AeroInjector $10.

00
TM

Owners Manual
Rev D 03/13

A Product of Sonex Aircraft, LLC

AeroInjectorTM Owners Manual TABLE of CONTENTS

Disclaimer and Limited Warranty Table of Contents.................................................. 2

Sonex Aircraft, LLC, makes every effort to assure that each Disclaimer and Limited Warranty............................................. 2
AeroInjector meets high quality and durability standards, and Table of Contents...................................................................... 2
warrants to the original purchaser that this product is free of Specifications........................................................ 3
defects in material and workmanship for the period of one Overview and Features............................................................. 3
year from the date of purchase. This warranty does not apply AeroInjector Size Recommendations....................................... 3
to damage due directly or indirectly to misuse, abuse, negli- Dimensions and Weights........................................................... 3
gence or accidents, repairs or alteration out side our facilities
or lack of maintenance. Due to the experimental nature of Walk Around........................................................... 4
the AeroInjector, the end user is solely responsible for deter- Pictorial Guide to the AeroInjector........................................... 4
mining AeroInjector's suitability, installation and use. Sonex Fuel System Overview.......................................... 5
Aircraft, LLC, will in no event be liable for death, injuries to Fuel Delivery Systems.............................................................. 5
person or property, or incidental, contingent, special, or conse-
quential damages arising from use of our product. Installation.............................................................. 6
Mounting the AeroInjector........................................................ 6
Important: Throttle Installations Acceptable for use with
By opening the package you agree to accept all responsibility the AeroInjector........................................................................ 7
for the use of this product and accept all such printed terms. Reversing Throttle Quadrants................................................... 7
Push / Pull and Vernier Throttle Cable...................................... 7
Cable Ends Suitable for Use with the AeroInjector.................. 8
Cable Routing........................................................................... 8
Solid Wire Throttle Cables........................................................ 9
Flexible Throttle Cable - Ball End with Adapter.................... 11
Install the Mixture Cable........................................................ 13
Install the Fuel Line................................................................ 15
Not TSO'd for Certified Aircraft Intake Air, Air Filter, and Carburetor Heat Installation.......... 15
Installing the Optional AeroConversions Air Filter
or Intake Flange Adapter......................................................... 16
This guide was written to help you achieve a depend-
able installation and outstanding performance from your Tuning Procedures.............................................. 17
AeroConversions AeroInjector. Properly installed and tuned, For Best Results... .............................................................. 17
the AeroInjector has gained a reputation for increasing power How the AeroInjector Works.................................................. 17
and reducing fuel consumption on a broad range of aircraft Mixture and Idle Adjustments................................................. 18
and auto-conversion engines. Changing the Mixture Needle................................................. 19
Adjusting the Idle Speed Stop Screw...................................... 20
Adjusting the "Full Throttle" Position of the Throttle Slide..... 20
When is it in Tune?................................................................. 21
Compensating for Seasonal Changes...................................... 21
Tuning the AeroInjector - Step by Step.................................. 22
Operating Checklists.......................................... 22
Troubleshooting.................................................. 24
A Product Line of Sonex Aircraft, LLC. Maintenance......................................................... 25
Body Assembly / Disassembly............................................... 25
511 Aviation Road Oshkosh, WI 54902
Phone (920) 231-8297 fax (920) 426-8333 Gaskets and Sealants............................................................... 25
[email protected] www.aeroconversions.com Delrin Anti-Friction gasket..................................................... 25
Distributed Worldwide by: Sonex Aircraft, LLC. O-Rings................................................................................... 25
Throttle Slide Lubrication....................................................... 25
© 2013 Sonex Aircraft LLC. All Rights Reserved. The information Throttle Slide Cleaning........................................................... 25
disclosed herein is the property of the originator who reserves all pat- Fuel Passage Cleaning............................................................ 26
ent, design, proprietary, manufacturing, use and sales rights thereto,
except for the rights expressly granted to others. This document shall Parts List.............................................................. 27
not be reproduced nor shall the information contained within be Manual Revisions................................................ 28
used by or disclosed to others except as expressly authorized by the
originator.
AeroInjectorTM is the trademark of Sonex Aircraft LLC

Sonex Aircraft, LLC Rev D 3/13 © 2013 All Rights Reserved. 2

AeroInjectorTM Owners Manual SPECIFICATIONS

Overview of Features AeroInjector Size Recommendations

The AeroInjector is precision machined from solid 6061 The following chart is a general guideline to injector sizing for
aluminum billets and premium Delrin. There are only two a variety of popular engines. Please call for recommendations
moving parts: a fuel/air "throttle slide" that moves with the for your particular engine.
cockpit throttle control and meters combustion air and fuel,
and a tapered needle that moves with the cockpit mixture Engine: Size: Model:
control to control in-flight mixture adjustments and serve as an
VW (1900 - 2180cc)....... 32mm................ ACV-C07
idle cut-off valve.
Jabiru 2200...................... 32mm................ ACV-C07
The throttle slide carries within it an infinitely adjustable
Jabiru 3300...................... 35mm................ ACV-C08
tapered fuel needle. Three (3) different needles are included
with each AeroInjector, and others are available. Spigot or Cont. 65, 85, 90............... 32mm................ ACV-C07
flange mounts easily adapt the AeroInjector to popular aircraft Cont. 0200....................... 35mm................ ACV-C08
and auto engine conversions. A clamp for the mixture cable is Corvair O-164, O-190..... 35mm................ ACV-C08
built in to the body of the AeroInjector, and the throttle cable
is attached directly to the throttle slide. The AeroInjector's
intake design accepts air filters or carb heat ducts.
The AeroInjector works in up-draft, side-draft, and down-draft
configurations. Gravity feed is recommended where possible.
If a fuel pump is required, a fuel pressure regulator must also
be used. By design, the AeroInjector is extremely resistant to
icing.
Combined, these features make the AeroInjector one of the Not TSO'd for Certified Aircraft
most versatile and adaptable injectors ever developed.

Weights:
AeroInjector*................ 1 lb. 4 oz.
Air Filter (optional)....... 11.6 oz.
Without Air Filter
3-1/2" (88.9mm)

*Average weight - actual weight varies

With Optional Air Filter

slightly by mount size and style.

5-5/8" (142.9mm)

7" (177.8mm)
6-1/4" (158.8mm)
3-1/8" (79.4mm)

Specifications subject to change without notice.

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AeroInjectorTM Owners Manual WALK AROUND

Mixture Cable Clamp

Mixture Arm

Model Number

Throttle Cable
Retainer

Fuel Inlet

Intake Bell (or Flange)

Mixture Screw
Dust Cap and Access Hole Assembly Screw (6 Total)

Mixture Cable Clamp Intake Spigot (shown)

Throttle Cable Retainer or Intake Flange

Assembly Screw (6 Total)

Mixture Arm

Close-out
Screw

Intake Bell or Flange

Idle Speed
Stop Screw Fuel Inlet

Sonex Aircraft, LLC Rev D 3/13 © 2013 All Rights Reserved. 4

AeroInjectorTM Owners Manual FUEL SYSTEM OVERVIEW

Fuel Delivery Systems Return Line System

Most fuel systems can be made to work with the AeroInjec- In a fuel return system a fuel line "T" is installed between the
tor's floatless design. If you have a system not represented on regulator and the AeroInjector with a return line to the tank.
this page, please call for advice. This will supply fuel to the AeroInjector without excessive
pressure. Excess fuel returns to the tank.
IMPORTANT: The fuel system must be able to deliver 1.5
times the engine's required fuel flow at full throttle.
Gravity Feed System
A gravity feed system is by far the safest and most reliable.
The AeroInjector requires very little head pressure to oper- AeroInjectorTM
ate effectively. For this system to be effective, the fuel tank
outlet must be higher than all the other components of the fuel
delivery system in a tail low (climb) configuration or fuel flow
may be disrupted. Fuel Pump

Fuel Tank
Fuel Valve
Gascolator

Fuel Tank
The return line system.

AeroInjectorTM Fuel Valve

Gascolator Header Tank System
Pumping fuel from the main tank(s) to a small header tank
mounted above the injector will provide gravity feed to the
The gravity feed system. AeroInjector. A return line from the header to the main tank(s)
is required so excess fuel can return to the main tank without
Fuel Pump and Regulator System a build-up of pressure. This type of system assures some
If your aircraft requires a fuel pump (i.e.: for wing tanks or reserve fuel in the event the fuel pump fails, and eliminates the
pusher engines) a fuel pressure regulator must also be installed need for a fuel regulator.
to limit fuel pressure to about 1 to 2 psi. A Holley Standard
Pressure Regulator (1-4 psi range, or equal), has been found to
be effective for these installations.

AeroInjectorTM
Regulator
(1-2 psi)
Fuel Tank

Fuel Pump AeroInjectorTM Fuel Valve

Gascolator

Fuel Tank

Fuel Valve The header tank system.

Gascolator

The fuel pump / regulator system.

Header Tank

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AeroInjectorTM Owners Manual INSTALLATION

Section Contents
Mounting the AeroInjector........................................................ 6
Throttle Installations Acceptable for use with
the AeroInjector........................................................................ 7
Reversing Throttle Quadrants................................................... 7
Push / Pull and Vernier Throttle Cable...................................... 7
Cable Ends Suitable for Use with the AeroInjector.................. 8
Cable Routing........................................................................... 9
Solid Wire Throttle Cables........................................................ 8
Flexible Throttle Cable - Ball End with Adapter.................... 11
Install the Mixture Cable........................................................ 13
Install the Fuel Line................................................................ 15
Intake Air, Air Filter, and Carburetor Heat Installation.......... 15
Installing the Optional AeroConversions Air Filter
or Intake Flange Adapter......................................................... 16

Mounting the AeroInjector

The ideal mounting position for an AeroInjector is in the up-
draft configuration, as low as possible, to assure constant grav-
ity fuel flow even in extreme nose high attitudes. However, the
AeroInjector functions well in any position.
WARNING: Fire hazard. Do not install the AeroInjector
where dripping fuel can contact hot exhaust or electrical
equipment. If necessary, install a drip pan to catch/deflect This spigot-mounted AeroInjector is also safety wired to the
dripping fuel. Always close the mixture shut-off valve and intake manifold for further security.
fuel valve when the engine is off.
IMPORTANT: If the cockpit mixture control is not pulled
Flange Mounted AeroInjector
to the Idle/Cut-off position when the engine is off, fuel will
continue to flow through the AeroInjector. This may fill the A flange mounted AeroInjector will bolt directly to a four-hole
AeroInjector/intake causing engine flooding or spill-over, Continental or Lycoming intake manifold. Use a standard
which is a fire hazard. gasket or a small amount of gasket-maker when mating the
AeroInjector to the manifold.
Note: If you are using an optional AeroConversions Air Filter
or Intake Flange Adapter it is easier to install these before To mount a standard four-hole flange to a two-hole manifold,
mounting the AeroInjector to the intake manifold. See page fabricate an adapter plate from 1/4" to 3/8" thick 6061-T6
15. aluminum flat stock. Use standard gaskets or a small amount
of gasket-maker on both sides of the adapter when mating the
Spigot Mounted AeroInjector AeroInjector to the manifold.
The outside diameter of the AeroInjector's spigot must match
the inside diameter of the engine's hose mount.
If you are replacing a carburetor, the existing hose mount can
mostly likely be reused after inspection. Replace the hose if it
shows signs of deterioration.
If you do not have a hose, we recommend fuel tank filler hose
(or equivalent fuel proof hose) of the proper diameter. Do not
use radiator hose.
Attach the hose and AeroInjector to the engine with two stain-
less steel hose clamps. Updraft and sidedraft installations must
be further secured with safety wire to the intake manifold, as
shown in the photo, next column.
This sample adapter plate has 4 holes matched to the AeroIn-
jector's flange, and 2 matched to the 2-hole intake manifold.
The center hole matches the inside diameter of the intake bell.

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AeroInjectorTM Owners Manual INSTALLATION

Throttle Installations Acceptable for Use Push / Pull and Vernier Throttle Cables
with the AeroInjector DANGER. DO NOT connect a push/pull or vernier throt-
tle cable directly to the AeroInjector as this will result in a
The AeroInjector's design requires the use of a reversing non-standard control installation where pulling the cockpit
throttle quadrant or reversing bellcrank for proper operation of throttle control will result in the application of full throttle.
the throttle slide. Either of these convert the standard "push to The installation of a push/pull or vernier throttle cable requires
accelerate" cockpit throttle motion into the AeroInjector's re- a reversing bellcrank between the cockpit throttle control and
quired "pull to accelerate" cable motion. As such, "push/pull" the AeroInjector to convert the pushing action of the cock-
throttle cables which do not reverse the throttle cable's motion pit throttle control into the pulling action the AeroInjector
must not be attached directly with the AeroInjector. requires to open the throttle.
Reversing Throttle Quadrants
The common push/pull throttle
A reversing throttle quadrant is the preferred installation for
cables, as shown here, can not
the AeroInjector as it provides the proper cockpit control and
be connected directly to the
cable motion while eliminating the need for an intermediate
AeroInjector. To use this type
reversing bellcrank. The AeroConversion Throttle Quadrants
of throttle cable a reversing
are the ideal match for the AeroInjector.
bellcrank must be installed be-
tween the throttle cable and the
AeroInjector.
Pulling a reversing
throttle quadrant back
to "Idle"...

...pushes the throttle closed.

For clarity, only a portion of the AeroInjector is shown.

Pushing a reversing
throttle quadrant
forward to "Open"...

...pulls the throttle open.

A reversing throttle quadrant is the ideal cockpit throttle con-

trol for the AeroInjector. AeroConversion offers two units: A
quadrant for use with the pilot's left hand (part number ACV-
Q01-01, shown here) and a quadrant for use between pilot and
passenger in a side-by-side aircraft (part no. ACV-Q01-03)

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AeroInjectorTM Owners Manual INSTALLATION

Cables Ends Suitable for Use with the AeroInjector

Three types of cable ends, all shown below, can be attached to
the AeroInjector.

Cable end types which

can be used with the
AeroInjector, from top to
bottom:
Solid wire (bent 90O ).
Flexible cable with inte-
gral barrel end.
Flexible cable with inte-
gral ball end (requires ball
adapter, shown).

Specific installation instructions for each type of cable

begin on page 8.

Ball End Cables - Recommended Installation

Ball end cables must have an integral ball end which measures
.1875" to .192" diameter. The cable must be galvanized or
stainless steel and minimum 1/16" diameter. Ball end cables
must be used with a 1/4" diameter x 1/4" long barrel adapter.

An 84" long ball end cable (part no. ACV-Q01-39) and ball
adapter (part no. ACV-Q01-36) are included as standard equip-
ment with all AeroConversions Throttle Quadrants.

Solid Wire
Solid (music) wire cables must be .062" minimum diameter
and be constructed of stainless steel or high carbon wire which
meets spring temper specification MIL-W-6101. After bending
the end of the cable 90 degrees, inspect the cable for cracks or
nicks. Reject any wire that has cracks or nicks.

Barrel End Cables

Barrel end cables must have an integral barrel end which
measures 1/4" in diameter and 1/4" long. The cable must be
galvanized or stainless steel and minimum 1/16" diameter.

Note: For detailed installation of a barrel end cable use the

Ball End Cable instructions but delete the use of the barrel
adapter.

Cable Routing
The throttle cable must be routed so it does not have any
sharp bends. A grommet must be used where the throttle cable
passes through the firewall.
CAUTION: Do not allow the throttle cable to come in con-
tact with the battery terminals.
CAUTION: Do not allow the throttle cable to come in
contact with the exhaust.

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AeroInjectorTM Owners Manual INSTALLATION

Solid Wire Throttle Cables 5. With the wire engaged in the throttle slide and the throttle
The throttle cable must be installed in the AeroInjector prior to slide back in the body of the AeroInjector, install the
connecting it to the Throttle Quadrant. mixture needle assembly. Make sure the flat side of the
needle faces towards the intake manifold. See "Chang-
Important: The wire diameter must be .065" to .075"
ing the Mixture Needle" in the "Tuning Procedures" sec-
minimum.
tion of the AeroInjector manual.
1. Disassemble the AeroInjector by removing the 6 machine
6. Make sure the inside of the AeroInjector body is free of
screws which hold the body together. You will need a
debris and re-assemble the AeroInjector. Check for free
9/64" hex wrench and a 7/32" open end wrench.
movement of the throttle slide.
2. Remove the mixture needle assembly. See "Changing the
7. Attach the AeroInjector to the intake manifold.
Mixture Needle" in the "Tuning Procedures" section of
the AeroInjector manual. 8. The throttle cable must be routed so it does not have any
sharp bends. A grommet must be used where the throttle
3. Pass the solid wire throttle cable through the cable ad-
cable passes through the firewall.
juster and bend the end 3/8" of the wire 90 degrees.
CAUTION: Do not allow the throttle cable to come in
contact with the battery terminals.
CAUTION: Do not allow the throttle cable to come in
contact with the exhaust pipes.
The cable housing must be long enough to be inserted in
the cable adjuster on the AeroInjector and on the throttle
quadrant.
3/8" After determining the best cable routing, trim the housing
to length. Do not trim the wire. The housing should be
removed from the wire to avoid cutting the wire.
9. Strip 3/8" of the black casing off each end of the cable
housing, exposing the metal core.
The solid wire is inserted through the cable adjuster and then
bent 90 degrees.
4. Install the wire in the slide so the bent end engages the
hole in the throttle slide. The throttle slide needs to be
removed from the AeroInjector body to do this. 3/8" Set Screw

Left: Strip away 3/8" of the outer jacket of the throttle cable
sleeve. Right: Insert the exposed metal core into the cable
retainer and tighten the set screw to secure the cable.

10. Push the exposed metal core into the cable adjuster and
secure it with the included set screw (ACV-Q01-23). Do
The bent end of the wire is inserted in the throttle slide. The not over-tighten or you may pinch and bind the cable.
dashed line in this photo represents the portion of the wire
which is inserted in the hole in the slide.

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AeroInjectorTM Owners Manual INSTALLATION
11. Insert the throttle
cable wire between the
washers and through
the hole in the throttle
cable clamp of the
throttle quadrant but do
not tighten it.

12. Push the exposed metal core of the throttle cable into the
cable adjuster on the throttle quadrant and secure it with
the included set screw (ACV-Q01-23). Do not over-tight-
en or you may pinch and bind the cable.
13. Push the throttle lever to the "full throttle" position.
14. Make sure the throttle slide of the AeroInjector is fully
open (full throttle position).
15. Tighten the nut which secures the throttle cable wire in
the throttle cable clamp.
16. Operate the cockpit throttle control through it's full range
of movement and make sure the throttle slide is opening
completely as well as closing against the idle stop screw.
17. Trim the exposed throttle wire, leaving 1/4" to 3/8" ex-
tending beyond the washers.

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AeroInjectorTM Owners Manual INSTALLATION

Flexible Throttle Cable - Ball End with Adapter 4. Make sure the inside of the AeroInjector body is free of
debris and re-assemble the AeroInjector. Check for free
This installation requires movement of the throttle slide.
a 1x19 flexible cable with Cable (ACV-Q01-39)
a 1/16" diameter cast ball 5. Attach the AeroInjector to the intake manifold.
end and a ball adapter. 6. Route the throttle cable so it does not have any sharp
Both of these parts are bends. A grommet must be used where the throttle cable
available from Sonex Air- passes through the firewall.
craft and are identified by
CAUTION: Do not allow the throttle cable to come in
part number in the photo,
Ball Adapter (ACV-Q01-36) contact with the battery terminals.
right.
CAUTION: Do not allow the throttle cable to come in
contact with the exhaust pipes.
1. Disassemble the AeroInjector by removing the 6 machine
The cable housing must be long enough to be inserted
screws which hold the body together. You will need a
in the cable adjuster on the AeroInjector and the cable
9/64" hex wrench and a 7/32" open end wrench.
adjuster on the throttle quadrant.
2. Remove the cable from the cable housing.
After determining the best cable routing, trim the housing
3. Pass the cable through the ball adapter and cable adjuster to length. Do not trim the cable.
and then place it in the recess in the throttle slide.
7. Strip 3/8" of the black casing off each end of the cable
housing, exposing the metal core.

3/8" Set Screw

Left: Strip 3/8" of the outer jacket off the throttle cable sleeve.
Right: Insert the exposed metal core into the cable adjuster
and tighten the set screw to secure the housing.

8. Push the exposed metal core into the cable adjuster and
secure it with the included set screw (ACV-Q01-23). Do
not over-tighten or you may pinch and bind the cable.

9. Insert the flexible

cable between the
washers and through
the hole in the throttle
cable clamp but do
not tighten the lock-
These photos show how easily the ball-end cable and ball ing nut.
adapter are to install.

9, 13, 15

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AeroInjectorTM Owners Manual INSTALLATION
10. Push the cable housing into the cable adjuster on the
throttle quadrant and secure it with the included set screw.
Do not over-tighten the set screw or you may pinch
and bind the cable.
11. Push the throttle quadrant lever to the "full throttle" posi-
tion.
12. Make sure the slide of the AeroInjector is fully open (full
throttle position).
13. Tighten the locking nut which secures the throttle cable
wire in the throttle cable clamp.
14. Operate the cockpit throttle control through it's full range
of movement and make sure the throttle slide is opening
completely as well as closing against the idle stop screw.
Adjust the cable length as needed to provide the full range
of throttle movement.
15. Trim the exposed throttle cable, leaving 1/4" to 3/8" ex-
tending beyond the washers.

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AeroInjectorTM Owners Manual INSTALLATION

Install the Mixture Cable 5. Rotate the mixture arm 45O from perpendicular to the
The mixture cable must be a push-pull bowden wire style AeroInjector body, as shown in the following photo.
cable.
Cable Routing 2"
The mixture cable must be routed so it does not have any
sharp bends. A grommet must be used where the mixture cable
passes through the firewall.
CAUTION: Do not allow the mixture cable to come in
contact with the battery terminals.
CAUTION: Do not allow the mixture cable to come in
contact with the exhaust pipes.

45O
Connecting the Mixture Cable
1. If necessary, up-drill the hole for the mixture cable clamp
to fit your cable. Do not over-size the hole. Setting up the mixture cable as shown in this photo will pro-
vide full-range mixture control.

6. Slide the mixture cable housing through the mounting

hole until there is 2" of wire exposed between the mixture
arm and the end of the mixture cable housing (see photo).
Make sure the mixture arm is still in position (step 5) and
the cockpit mixture control knob is still pushed all the
way in ("Full Rich").
7. Secure the mixture cable in the mixture cable clamp with
the set screw. Do not over-tighten the set screw. The set
screw should firmly grip the mixture cable housing, but
not bind the movement of the wire.
8. Tighten the screw of the swivel nut against the wire. Do
not over-tighten the screw. The set screw should firmly
grip the mixture cable but still allow the swivel freedom
to turn as the mixture arm is operated.
A passage through the injector's body and a set screw (arrow) 9. Operate the mixture knob several times. The mixture
secure the mixture cable to the AeroInjector. should operate smoothly. If it does not, make sure the
mixture cable set screw has not been over-tightened (step
2. Insert the mixture cable housing in the mounting hole. Do 7), the swivel nut has not been over-tightened, and the
not tighten the clamping screw at this time. cable routing is free of sharp bends.
3. Pass the mixture cable through the swivel nut in the mix-
ture arm. Do not tighten the swivel nut at this time.
4. Push the cockpit mixture control knob all the way in (full
rich).

Pass the mixture cable through the swivel nut as shown.

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AeroInjectorTM Owners Manual INSTALLATION
10. Pull the mixture cable out until it stops ("Idle Cut-Off"). d. Rotate the mixture arm on the fuel shaft to the desired
The mixture control arm must be in the "closed" position position. This will be the new "Idle Cut-off" position
with some wire still exposed beyond the cable housing. If of the mixture arm.
there is no wire visible (bottom photo), the mixture arm e. Tighten the screw to lock the mixture arm in place.
may not be fully closed.
f. Reconnect the mixture cable.
g. Make sure the cockpit mixture control still provides
enough movement of the mixture arm to open the
valve from "Idle Cut-off" to "Full Rich".

When the cockpit mixture control knob is pulled all the way
out (Idle Cut-off), there must still be some wire exposed
between the cable housing and the mixture lever (see arrow).
If there isn't, contact with the cable housing may keep the
mixture arm from closing fully.

11. Push the cockpit mixture control all the way in ("Full
Rich"). The mixture arm must be at least 45O from per-
pendicular to the AeroInjector body, as shown in step 5.
Note: The position of the mixture arm on the fuel valve can be
adjusted if needed.
a. Loosen the swivel nut and remove the mixture cable.
b. Turn the mixture arm clockwise until the fuel valve is
seated in the off position.
c. Loosen the screw which locks the mixture arm on the
fuel valve.

Fuel Valve

Lock Screw
A screw locks the mixture arm in place on the fuel valve.
Loosening the screw allows the position of the mixture arm in
relation to the valve to be adjusted.

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AeroInjectorTM Owners Manual INSTALLATION

Install the Fuel Line Intake Air, Air Filter, and

Use "AN" aircraft grade fuel lines and fittings to connect the Carburetor Heat Installation
AeroInjector to your fuel system. The use of barbed fittings The intake bell of the AeroInjector is designed to accept 2-1/4"
and hose clamps in the fuel system is strongly discouraged. SCAT tubing. It may also be fitted directly with the optional
AeroConversion recommends a 3/8" diameter fuel line (-06 AeroConversions air filter assembly (see next page).
hose).
The body of the AeroInjector is tapped to accept 1/8 NPT Carburetor Heat
fittings. Apply teflon paste (do not use teflon tape) to the The design of the AeroInjector makes it resistant to icing typi-
threads before installation. cally associated with carburetors that have venturis and but-
terfly valves. While each owner must make their own decision
on installing and using carburetor heat - and some countries
require it - we do not recommend it's use.

Intake Air and Air Filtering

The AeroInjector must be allowed to draw combustion air
freely - it is not designed for use with ram air. Ram air will
cause the mixture to become lean as speed increases.
Intake air can be drawn through a remotely mounted carb heat/
air filter box, or the optional AeroConversions air filter. Instal-
lation of the optional AeroConversions air filter is described
on the next page.

An AN pipe fitting is installed in the 1/8 NPT fuel orifice.

The small plug (or screw) on the end of the AeroInjector can
be ignored, it seals a hole required for the production of the
AeroInjector.

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AeroInjectorTM Owners Manual INSTALLATION

Installing the Optional AeroConversions 6. Slide the air filter in place, apply Locktite 242 to the
Air Filter or Intake Flange Adapter threads of the AN3 bolt, and install the bolt and AN960-
The optional AeroConversions air filter or intake flange adapt- 10 washer.
er are mounted directly to the intake bell of the AeroInjector. Note: If the bolt does not smoothly engage the threaded
IMPORTANT: While drilling and tapping the intake bell hole it is acceptable to enlarge the hole in the air cleaner
use care to keep debris from entering the AeroInjector. or intake flange adapter to provide a degree of play.
1. Slide the air filter or intake flange adapter onto the intake
bell as far as it will go.
Note: Only one bolt is needed to secure the air filter to the
AeroInjector. At least two bolts must be used to mount the
intake flange adapter.
2. Insert a 3/16" diameter drill bit through any of the mount-
ing holes in the air filter or intake flange adapter and twist
it a few times to mark the AeroInjector's intake bell.

The hole in the intake flange adapter or air cleaner can be

enlarged slightly if the AN3 bolt does not smoothly engage the
threaded hole in the intake bell.

A 3/16" drill bit inserted in a mounting hole and twisted by

hand will mark the intake bell of the AeroInjector for drilling.

3. Remove the air filter or intake flange adapter and carefully

drill a 1/8" diameter pilot hole squarely through the intake
bell at the mark.
4. Up-drill the hole with a #21 drill.
The intake flange adapter (shown) and air filter are attached
5. Tap the hole with a 10-32 tap and cutting fluid. with the AN3 bolt(s) and AN960-10 washer(s).

The intake bell drilled and tapped for an AN3 bolt.

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AeroInjectorTM Owners Manual TUNING PROCEDURES

Section Contents The fuel passing through the AeroInjector for combustion is
For Best Results... .............................................................. 17 metered by a tapered fuel needle. The needle moves with the
How the AeroInjector Works.................................................. 17 throttle slide as the cockpit throttle control is operated, allow-
Mixture and Idle Adjustments................................................. 18 ing more fuel to enter as the throttle is opened.
Changing the Mixture Needle................................................. 19
Adjusting the Idle Speed Stop Screw...................................... 20
Tapered Fuel Needle
Adjusting the "Full Throttle" Position of the Throttle Slide..... 20
When is it in Tune?................................................................. 21
Fuel Orifice
Compensating for Seasonal Changes...................................... 21
Tuning the AeroInjector - Step by Step.................................. 22

For Best Results...

Read and understand this entire chapter before tuning your
AeroInjector. This chapter is broken into three sections: How
the AeroInjector Works, Idle and Mixture Adjustments, and
Tuning the AeroInjector. The first two sections contain impor-
tant information you should understand before you begin to
tune your AeroInjector.

How the AeroInjector Works

The Fuel Mixture Needle and Throttle Slide move as one unit Throttle Slide
when the cockpit throttle control is operated. The position
of the mixture needle relative to the throttle slide determines
the fuel/air ratio. The tuning process establishes the optimum This cut-away view shows the tapered fuel needle and fuel
fuel/air ratio for the full range of throttle travel. orifice. The throttle slide, in which the fuel needle is mounted,
Fuel Metering is also identified.
Fuel enters the AeroInjector at the Mixture Control Valve,
which is cockpit controllable with a mixture control cable. The AeroInjector is supplied with 3 different fuel needles.
The valve controls the volume of fuel available to the engine: Each needle provides a different over-all fuel/air ratio and is
from none (cockpit mixture control set to "Full Lean" or "Idle stamped with a number: 2, 2.5, and 3. The #2 needle is the
Cut-off"), to maximum (cockpit mixture control set to "Full leanest, and the #3 needle is the richest. The #2 needle is pre-
Rich"). Like any other carburetor with a cockpit mixture installed, and is the correct needle for the majority of installa-
control, the mixture is normally set to "Full Rich" for start-up, tions.
climb, and landing, yet provides mixture control (leaning) for Note: A more lean no. 1 needle (part no. ACV-C10-11) and
optimum performance and fuel efficiency while cruising. more rich no. 4 needle (part no. ACV-C10-14) are available
Important: When tuning the AeroInjector, the Mixture Control options.
Valve must be in the "Full Rich" position. Air Metering
Combustion air is metered by the Throttle Slide. The throttle
Mixture Control Valve
slide moves when the cockpit throttle control is operated,
altering the opening of the air passage.

1/4 NPT Fuel Inlet These cut-away views show the slide in the idle position (left
photo) and in the wide open throttle position (right photo).
The fuel inlet and Mixture Control Valve.

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AeroInjectorTM Owners Manual TUNING PROCEDURES
For most installations the throttle slide should be allowed to Mixture and Idle Adjustments
open all the way. However, some installations may encounter IMPORTANT: Read and become familiar with the entire
rough engine operation or "balking" near full throttle. If this Tuning Procedure before tuning your AeroInjector. This sec-
occurs - a characteristic of "over-carburation" - note the posi- tion does not describe how to tune the AeroInjector, rather,
tion of the throttle slide just before the engine balks and adjust how to make the individual mixture and idle adjustments
the throttle linkage to prevent the throttle slide from opening which will be necessary during the tuning process.
further. See page 19.
Adjusting the Mixture Needle
The mixture needle is mounted in a needle carrier which is
Idle Speed installed in the throttle slide. The needle carrier has an adjust-
The idle speed is set by the position of the idle speed stop ment screw which allows infinite adjustment of the mixture
screw. This screw, located near the fuel inlet, limits how far needle.
the throttle slide can close, assuring the engine has an ad-
equate supply of air to run when the cockpit throttle control is Mixture Needles
fully retarded.

Needle Carrier and Adjustment Screw.

While it is seldom necessary to remove the needle carrier

during tuning, this photo shows the needle carrier which is
installed in the throttle slide. The AeroInjector is shipped with
Idle Speed Stop Screw three different needles, no. 2, no. 2.5, and no. 3.

The idle speed stop screw limits how far the throttle can close. To adjust the Mixture Needle:
The idle screw is locked in position by a locknut which is tight- 1. Lock the throttle in the "Full Throttle" position.
ened against the body of the AeroInjector after the idle speed 2. Remove the dust cap
has been set.

Dust Cap

Remove the dust cap to gain access to the Needle Adjustment

Screw.

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AeroInjectorTM Owners Manual TUNING PROCEDURES
3. A set screw locks the needle carrier in place. Remove the Changing the Mixture Needle
set screw with a 3/16" ball end hex wrench. The AeroInjector is supplied with three different mixture nee-
dles, each offering a richer or leaner fuel ratio across the entire
throttle range. Each needle is stamped with a number on its flat
Set Screw taper: 2, 2.5, or 3. Needle 2 provides the leanest mixture, and 3
the richest. The number 2 needle is factory installed and is the
correct needle for most applications.
Note: Other needle profiles (no. 1, more lean, and no. 4, more
rich) are available. Please contact AeroConversions to discuss
your needs if the standard needles do not provide proper
results.
A needle should only be replaced after tuning efforts have
shown the installed needle is too rich or too lean across the en-
tire throttle range, as described in "Tuning the AeroInjector".

Use a 3/16" ball end hex wrench to remove the set screw To Replace a Mixture Needle:
which locks the needle carrier in place. 1. Lock the throttle in the "Full Throttle" position.
2. Remove the dust cap.
4. Adjust the mixture needle with a 3/16" ball end hex
wrench. Adjust the needle in 1/8 to 1/2 (maximum) turn 3. Remove the needle locking set screw with a 3/16" ball
increments. end hex wrench.
To richen the mixture, turn the wrench counter-clockwise. 4. Remove the needle carrier from the throttle slide with a
3/16" ball end hex wrench turned counter-clockwise.
To lean the mixture, turn the wrench clockwise.
5. Loosen the set screw which locks the mixture needle in
the needle carrier with a 1/16" hex wrench and remove the
needle.

Notch

Needle
Number
Set Screw

Use a 3/16" hex wrench to adjust the position of the Mixture Use a 1/16" hex wrench to remove the set screw which locks
Needle. the needle in the needle carrier in place.

5. Re-install the set screw so it is snug against the needle 6. Install a needle with a richer or leaner profile, as needed.
carrier. Make sure the notch in the needle lines up with the set
IMPORTANT: Always re-install the set screw after an screw in the needle carrier and re-install the set screw.
adjustment has been made. Running the engine without 7. Use a fine point marker to mark the beginning of the
the set screw in place can allow the position of the mix- needle's taper. Make sure the mark encircles the entire
ture needle to change. needle.
6. Re-install the dust cap.

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AeroInjectorTM Owners Manual TUNING PROCEDURES
8. Re-install the needle carrier in the throttle slide. Make Adjusting the Idle Speed Stop Screw
sure the flat, tapered side of the needle faces the engine The Idle Speed Stop Screw controls the idle speed by limiting
side of the AeroInjector. Screw the carrier into the how far the throttle slide can close. If the slide closes too far,
throttle slide until the marker line on the needle is visible fuel and air will be restricted and the engine will stop. If the
at the edge of the throttle slide. slide does not close enough, the engine will idle too high.
The idle speed stop screw is adjusted with a 9/64" hex wrench.
The screw is locked in place with lock nut tightened against
the AeroInjector's body.
To increase the idle speed, turn the idle screw clockwise.
To decrease the idle speed, turn the idle screw counter-
clockwise.
Idle adjustments may be needed during initial tuning, but the
final idle setting is performed after the mixture needle has
been properly set and the engine is warm (oil temperature at
least 100O F.) Refer to your engine specifications for the cor-
rect idle speed.

Marker line where taper begins

Draw a line around the needle where the taper begins.

9. Re-install the set screw so it is snug against the needle
carrier.
IMPORTANT: Always re-install the set screw after an
adjustment has been made. Running the engine without
the set screw in place can allow the position of the mix-
ture needle to change.
Idle Speed Stop Screw

A 9/64" hex wrench is used to adjust the idle speed stop screw.
Marker line where The lock nut is tightened / loosened with an 11/32" open-end
taper begins wrench.

Adjusting the "Full Throttle" Position of the Throttle

Slide
Some installations may encounter rough engine operation or
"balking" near full throttle. If this occurs, the movement of the
throttle slide needs to be limited to prevent it from opening
and exposing the entire intake air passage.
1. Note the position of the throttle slide just before rough
operation begins.
2. Adjust the throttle cable's length/position so the throttle
Screw the needle carrier into the throttle slide until the begin-
lever is in the full throttle position, but the throttle slide is
ning of the needle's taper is even with the edge of the slide, as
in the position noted in step 1. This will generally require
shown in this cut-away.
shortening the throttle cable.
10. Re-install the cap.

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AeroInjectorTM Owners Manual TUNING PROCEDURES

When is it in Tune? l EGT climbs quickly to, and above, temperatures recom-
A properly tuned AeroInjector will accept throttle changes mended for your engine.
smoothly, without missing or balking, and, at full throttle, will l EGT increases less than 90OF when the cockpit mixture
exhibit an Exhaust Gas Temperature (EGT) increase of 90O to control is pulled back from "Full Rich" to peak lean.
100OF when the cockpit mixture control is pulled from "Full
Rich" to "Peak Lean". Action to take:

We define Peak Lean as the engine manufacturer's maximum l Turn the needle adjustment counter- clockwise in 1/8 to
recommended EGT. While this varies from engine to engine, 1/4 turn increments and run the engine to test the new
most engines set a maximum EGT near 1400OF. Refer to your setting.
engine's operating limits. l If continued needle adjustments do not produce the de-
Note: Since calibration of EGT gauges/probes is difficult, the sired 90O to 100OF EGT spread, install a higher number
EGT should be used to measure change in temperature rather needle. See page 18.
than absolute temperature. l If your fuel system requires a fuel pump, the pressure
Peak Lean generally occurs just before the engine begins to regulator may need to be set higher (1 to 2 psi is normal).
run rough. Continuing to pull the cockpit mixture control fur-
ther lean will result in higher than recommended EGTs, rough
engine operation, and, eventually, fuel starvation.
Compensating for Seasonal Changes
Some climates may require small seasonal adjustments to
What is "Rich"? the mixture needle. These are generally needed once in late
We define "rich" as a fuel/air ratio which has too much fuel. Fall and again in late Spring to compensate for changing air
Symptoms: density. If your engine exhibits symptoms of running too rich
as the weather warms, and too lean as the weather cools, the
l Black, smoky exhaust.
mixture needle may need to be adjusted no more than 1/4 to
l Engine runs with weak, intermittent firing. 1/2 turn richer or leaner, as appropriate.
l Pulling the mixture control knob towards lean will
improve engine firing and reduce the amount of black
exhaust.
l EGT increases more than 100OF when the cockpit mix-
ture control is pulled back from "Full Rich" to "Peak
Lean".
Action to take:
l Turn the needle adjustment clockwise in 1/8 to 1/4 turn
increments and run the engine to test the new setting.
l If continued needle adjustments do not produce the de-
sired 90O to 100OF EGT spread, install a lowered number
needle. See page 18.
l If your fuel system requires a fuel pump, the pressure
regulator may need to be set lower (1 to 2 psi is normal).

What is "Lean"?
We define "lean" as a fuel/air ratio which has too little fuel.
Symptoms:
l Engine will not start
l Engine runs rough and exhaust is free of black smoke.
l Engine runs rough and does not improve, or stalls, as the
cockpit mixture control is pulled towards lean.
l Engine will not take throttle.

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AeroInjectorTM Owners Manual TUNING PROCEDURES

Tuning the AeroInjector - Step by Step 5. Gradually increase the throttle to full static RPM.
IMPORTANT: Read and understand this entire chapter before l If the engine takes full throttle well with clean exhaust,
tuning your AeroInjector. This chapter is broken into three continue with step 6.
sections: How the AeroInjector Works, Mixture and Idle Ad-
l If the engine takes full throttle well but exhibits some
justments, and Tuning the AeroInjector. The first two sections
black exhaust, shut down the engine using an appropri-
contain important information you should understand before
ate checklist and adjust the mixture needle leaner. See
you begin to tune your AeroInjector.
"When is it in Tune?" page 20. After making an adjust-
DANGER: Avoid serious injury or death. Turn the engine ment, repeat step 4.
off using a checklist before making any adjustments to
l If the engine runs rough, balks, or quits, shut down the
the AeroInjector. A typical checklist is provided on page
engine using an appropriate checklist and adjust the mix-
22 of this manual, but it may need to be modified for your
ture needle as needed. See "When is it in Tune?" page
particular aircraft.
20. After making an adjustment, repeat step 4.
DANGER: Avoid serious injury or death. Remain clear of
l If the engine takes throttle well but balks or runs rough
the propeller at all times while tuning the AeroInjector.
only at or near full throttle, the Throttle Slide's travel
DANGER: Avoid serious injury or death. Tie down and needs to be limited. Shut down the engine using an ap-
chock the aircraft while tuning the AeroInjector. propriate checklist and adjust the Throttle Slide. See page
WARNING: Avoid serious burns. The engine and exhaust will 19. After making an adjustment, repeat step 4.
become hot during the tuning process. 6. With the engine running at full throttle:
CAUTION: Avoid damaging the engine. Air cooled engines a. Gradually pull the cockpit mixture control lean until
are not adequately cooled during ground operations. Monitor the engine begins to run rough, and then richen
your engine's temperatures and oil pressure, and limit ground slightly for smooth operation. Note the EGT.
running as much as possible.
b. Advance the cockpit mixture control to full rich and
IMPORTANT: Tuning should be done with a qualified helper. note the EGT.
One person remains in the cockpit to operate the throttle and
c. Retard the throttle smoothly to idle and shut down the
monitor the engine instruments while the other makes adjust-
engine using an appropriate checklist
ments to the AeroInjector (only after the engine is shut down!)
and observes the exhaust. l If the EGT spread was 90O to 100OF, and the engine re-
sponded well to the throttle through the entire range, the
mixture needle is properly set. Continue with step 7.
Tools Required
l If the EGT spread was greater than 90O to 100OF, the
q 3/16" Hex Wrench mixture is too rich. Adjust the mixture needle for a leaner
q 9/64" Hex Wrench mixture (see page 18).
q Start-up checklist (see page 22.) l If the EGT spread was less than 90O to 100OF, the mixture
q Shut-down Checklist (see page 22.) is too lean. Adjust the mixture needle for a richer mixture
(see page 18).
To Tune the AeroInjector:
l If continued adjustment does not achieve the desired 90O
1. Tie-down and chock the aircraft.
to 100OF spread, try the next numbered mixture needle.
2. Set the parking brake See "Changing the Mixture Needle", page 19.
3. Make sure the aircraft has an adequate fuel supply. The 7. After the mixture needle is properly set, final idle adjust-
use of 100LL is strongly recommended during the tuning ments can be made (see page 21).
process to eliminate poor fuel quality as a possible source
8. Test run the engine through it's full RPM range and make
of poor engine performance and tunability.
sure it:
4. Start the engine using an appropriate checklist.
l Responds to the throttle smoothly
l If the engine starts and idles smoothly, even with slightly
l Idles properly
black exhaust, allow the engine's oil temperature to warm
up to 100OF. Do not allow the CHT and EGT to exceed l Exhibits a 90O to 100OF EGT differential at full throttle
the engine manufacturer's limit. Continue to step 5. when the cockpit mixture control is pulled from full rich
to "peak lean".
l If the engine does not start, or starts and runs rough, shut
down the engine using an appropriate checklist and adjust Note: Additional tuning may be needed after initial flight test-
the mixture needle as needed. See "When is it in Tune?" ing or after a new engine has been broken in.
page 20. After making an adjustment, repeat this step.

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AeroInjectorTM Owners Manual OPERATING CHECKLISTS
Note: These basic checklists may need to be altered for your Flooded Engine - Clearing
particular aircraft. Weak, intermittent firing indicates flooding. Excess fuel can
be cleared from the combustion chambers with the following
Starting Checklist - Electric Start procedure:
1. Brakes - Set 1. Mixture - Full Lean (Idle Cut-off)
2. Mixture - Full Lean (Idle Cut-off) 2. Fuel pump - Off
3. Fuel Valve - On 3. Fuel shut off valve - Off
4. Master - On 4. Mag switch - Off
5. Mags - On 5. Throttle - Full Open
6. Throttle - Slightly Open 6. Engage the starter for a few seconds.
7. Fuel Pump - On 7. Repeat the starting procedure.
8. Clear Prop
9. Mixture - Full Rich
Leaning for Best Performance at Cruise
Note: With the mixture open and the fuel valve on, fuel Take-off, full-power climb, and landing must always be
will flow through the AeroInjector. Do not delay starting performed with the mixture set at full rich. Once level cruise
the engine. has been established, however, engine performance and fuel
10. Starter - Engaged economy will both benefit by proper leaning.
The engine will normally start with one or two turns of the 1. Establish level cruise.
propeller in warm weather and six to eight turns in cold 2. Slowly pull the mixture control Lean until the engine
weather. If the engine does not start immediately, pull the mix- begins to run a little rough.
ture off, turn off the fuel pump, and close the fuel valve before
investigating the problem. 3. Note the maximum indicated EGT (if the aircraft is
equipped with an EGT).
4. Slowly push the mixture control Rich until the engine
Starting Checklist - Hand Propping runs smooth. If your aircraft has an EGT, this will be
DANGER: Do not attempt to hand prop an aircraft with- approximately 50 degrees F. cooler than the temperature
out proper training. Serious injury or death can occur. noted in step 3.
WARNING: Do not hand prop an aircraft equipped with an Adjusting the mixture as described above will result in maxi-
electric starter. Remove the aircraft from service until proper mum power (higher RPMs), as well as minimum fuel con-
repairs can be made to the electric starting system. sumption for any throttle setting.
1. Tie down and chock the aircraft. Important: Mixture adjustment must be repeated with any
2. Brakes - Set change in throttle setting or altitude.
3. Mags - Off 5. Push the mixture control to "Full Rich" before landing.
4. Mixture - Full Lean (Idle Cut-off)
5. Fuel Valve - On Shut-Down Checklist
6. Throttle - Slightly Open 1. Mixture - Full Rich
7. Mixture - Full Rich for a few seconds then Full Lean. 2. Throttle - Idle
This "primes" the engine. 3. Fuel Pump - Off
8. Pull prop through 2 to 4 blades 4. Mixture - Full Lean (Idle Cut-off)
9. Mags - On 5. Ignition - Off
10. Prop engine until it starts. 6. Fuel Valve - Off (Closed)
11. Mixture - Full Rich WARNING: Fire hazard. Failure to turn off the
main fuel valve may result in fuel flowing from the
If the engine does not start, repeat procedure.
AeroInjector after shut-down.
7. Master switch - Off
8. Mags - Off

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AeroInjectorTM Owners Manual TROUBLESHOOTING
The AeroInjector is an extremely simple design which can be Engine requires service.
expected to function faultlessly if properly installed and tuned. An engine in need of maintenance will be difficult or impos-
If you experience problems with your AeroInjector, please sible to tune. Check valve settings, cylinder compression, tim-
review this list of troubleshooting tips for possible causes, and ing, magnetos, spark plugs and wires. Inspect intake manifold
the contents of this manual for proper installation/tuning/op- for leaks.
eration. Should you be unable to identify or resolve your
problem, contact AeroConversions for technical assistance. Sticky Throttle
Improper throttle cable used.
Unable to Tune the AeroInjector Replace cable.
Fuel delivery inadequate. Kinked or sharply bent throttle cable.
Inspect fuel system for restrictions. Reroute cable to eliminate kinks, sharp bends.
Make sure the cockpit mixture control is set on "Full Rich" AeroInjector modified by installer with additional link-
and the AeroInjector mixture lever is properly positioned. ages, return springs, brackets, etc.
Make sure the fuel tank has sufficient fuel for consistent head Restore AeroInjector to original configuration and install ac-
pressure while tuning. cording to this manual.
Fuel delivery excessive. Throttle cable lining melted from excessive heat.
Install a pressure regulator if a fuel pump is used. Replace cable. Route cable clear of exhaust system.
Fuel pressure set too high/low on aircraft requiring a fuel Dirty throttle Slide.
pump. If the AeroInjector ingests exhaust gases, oil fumes (saturated
air filter, etc.), or other materials, they can coat the throttle
Mixture needle improperly installed.
slide and cause binding. Clean the slide and injector body.
"Flat" of the mixture needle not facing the proper direction.
Refer to the "Tuning Procedures" section of this manual.
Mixture needle lock screw not installed after each mixture Sticky Mixture Cable
needle adjustment, allowing the needle to move while the Kinked or sharply bent mixture cable.
engine is running. Reroute cable to eliminate kinks, sharp bends.
Install the mixture needle lock screw after each mixture ad-
justment. Unsupported length of mixture cable too long near
AeroInjector mixture lever.
Incorrect needle installed. Install mixture cable as shown in this manual.
Install a different needle per tuning instructions in this manual.
AeroInjector modified by installer with additional link-
Needle has been modified from original profile. ages, brackets, etc.
Discard needle and replace with a new one from Restore AeroInjector to original configuration and install ac-
AeroConversions. cording to this manual.
Needle adjustments too aggressive. Mixture cable lining melted from excessive heat.
Limit needle adjustments to 1/4 turn or less. Replace cable. Route cable clear of exhaust system.
AeroInjector modified by installer.
Restore AeroInjector to original configuration.
Air intake restricted. Fuel Leaks from AeroInjector
Inspect air intake for restrictions, sharp bends, dirty air filters, Because of the AeroInjector's floatless design, fuel will
etc. drip/flow from the AeroInjector if the fuel is on. The flow will
increase if the throttle is open, the cockpit mixture control is
Ram air installed. moved towards "Rich", or a fuel pump is on. This is normal
Remove ram air. and does not represent a defect.
Incorrect propeller installed. To keep fuel from flowing from the AeroInjector when the
A propeller which is too coarse or too large will limit the engine is turned off, always keep the fuel shut-off valve turned
engine's ability to produce power. This cannot be tuned away off, the cockpit mixture control pulled out to "Idle Cut-off",
with the AeroInjector. Install a propeller that will allow the en- the fuel pump off, and the throttle at "Idle". Always use one
gine to reach the engine manufacturer's minimum static RPM of the start-up/shut-down checklists in this manual to prevent
at wide open throttle. fuel from running from the AeroInjector.
Fuel leak from Mixture Control Valve
Remove mixture control valve, replace O-Ring and lubricate it
with fuel-proof valve seal.

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AeroInjectorTM Owners Manual MAINTENANCE
Simplicity of design, combined with a proper installation, O-Rings
result in the AeroInjector requiring no routine or preventive The spigot (or flange) is sealed against the cover plate with
maintenance, year after year. a reusable Viton O-ring (part no. ACV-Z01-50) installed in a
If you are experiencing a problem with your AeroInjector, groove in the mating surface of the spigot or flange. This O-
refer to the Troubleshooting section of this manual. ring can be expected to last the lifetime of the AeroInjector.

The following common topics arise concerning the operation, The spigot (or flange) has
assembly, and disassembly of the AeroInjector. a Viton O-ring that can be
expected to last the life of the
AeroInjector. If replacement
Body Assembly and Disassembly
should become necessary,
Only six (6) screws and MS nuts hold the AeroInjector togeth-
see parts list for correct
er. There is no specific torque value, nor tightening sequence.
replacement part.
The 6 screws that secure
the AeroInjector's body can
be removed / installed with
a 9/64" hex wrench and a The fuel shut-off valve has a Viton O-ring (part no. ACV-Z01-
7/32" box wrench. 51) which is factory coated with a fuel proof lubricant. Under
normal use the O-ring and lubricant never need replacement.
If replacement should become necessary, see the parts list for
correct replacement O-ring. If the mixture valve is wiped clean
or the O-ring is replaced, the O-ring must be recoated with a
light coat of fuel proof lubricant. Do not use grease.
Gaskets and Sealants
There are no sealants or gaskets used anywhere in the
AeroInjector.

The mixture adjusting screw unscrews from the AeroInjector's

body, revealing the viton O-ring. The O-ring must have a light
coat of fuel proof lubricant applied. Do not use grease.

The AeroInjector is assembled without gaskets or sealants. Throttle Slide Lubrication

The thin, black, anti-friction delrin gasket (arrow) is not a The throttle slide should never require lubrication. If it binds,
sealing gasket. identify and correct the cause. Under no circumstances should
any lubricant other than a light spray lubricant be applied,
and this should never be necessary.
Delrin Anti-Friction Gasket
The black, anti-friction delrin gasket (see photo, above) is Throttle Slide Cleaning
often believed to be a sealing gasket but it is not. Its purpose If an AeroInjector is exposed to oily intake air (leaking engine,
is to reduce the sliding friction of the throttle slide. It can be oil-soaked air cleaner) or is able to ingest exhaust gasses
expected to last the lifetime of the AeroInjector unless it is (exhaust leaks, improper exhaust system) the throttle slide can
warped from excessive heat (improper installation), or se- become covered with a black, sticky residue. This must be
verely scratched by debris entering the AeroInjector. removed with solvents and the cause identified and corrected.

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AeroInjectorTM Owners Manual MAINTENANCE
Fuel Passage Cleaning
Debris in the fuel passages (from improper fuel filtering) is
easily removed, often without removing the AeroInjector from
the aircraft.
The main fuel passage (right)
can be cleaned by remov-
ing the fuel shut-off valve
and the fuel line. Clear the
passage with compressed air
or by flushing with mineral
spirits.

The fuel passage for the

tapered mixture needle can
be cleaned by removing both
the needle carrier from the
throttle slide and the small
plug from the end of the
AeroInjector (right). Clear
the passage with compressed
air or by flushing with min-
eral spirits.

Removing this plug exposes

the metered fuel passage.

Sonex Aircraft, LLC Rev D 3/13 © 2013 All Rights Reserved. 26

AeroInjectorTM Owners Manual PARTS LIST

Mixture Needles, Key 9:

Part No. Description 1
ACV-C10-41........... #1 Needle, Stainless
ACV-C10-42........... #2 Needle, Stainless
ACV-C10-46........... #2.5 Needle, Stainless
ACV-C10-43........... #3 Needle, Stainless
ACV-C10-44........... #4 Needle, Stainless 2 Engine Side of
AeroInjector

25 23
5 22
26

27 6

21
7 20
19
8
18
9
10 17
11 15
12
24
14
16

Intake Side of
13 AeroInjector
When an x appears in a part number, substitute the
AeroInjector identifier ("7" or "8") for the x.
AeroInjector 32mm x = 7
AeroInjector 35mm: x = 8
Key Part No. Description
1.........ACV-Z01-78..............8-32 x 1-3/8" SHCS 13........ACV-Z01-61..............MS Hex Nut (MS21042-08)
2.........ACV-C07-05..............32mm Spigot, 1.5" O.D. (shown) 14........ACV-C0x-04..............Intake Bell
ACV-C08-05..............35mm Spigot, 2" O.D. (not shown) 15........ACV-Z01-54..............8-32 x 1/4" Patched SHCS - S/S
ACV-C0x-07..............2.5" Square Flange (not shown) 16........ACV-Z01-62..............Azusa Wire Swivel Nut and Screw
ACV-C0x-08..............3" Square Flange (not shown) 17........ACV-Z01-55..............8-32 x 1/2" Patched Cap Screw
3.........ACV-Z01-50..............Viton O-Ring (#135) 18........ACV-C10-01..............Mixture Adjustment Arm
4.........ACV-Z01-52..............8-32 x 1" Socket Head Cap Screw 19........ACV-C10-06..............Mixture / Fuel Shaft
5.........ACV-COx-02.............Cover Plate 20........ACV-Z01-51..............Viton O-Ring (#010)
6.........ACV-COx-09.............Delrin Gasket 21........ACV-Z01-77..............Close-out Screw, 1/16 NPT
7.........ACV-COx-01.............AeroInjector Body 22........ACV-Z01-66..............8-32 Jam Nut
8.........ACV-C0x-03..............Slide 23........ACV-Z01-65..............8-32 x 3/4" Socket Head Cap Screw
9.........See chart above..........Needle 24........ACV-Z01-60..............Plug, Black Plastic
10........ACV-Z01-58..............6-32 x 1/8 Set Screw - S/S 25........ACV-T01-28..............5/16-24 Jam Nut (AN316-5)
11.........ACV-C10-17..............Needle Holder/Adjuster Assembly 26........ACV-Q01-23..............Patched Socket Set Screw
12........ACV-Z01-57..............3/8-16 x 1/4" Cup Point Set Screw 27........ACV-Q01-21..............Cable Retainer

Sonex Aircraft, LLC Rev D 3/13 © 2013 All Rights Reserved. 27

AeroInjectorTM Owners Manual MANUAL REVISIONS

Rev. Date Page Change

A............. 04/08/10...... 7............. Added photos of reversing throttle quadrant connected to the AeroInjector.
B............. 04/27/11...... 27........... Key 1, ACV-Z01-78, 8-32 x 1-3/8" SHCS, was ACV-Z01-53, 8-32 x 1-1/2" SHCS
C............. 06/21/12...... 27........... Key 9, Changed part number to Stainless Steel Needles. Key 2, Corrected part numbers for
Spigots.
D............. 03/15/13...... 2............. Replaced P.O. Box with physical address.
03/15/13...... 27........... Deleted Individual part numbers for Needle Holder / Carrier Assembly.

Sonex Aircraft, LLC Rev D 3/13 © 2013 All Rights Reserved. 28