20
AeroVee 2.1
Rev Z. 01/14/2015
Sonex Aircraft
LLC
© 2014 All Rights Reserved
Tools Required:
__ Needle-Nose Pliers
__ SAE 30 Motor Oil
__ 1” Utility Brush
__ Permatex Aviation Form-A-Gasket No. 3 Sealant
__ Rubber Mallet
__ Ring Compressor
__ Vise-Grips
__ Micrometer Caliper
Parts Required:
__ Crank Case Sub-Assembly
__ Big Bore Piston and Cylinder Kit, ACV-P02-14
__ Barrel Shims, .090, ACV-P01-39
__ Barrel Shims, .040, ACV-P01-40
__ Barrel Shims, .060 (2 sets), ACV-P01-41
__ Super Tin, ACV-P06-71
PISTON & CYLINDER ASSEMBLY
1
3
5
tween the top of the piston and the top of the cylinder).
If the piston is below the top of the cylinder you have a
positive (+) deck height. If the piston is higher than the
top of the cylinder, you have a negative (-) deck height.
Use your measured deck height to determine which
cylinder shims are required from the chart on page 21.
__6. Remove the cylinder and piston assembly from the case.
__7. Apply a light coat of motor oil to the outside of each
piston and the inner wall of each cylinder.
__8. Install the cylinder shims (as required, see chart on next
page) onto each cylinder. Align the 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 and
pins have been matched to
within 5 grams. Keep each
piston and pin together as a
set.
__ 1. Remove a piston ring
from each piston and
slide it squarely inside
it's matched cylin-
der. Measure the gap
between the ends of
the ring - it should be
between 0.012"-0.022".
Re-install the ring on
the piston.
__2. Re-install the piston
into the cylinder using
a ring compressor.
__3. Slide one piston and
cylinder assembly into
place on the crank
case. Install the piston
pin and make sure the
cylinder is well seated.
__ 4. Bring the piston to Top
Dead Center.
__5. Measure the deck
height (distance be-
11
__10. Rotate the crank to
bring a connecting rod
to top dead center - this
eases installation of the
piston and cylinder.
__11. Note: The arrow on
each piston face points
to the flywheel end of
the engine.
Partially slide the
cylinder over the head
studs. Push the piston
out the bottom of the
cylinder just far enough
to attach the piston to
the connecting rod with
a piston pin, and secure
the pin in place with a
snap ring on each side
of the piston pin.
Note: The snap rings
were included in the
piston/cylinder box.
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