine assembly DVD may show an O ring being used instead The O ring...

Page 33: ...Cap Screws and ACV Z01 30 hex nuts Install bolt at the bottom of the slot The note THIS SIDE OUT stamped in each Magnatron must face towards the front of the engine This Side Out __ 3 Match the acces...

Page 34: ...l s witness hole B near the 12 o clock position For clarity the flywheel is shown removed from the engine A B The C identifies the witness hole on the trigger shaft Alin this hole with the witness hol...

Page 35: ...Anti Seize Compound Parts Required __ Autolite 4163 Spark Plugs Qty 8 ACV P01 21 SPARK PLUG INSTALLATION Plug Installation __ 1 Gap four 4 TOP spark plugs to 0 018 __ 2 Gap four 4 BOTTOM spark plugs...

Page 36: ...Permatex side against the cylinder head __3 Apply Permatex Avia tion Form A Gasket 3 to each intake elbow and secure the elbows to the cylinder heads with ACV Z01 26 Washers Qty 4 and ACV Z01 49 Cap...

Page 37: ...osition and the bottom pick up near the 7 O clock position The magnet ring may force the stator assembly into an unwanted position Rotate the flywheel until the stator plate can be properly positioned...

Page 38: ...ted ground wires will be necessary between the regulator and a suitable ground point __ 1 Mount the voltage regulator to the firewall in a location which allows easy connection of the wires from the a...

Page 39: ...ay be used as needed and washers may be used behind the rear bushings as spacers to shim the thrust line as needed Sonex Aircraft Airframes Bolting the engine to the engine mount is shown in detail in...

Page 40: ...ock Absorber Bushing 4 Sets required AN4 36A Bolt 4 Required on 01 02 AN960 416 Washer 8 Required on 01 02 AN363 428 Nut 4 Required on 01 02 Typical Detail of Engine Mount Cushions Bolts Typical 4 Loc...

Page 41: ...magnatron is a very simple ignition system however understanding the circuit wiring is often confusing Unlike most other electrical devices when the switch is Off the Magnatron circuit is closed and...

Page 42: ...inal must only be used for the ignition switch wiring A large spade terminal will slip over a stud A provid ing a ground point for each Magnatron A __ 2 Attach a 20 gauge minimum wire be tween a DPST...

Page 43: ...same ground point __ 2 Red wire 12V Attach to the rear terminal screw of left coil terminal C in photo __ 3 Orange wire Trigger Attach to the front terminal ter minal D in photo of left coil Coil Wiri...

Page 44: ...res ACV A01 24 SPARK PLUG WIRES __3 Remove the black outer jacket and the white insulation core to expose a 3 8 length of the inner conductor The crimped end of each plug wire is re used do not cut th...

Page 45: ...nt The secondary ignition will spark when the ignition is on and the trigger magnet passes by the sensor This can cause ignition Avoid serious injury or death by turning off the fuel ignition switch a...

Page 46: ...the engine and performing a mag check will indicate the accuracy of the timing of the second ary ignition A mag check at 1600 2000 RPM should reveal little or no change in RPM If a change of 50 RPM o...

Page 47: ...terminal __ 2 Attach an 8 or 10 gauge wire from the center terminal of the voltage regulator to the positive battery terminal __ 3 If you will be using a tachometer which senses pulses from the alter...

Page 48: ...recommended use of Locktite can degrade this ground path You may wish to install an 8 to 10 gauge supplemental ground wire under one of the starter attachment bolts and attach the other end to an appr...

Page 49: ...tube should curve up slightly after exiting the breather plate This encourages oil to flow back into the case rath er than get discharged Additionally a 1 16 diameter hole drilled at the top of the cu...

Page 50: ...tion begins with a list of items that will be needed to complete the installation In many cases these are common parts which may be sourced locally from automotive supply stores or hardware stores Add...

Page 51: ...hroud This photo shows the oil cooler hoses and baffle seal already installed on the cooler however these steps come later 2 Drill four 3 16 diameter mounting holes in the shroud to match those in the...

Page 52: ...xt column This photo shows the oil cooler lines attached to the oil pump OIL COOLER BOTTOM MOUNT Oil cooler bypass plate A with optional oil pressure sender installed B If no oil pressure sender is in...

Page 53: ...op mounted oil cooler positions the oil cooler on top of the case near the accessory plate The Oil Cooler Mount Plate is attached with the following hardware A ACV Z01 80 M8 1 25 x 20mm button head sc...

Page 54: ...ler is attached with the following hardware D AN4 27A Bolt with AN960 416 washer E AN4 23A Bolt with two AN960 416 washers one top one bottom and MS20365 428 stop nut D D E OIL COOLER TOP MOUNT __ 6 I...

Page 55: ...This will result in oil starvation and engine damage To properly eliminate the oil cooler from the system you must complete one of the options in step 4 below 4 Run a loop of 06 braided hose from the...

Page 56: ...lide an extension pipe onto each manifold It may be necessary to shorten the length of the exhaust manifold if the extensions interfere with the firewall Do not shorten the expanded portion of the ext...

Page 57: ...fuel system IMPORTANT Because of the wide range of possible in stallation variations the hardware and fittings mentioned in this manual and included in the 3rd party hardware kits may or may not matc...

Page 59: ...Sonex Aircraft LLC has developed a fence baffle system specifically for use on Sonex Airframes AeroVee installations These system may also be adapted to other airframe installa tions Each fence baffl...

Page 60: ...ow mark for the oil level __ 3 Add an additional 75 quart of oil to the crankcase and allow it to settle into the sump __ 4 With the aircraft in its normal ground attitude on its tailwheel for tailwhe...

Page 61: ...rate the engine at 3000 rpm and above for at least an hour This will seat the rings Monitor the engine s temperatures and reduce throttle as needed to keep the engine temperatures in the green Step cl...

Page 62: ...rque the heads to 18 foot pounds Do NOT loosen the nuts prior to torquing them See page 22 for proper torque sequence The rocker shaft assemblies must be removed to torque the heads ___ Adjust the val...

Page 63: ...ly after warm up period and or smokey exhaust emission Possible Cause Remedy 1 Rich idle setting Adjust AeroCarb See AeroCarb manual 2 Intake manifold leak Tighten all connections replace hose Engine...

Page 64: ...rly install oil pump cover Engine Keeps Running with Ignition Off Possible Cause Remedy 1 Faulty ignition switch Check switch cables 2 Overheated engine Conduct cooling run at 900 RPM 3 Bad fuel or oc...

Page 65: ...ICAL SCHEMATICS This page is a quick reference of electrical schematics associ ated with the AeroVee installation Detailed instructions for each sub system are provided elsewhere in this manual 18 GA...

Page 66: ...ermined by fitting one cowl half and centering the cut out on the oil cooler baffle fitted to your engine see bottom photo This photo identifies the size and approximate location of the oil cooler inl...

Page 67: ...ts cut open to the proper size and have air deflector lips added as shown in the accompanying photos In addition 025 aluminum sheet is riveted to the exhaust tunnel to protect the fiberglass from the...

Page 68: ...for Cowl with Pre molded Fiberglass Exhaust Tunnels Universal Cowl with No Existing Exhaust Tunnel Fitting the 2 into 1 exhaust to a cowling with no existing outlets is very simple A 4 x 12 5 cut out...

Page 69: ...non ported oil pump Rev N 09 1 11 Screws to attach stator is ACV Z01 76 was ACV Z01 12 Added note to use ARP Ultra Torque if provided Increased torque of rod bolts to 30 Rev M 04 14 11 Added ACV P02 2...

Page 70: ...copy of the original packing list attached after third page If there is no packing list attached the manual you have may have printed from the website provided as a replacement or the packing list may...

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