AEROVEE 2.1 TURBO Retrofit Instructions Rev. D 06/30/2017 Applies to turbo kits supplied for fitting to pre-assembled Aerovee 2.1 engines Photo for illustration only and does not represent the specific contents of your kit. A Product Line of Sonex Aircraft LLC

AeroVee 2.1 Turbo Retrofit © Sonex Aircraft, All Rights Reserved Rev D 06/30/2017

AeroVee 2.1 Turbo Retrofit Disclaimer and Limited Warranty The Experimental AeroVee Engine Kit is sold “as is”. No Warranty is expressed or implied! Sonex Aircraft LLC makes every effort to assure the supplied components of the AeroVee Engine Kit meet high quality and durability standards, and warrants to the original purchaser that these components are free of defects in material and workmanship for the period of one year from the date of purchase. This warranty does not apply to damage due directly or indirectly to improper assembly, misuse, abuse, negligence or accidents, repairs or alteration...

AeroVee 2.1 Turbo Retrofit AeroConversions Resources AeroConversions continually improves and monitors its products. It is in your best interest to stay abreast of these improvements and implement them as needed. AeroConversions Website AeroConversions, Inc. maintains a website which is continuously updated. Perhaps the most important part of the website for an AeroVee builder/operator is the Service Bulletin section. You are encouraged to periodically check for Service Bulletins which may affect the performance of your AeroVee engine. The AeroConversion website is aeroconversions.com Internet...

AeroVee 2.1 Turbo Retrofit SPECIFICATIONS Weights and Dimensions: © Sonex Aircraft, All Rights Reserved Rev D 06/30/201

AeroVee 2.1 Turbo Retrofit General Specifications (Subject to change without notice) Power and Displacement: SPECIFICATIONS Firing Order The AeroVee has a "wasted spark" ignition system which allows the spark plugs to fire on non-combustion strokes as well as combustion strokes. The arrows in this diagram illustrate the order of combustion. CYLINDER NUMBERING, FIRING ORDER, and ENGINE ORIENTATION Front Right Cylinder Identification, Engine Orientation, and Firing Order Cylinder Identification For assembly and maintenance, the AeroVee uses the cylinder identification numbers shown below. Operating...

A Successful, Reliable Engine Installation Begins Here. Protect Yourself Always wear safety glasses When using paint and chemicals, work in a well ventilated room and wear appropriate protective gear (gloves, mask, etc.). The use of compressed air to clean parts is not recommended. Compressed air can send debris flying at great speed and cause serious injury. Do not use flammable liquids near open ignition sources such as water heaters, furnaces, electric motors, etc. Read, Understand, and Follow the Instructions Read through each procedure before performing the individual steps. Make sure you...

AeroVee 2.1 Turbo Retrofit PREPARING YOUR ENGINE Important: The Aerovee engine has been sold in various kit forms since 2000. In addition to the numerous engine upgrades released by AeroConversions, builder's have made their own modifications; some small, some large. These instructions are written for an AeroVee 2.1 engine than has been assembled correctly from AeroConversions'provided parts. AeroConversions provide no installation support for engines that have been modified. Your particular engine may also need additional items not included in Turbo Upgrade package. Some of these may need to...

DUAL OIL PUMP INSTALLATION AeroVee 2.1 Turbo Retrofit Parts Required: __ Dual Oil Pump, ACV-T05-47 __ ACV-T05-69, M8x1.25 x 50mm Socket Cap Screws, (Qty. 4) __ White Lithium Grease __6. Install the secondary pump. Make sure the lug of the driven gear engages the slot in the cam. Note: Any "alignment" marks on the pump gears can be ignored. Assembly Instructions Important: Disassemble the oil pump carefully and deliberately, paying close attention to the orientation and location of each component. Be particularly watchful for the two small alignment pins between the two pump halves, as they can...

VALVE ADJUSTMENT AeroVee 2.1 Turbo Retrofit __13. Install the valve covers using the valve cover gaskets, hex head cap screws, O-rings, and washers included with the valve covers. The cap screws are tightened by feel to secure the covers and prevent leaks. Tools Required: __ Feeler Gauges __ Flat blade screw driver __ Socket Wrench __ 13 mm Socket Parts Required: __ Valve Covers, ACV-P01-15 Assembly Instructions: __ 1. Rotate the prop hub until the # 1 cylinder is at top dead center and both the intake and the exhaust valves are closed (valve springs fully extended). __ 2. Insert a .008" feeler...

AeroVee 2.1 Turbo Retrofit Assembly Instructions The turbo installation requires the oil temperature sender to be located in the block-off plate at the front of the engine. If your engine already has the temperature sender in this location you can skip this section. __ 1. Remove the Oil Temperature block-of plate. __ 2. Drill and tap a hole in the center of the Oil Temperature Plate to accept the oil temperature sender. If you are using the optional temperature sender offered by Sonex Aircraft you will drill a 1/2" diameter hole and tap it with a M14x1.5 tap. __ 3. Re-install the temperature...

AeroVee 2.1 Turbo Retrofit MINI SUMP INSTALLATION The turbo installation requires the use of the Mini Sump. If your engine already has the Mini Sump installed you can skip this section. Parts Required: __ ACV-P06-75, Mini Sump with Filter __ ACV-Z01-22, 6mm Elastic Stop Nut (Qty. 6) __ ACV-Z01-83, 1/4 NPT Brass Pipe Plug (Qty. 1) Service Parts to Keep on Hand: __ ACV-P01-54, Oil Change Gaskets Assembly Instructions: Note: Refer to the exploded photo and the instructions included with the Mini Sump (and reproduced on this page) while installing the mini sump. The following additional notes will...

AeroVee 2.1 Turbo Retrofit 2. Carefully position the Oil Cooler Mount Plate over the seals and bolt the plate to the engine case using the hardware identified in the photo below. The turbo installation requires the use of the top-mounted oil cooler. If your engine already has this cooler installed you can skip this section. Parts Required The following items are all included as part of Sonex Aircraft part number ACV-P01-106: __ Oil Cooler Mount Plate __ Rubber gaskets from ACV-P02-15 Gasket Kit __ AN4-14A bolt, Qty. 2 __ MS20365-428 Stop Nut, Qty. 3 __ ACV-Z01-80, M8-1.25 x 20mm Button Head Screw,...