Post on 11-Mar-2021
LycomingReciprocating Engine Division/Subsidiary of Textron Inc.
652 Oliver StreetWilliamsport, PA 17701 U.S.A.717/323-6181
TECHNICALPUBLICATION REVISION
REVISION No.
PC-315-1A
PUBLICATION
TIO,LTIO-540-U2A
PUBLICATION No.
PC-315-1
PUBLICATION DATE
February, 1983
The page(s) furnished herewith are intended to replace the correspondingpage(s) of the publication indicated above.
Previous revisions to this publication This revision consists of: -
None February, 1995
Added Figure 19A
Slick Pressurized MagnetosPages 4-2A & 4-2B
PARTS CATALOG
PC-315-1
Textron Lycoming
TIO/LTIO-540-U2A Series Wide Cylinder Flange Model
AIRCRAFT ENGINES
FEBRUARY 1983
Reciprocating Engine Division/ Subsidiary of Textron Inc.
652 Oliver Street Williamsport, PA 17701 U.S.A 717/323-6181
Courtesy of Bomar Flying Service www.bomar.biz
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
INTRODUCTION
This illustrated parts catalog contains a complete parts listing for the Textron Lycoming TIO/LTIO-540-U2A widecylinder flange model aircraft engines.
Major assembly and sub-assembly parts of the engines are listed in the Group Assembly sections in the generalsequence of engine build up.
A Service Kits section and Oversize and Undersize Parts List are included to aid in ordering parts as necessary duringoverhaul.
The Numerical Index is provided for convenience in finding parts when only the part number is known.
Parts coverage of Vendor Accessories used on Textron Lycoming engines may be found in the appropriate Vendor'sParts Catalog. A list of these publications appear in the latest edition of Service Letter No. L114.
NOTES
The illustrations, pictures and drawings shown in this publication are typical of the subject matter they portray; in noinstance are they to be interpreted as examples of any specific engine, equipment or part therof.
Any reference in this document to a suppliers/parts manufacturers' product, by name, trademark, part number or otherdescription is solely for the purposes of identification and does not indicate or infer that Textron Lycoming acceptsresponsibility for quality control and/or airworthiness of parts which do not pass through the Textron Lycoming qualitycontrol system.
The Turbocharger and Control Components for this engine shall be supplied by the Airframe Manufacturer.
SERVICE BULLETINS, INSTRUCTIONS AND LETTERS
Although the information cotained in this parts catalog is up-to-date at time of publication, users are urged to keepabreast of later information through all Textron Lycoming distributors of from the factory by subscription. Consult the latestedition of Service Letter No. L114 for subscription information.
i
SECTION
Introduction...Table of ContentsOversize and 1
1. CRANKCACrankcase AOil Level GageCrankcase Related PartsCrankshaftCamshaft andPropeller Governor Drive AssemblyCrankshaft and Fuel Pump Idler GearsCrankcase Attaching Parts
2. ACCESSO]Accessory HOil Pump AFuel Pump AssembliesVacuum Pump Drive, Oil Cooler and Breather FittingsHydraulic POil Filter Assembly and oil Cooler Bypass Valve
3. CYLINDEIConnectingCylinder AsValve AssemblyCylinder Re
4. IGNITIONMagnetos, Magneto Drives and Spark Plugs
5. ELECTRICAlternator aStarter Motor and Attaching PartsAlternator Mounting and Attaching Parts
6. OIL SUMPOil Sump and Induction Housing AssemblyIntake PipesFuel Injector, Fuel Manifold and Air Bleed Nozzles
7. TURBOCHIntercooler Assembly and Related PartsNote Page -
8. SERVICE KIT SECTION
9. NUMERIC
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
TABLE OF CONTENTS
PAGE
.................................................................................................................................................... icontents............................................................................................................................................iients.........................iiUndersize Parts..........................................................................................................................iii
CASE, CRANKSHAFT AND CAMSHAFT GROUPAssembly...............................................................................................1-1ge and Engine M ounting Brackets..........................................................................................1-2elated Parts.............................................................................................................................1-5
and Related Parts . ............................................. ...... ....... ............................. ................... 1-6d Related Parts........................................................................................................................ 1-9vernor Drive A ssem bly.......................................................................................................... 1-11
and Fuel Pum p Idler G ears......................................................................................................1-13Attaching Parts........................................................................................................................ 1-15
RY HOUSING AND RELATED PARTSousing A ssem bly.....................................................................................................................2-1ssy. and Accessory H ousing A ttaching Parts............................................................................2-3ssem blies...............................................................................................................................2-5
mp D rive, O il Cooler and Breather Fittings..............................................................................2-7m p Drive and Covers.............................................................................................................2-9
ssem bly and Oil Cooler Bypass V alve.....................................................................................2-11
R, PISTON AND VALVE TRAINRods, Pistons and Ring A ssem blies ................................ .......... 3-1sem bly.....................................................................................................................................3-2nbly.........................................................................................................................................3-5lated Parts...............................................................................................................................3-7
SYSTEMagneto Drives and Spark Plugs..............................................................................................4-1
AL COMPONENTSnd Belt.....................................................................................................................................5-1or and A ttaching Parts..............................................................................................................5-2ounting and A ttaching Parts...................................................................................................5-3
AND INDUCTION SYSTEMd Induction H ousing A ssem bly...............................................................................................6-1and A ir Inlet H ousing ............................................................................................................ 6-3
r, Fuel M anifold and A ir Bleed N ozzles...................................................................................6-5
ARGER AND EXHAUST SYSTEMSAssem bly and Related Parts......................................................................................................7-1Turbocharger and Com ponents................................................................................................7-2
KIT SECTIO N ....................................................................................................................... 8-1
AL IND EX ............................................................................................................................. 9-1
ii
LycomingLycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
Oversize and Undersize Parts Listing
PART NO. DESCRIPTION OVERSIZE UNDERSIZE
P02 P05 P10 P15 P20 P30 P50 M03 M06 M10X X66670
66713
69260
69796
71894
71903
72155-S
73810
73857
74241
75656-S
75838
79024-S
LW-12688
LW-13212
LW-13885
LW-14830
LW-15628
STD-1065
BUSHING
GUIDE
INSERT
DOWEL
SEAT
BUSHING, Counterweight
BUSHING
BUSHING
RING
RING
BUSHING
GUIDE
BUSHING
SEAT
BEARING
BEARINGBEARING
SEAL
DOWEL
X X
X
X
X X
X X XSEE LATEST EDITION OF SERVICE INSTRUCTION NO.
X X X XSEE LATEST EDITION OF SERVICE INSTRUCTION NO.
X X
X
1143 FOR APPLICATION.
I I1142 FOR APPLICATION.
X X
X X
X X
X X
X X X X
X X X
X* X* X*
X X X
X X X
XX X X X
Studs available in P03, P07 and P12.
* Also available in P10 oversize.
NOTE
When ordering oversize and undersize parts, be sure to specify the required oversize and undersize dimension along with the properpart number. For example, to order bearing LW-13885 in .003 undersize, order part number LW-13885-M3. Oversize code letter is"P" while undersize code letter is "M". These letters are then followed by the number designating the size in thousandths of aninch.
iii
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
FIG.REF.
1123456789
101112131415161718
PARTNUMBER
LW-1820831C-1231C-1338-1338-1638-2238D-1750-15LW-13794STD-557110265007STD-133969796STD-5147215831C-1473772
CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUPCRANKCASE ASSEMBLY
DESCRIPTION
CRANKCASE ASSEMBLYSTUD. 5/16-18 x 1-1/2 longSTUD, 5/16-18 x 1-5/8 longSTUD, 3/8-16 x 1-5/8 longSTUD. 3/8-16 x 2.00 longSTUD. 3/8-16 x 2-3/4 longSTUD. 3/8-16 x 2-1/8 long, drilledSTUD. 1/2-13 x 1-7/8 longSTUD. 5/16-18 x 1.00 long, drilledDOWEL, 1/2 dia. x 11/16 long, hollowPLUG, 1/8 pipe x 3/8 longRETAINER. Shroud tube sealPLUG, 1/16-27 pipe. Allen headDOWEL, Crankshaft bearingDOWEL, 5/16 dia x 1/2 longBUSHING, Governor drive idler shaft
STUD. 5/16-18 x 1-3/4 longNOZZLE ASSEMBLY. Piston cooling
QUALTITYPER
ASSEMBLY
1-1
Lycom
ingT
IO/LT
IO-540-U
2A
PA
RT
S C
AT
ALO
GW
IDE
CY
LIND
ER
FLAN
GE
CR
AN
KC
AS
E MO
DE
L ENG
INE
Figure 1. CR
AN
KC
ASE
ASSE
MB
LY
1-2
Lycomlng TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUPCRANKCASE ASSEMBLY
FIG.REF.
212345678
PARTNUMBER DESCRIPTION
704577573772059LW-16783-372306STD-33STD-678STD-596
GASKET. Oil filler extensionEXTENSION. Oil filler, 2-11/16 longGASKET. Oil level gageGAGE ASSY . Oil levelBRACKET. Engine mounting (Dynafocal)WASHER. 3/8 plainWASHER. 3/8 lock, internal teethNUT. 3/8-24 plain. 21/64 thick
QUALTITYPER
ASSEMBLY
1-3
2
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
8
1
Figure 2. OIL LEVEL GAGE AND ENGINE MOUNTING BRACKETS
1-4
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUPCRANKCASE RELATED PARTS
FIG.REF.
3123456789
PARTNUMBER DESCRIPTION
1028BLW-11713STD-104577808LW-14830LW- 13885LW-156287209172877
BALL, 11/16dia.SPRING, Oil pressure relief valveGASKET, 1-1/4 I.D. x 1-1/2 O.D. x 3/32 annularVALVE ASSY., Oil pressure relief, adjustableBEARING, CrankshaftBEARING, Crankshaft (front)SEAL, Crankshaft, oilRING, Oil seal, 23/64 I.D. x 7/64 dia.BODY, Hydraulic tappet
QUALTITYPER
ASSEMBLY
1-5
Lycomlng TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
Figure 3. CRANKCASE RELATED PARTS
1-6
Lycoming TIO/LTIO-540-U2AWIDE CYLINDER FLANGE
CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUPCRANKSHAFT AND RUEL PUMP IDLER GEARS
A PARTS CATALOGCRANKCASE MODEL ENGINE
FIG.REF.
4
PARTNUMBER DESCRIPTION
1 LW-17788LW-17789
2 LW-17763*LW-17764
3 STD-12114 738105 609456 756567 721558 790249 STD-1065
10 7364411 7190312 7678813 7678714 LW-1482015 7190716 7678617 LW-1863818 STD-2209
CRANKSHAFT AND COUNTERWEIGHT ASSEMBLYCRANKSHAFT AND COUNTERWEIGHT ASSEMBLY
CRANKSHAFT AND PLUG ASSEMBLYCRANKSHAFT AND PLUG ASSEMBLY
PLUG, 2.00 dia. expansionBUSHING, Crankshaft dynamic counterweightPLUG, 1-1/4 dia.BUSHING, Propeller flange, longBUSHING, Propeller flange, shortBUSHING, Propeller flange, indexingDOWEL, Stepped, 5/16 & 1/4 dia. x 35/64 long
COUNTERWEIGHT ASSEMBLYBUSHING, Dynamic counterweight
ROLLER, Dynamic counterweight, 6.3 orderROLLER, Dynamic counterweight, 5.1 orderRING, Internal retainingWASHER, Dynamic counterweight
GEAR, CrankshaftLOCKPLATE, Crankshaft gearBOLT, 5/16-24 x 1-3/4 long, hex. hd.
QUALTITYPER
ASSEMBLY
* Used on TIO-540-U2A engines.Used on LTIO-540-U2A engines.
1-7
12
Lycoming Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
3
5
6
45
1
8 1-13
14
Figure 4. CRANKSHAFT AND RELATED PARTS
1-8
FIG.REF.
51
2345
PARTNUMBER
76148*LW-12201761557836876118MS16625-1081
Lycoming Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUPCAMSHAFT AND RELATED PARTS
DESCRIPTION
CAMSHAFTCAMSHAFT (Reverse rotation)SHAFT ASSY., Tachometer
PIN, 3/16 x 2-21/64 longSPACER, Tachometer shaft centeringRING, Internal retaining
QUALTITYPER
ASSEMBLY
* Used on TIO-540-U2A engines.** Used on LT10-540-U2A engines.
1-9
1-
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
5
N
Figure 5. CAMSHAFT AND RELATED PARTS
1-10
Minimum Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
FIG.REF.
6
PARTNUMBER
1 LW-104422 LW-140213 LW-105414 778725 STD-196 STD-7987 73249
732507325173252
8 AN565B1032H59 70455
10 LW-1389611 7205312 7237813 STD-35
STD-3514 STD-47515 STD-1410
CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUPPROPELLER GOVERNOR DRIVE ASSEMBLY
DESCRIPTION
GEAR, Governor driveSHAFT, Propeller governor idler gearGEAR ASSY., Propeller governor idler
BUSHING, Propeller governor idler gearDOWEL, 3/32 dia. x 7/32 longDOWEL. 3/32 dia. x 9/32 long
WASHER, ThrustWASHER, ThrustWASHER, ThrustWASHER, ThrustSET SCREW, No. 10/32 x 5/16 longGASKET, 25/32 I.D. x 1-1/8 O.D. x 1/16 thickPLUG, 3/4-16 hex. hd.GASKET, GovernorCOVER, Governor driveWASHER, 5/16 plain (Woodward governor)WASHER, 5/16 plain (AN governor)WASHER, 5/16 lock, internal teethNUT, 5/16-18 plain
QUALTITYPER
ASSEMBLY
1-11
1
Lycoming Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
12
11-
/
I
Figure 6. PROPELLER GOVERNOR DRIVE ASSEMBLY
1-12
Lycoming TIO/LT10-540-U21WIDE CYLINDER FLANGE
CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUPCRANKSHAFT AND RUEL PUMP IDLER GEARS
A PARTS CATALOGCRANKCASE MODEL ENGINE
FIG.REF.
7123456789
1011121314151617
PARTNUMBER
LW-13795STD-2167STD-216871668675307224671667STD-705716647730970474STD-1737729726916469159STD-1774STD-213
DESCRIPTION
SHAFT, Crankshaft idler gearSCREW, 5/16-18 x 7/8 long, hex. hd.NUT, 5/16-18 NC-3 slotted shearGEAR ASSY., Crankshaft idler, plain
BUSHING, Crankshaft idler gearSHAFT, Fuel pump idler gearLOCKPLATE, 1/4 bolt x 1-3/4 spacing (offset)SCREW, 1/4-20 x 11/16 long, hex. hd.GEAR ASSY., Fuel pump idler
BUSHING, Crankshaft idler gearWASHER, Fuel pump gear thrustRING, 37/64 dia. x 3/64 thick, external retainingSHAFT GEAR ASSY., Fuel pump driveGASKET, Fuel pump adapterADAPTER ASSY., Fuel pump drive
PIN, 1/8 dia. x 1/4 longSEAL, Oil, 3/4 I.D. x 1-3/8 O.D.
QUALTITYPER
1-13
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
7
1
11
4
Figure 7. CRANKSHAFT AND FUEL PUMP IDLER GEAR
1-14
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUPCRANKCASE ATTACHING PARTS
FIG.REF.
8123456789
1011121314151617
PARTNUMBER DESCRIPTION
STD-1414STD-8STD-141960803STD-2084STD-160STD-1411STD-1416STD-8STD-1409AN6-34ASTD-33STD-872STD-33STD-678STD-59676220
BOLT, 1/4-20 x 1-1/2 long, hex. hd.WASHER, 1/4 plainBOLT, 1/4-20 x 1-1/8 long, hex. hd.STRAP, LiftingBOLT, 1/4-20 x 1-3/4 long, hex. hd.WASHER, 1/4 lock, internal teethNUT, 1/4-20 plainBOLT, 1/4-20 x 1-1/2 long, hex. hd.WASHER, 1/4 plain (Max. 6)NUT, 1/4-20 slotted shearBOLT, 3/8-24 x 3-1/2 long, hex. hd.WASHER, 3/8 plainNUT, 3/8-24 slottedWASHER, 3/8 plainWASHER, 3/8 lock, internal teethNUT, 3/8-24 plainSTUD, 1/2-20 x 10-45/64
QUALTITYPER
ASSEMBLY
1-15
Lycom
ingT
IO/L
TIO
-540-U2A
PA
RT
S C
AT
AL
OG
WID
E C
YLIN
DE
R FLA
NG
E CR
AN
KC
AS
E MO
DE
L ENG
INE
Figure 8. CR
AN
KC
ASE
AT
TA
CH
ING
PA
RT
S
1-16
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
ACCESSORY HOUSING AND RELATED PARTSACCESSORY HOUSING ASSEMBLY
FIG.REF.
9
PARTNUMBER DESCRIPTION
1 738182 LW-10641'
LW-183093 31C-124 31CD-20*5 31CD-196 31CD-24**7 31C-218 31C-199 25C-21
10 STD-78311 STD-784*12 110213 76156
GASKET, Accessory housingHOUSING ASSEMBLY, AccessoryHOUSING ASSEMBLY, Accessory
STUD. 5/16-18 x 1-1/2 longSTUD, 5/16-18 x 2-1/2 long, drilledSTUD, 5/16-18 x 2-21/64 longSTUD, 5/16-18 x 3.00 longSTUD, 5/16-18 x 2-5/8 longSTUD, 5/16-18 x 2-3/8 longSTUD, 1/4-20 x 2-5/8 longPLUG, 1/4-18 NPTPLUG, 3/8 pipe, Allen hd.PLUG, 1/8 pipe x 3/8 long, socketSHIELD, Oil accessory breather
QUALTITYPER
ASSEMBLY
* Used on TIO-540-U2A engines.Used on LTIO-540-U2A engines.
2-1
3-7
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
8-
Figure 9. ACCESSORY HOUSING ASSEMBLY
2-2
Courtesy of Bomar Flying Service www.bomar.biz
LycomingLycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
ACCESSORY HOUSING AND RELATED PARTSOIL PUMP ASSEMBLY AND ACCESSORY HOUSING ATTACHING PARTS
FIG.REF.
10
PARTNUMBER DESCRIPTION
1 75287*LW-16718**
2 603293 STD-714
AN380C4-24 STD-13395 767846 612977 612988 STD-359 STD-1420
10 LW-1426011 STD-812 STD-16013 STD-120414 STD-141915 STD-193116 STD-122717 STD-1904*18 STD-8*19 STD-1409
BODY ASSEMBLY, Oil pumpBODY ASSEMBLY, Oil pump
SHAFT, Oil pump idlerPIN, 1/8 dia. x 1.00 long, cotterPIN, 1/8 dia. x 1/2 long, cotterPLUG, 1/16-27 NPT Allen head
SHAFT, Oil pump driveIMPELLER, Oil pump, drivingIMPELLER, Oil pump, drivenWASHER, 5/16NUT, 5/16-18 slottedSEAL, Tachometer drive, oilWASHER, 1/4 plainWASHER, 1/4-20 lock, internal teethBOLT, 1/4-20 x 15/16 long, hex hd.BOLT, 1/4-20 x 1-1/8 long, hex hd.BOLT, 1/4-20 x 1-7/8 long, hex hd.WASHER, 1/4 copperBOLT, 1/4-20 x 2-3/4 long, hex hd., drive endWASHER, 1/4 plainNUT, 1/4-20, slotted shear
QUALTITYPER
ASSEMBLY
* Used on TIO-540-U2A engines.** Used on LT10-540-U2A engines.
2-3
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
-11-12-13
1 1-12-15
19
1 1-12-13
1-12-14
7-
8-
Figure 10. OIL PUMP AND ACCESSORY HOUSING ATTACHING PARTS
2-4
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
ACCESSORY HOUSING AND RELATED PARTSFUEL PUMP ASSEMBLIES
FIG.REF. PART
NUMBER DESCRIPTION
1 LW-107992 LW-13909*
LW-18461**3 LW-14444*4 764225 MS20822-6-86 754477 STD-358 STD-4759 STD-1410
SPACER, Fuel pump insulatingPUMP, Fuel (RG9080-J4A)PUMP ASSY., Fuel
PUMP, Fuel (RG9080-J6A)ELBOW, Fuel pumpELBOW, 3/8 tube to 1/2 NPT, 90°
NIPPLE, Fuel pump ventWASHER, 5/16 plainWASHER, 5/16 lockNUT, 5/16-18 plain
QUALTITYPER
ASSEMBLY
* Used on T10-540-U2A engines.** Used on LTIO-540-U2A engines.
2-5
5
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
6
-4
Figure 11. FUEL PUMP ASSEMBLIES
2-6
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
ACCESSORY HOUSING AND RELATED PARTSVACUUM PUMP DRIVE, OIL COOLER AND BREATHER FITTINGS
FIG.REF. PART12 NUMBER
1 611832 675363 STD-17744 STD-2085 729746 715967 83138 604309 STD-8
10 STD-16011 STD-141112 STD-29413 6241714 MS20823-815 AN-844-16D
DESCRIPTION
GASKET, Accessory adapterADAPTER ASSEMBLY, Vacuum pump
DOWEL, 1/8 dia. x 1/4 longSEAL, Oil 7/8 I.D. x 1-1/2 O.D. x 5/16 wide
GEAR ASSY., Vacuum pump drivenWASHER, Accessory driven gearGASKET, Vacuum pumpCOVER, Vacuum pumpWASHER, 1/4 plainWASHER, 1/4 lock, internal teethNUT, 1/4-20 plainGASKET, 7/8 O.D. x 5/8 I.D. x 3/32 annularPLUG, Oil cooler bypassELBOW, 1/2 flared tube, 3/8 NPT, 45°
ELBOW, 3/4 pipe thread to 1.00 I.D. hose, 45°
QUALTITYPER
ASSEMBLY
2-7
5
LycomingLycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
15
2
13
7-
910
11
-14
-4
Figure 12. VACUUM PUMP DRIVE, OIL COOLER AND BREATHER FITTINGS
2-8
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
FIG.REF.
13123456789
10111213141516
PARTNUMBER
729647159668315LW-10807STD-20825C-32STD-1774STD-35STD-475STD-1410831360430LW-10806STD-8STD-160STD-1411
ACCESSORY HOUSING AND RELATED PARTSHYDRAULIC PUMP DRIVE AND COVERS
DESCRIPTION
GEAR ASSY., Hydraulic pump drivenWASHER, Accessory drive gearGASKET, Accessory drive adapterADAPTER ASSY., Hydraulic pump
SEAL, Oil, 7/8 I.D. x 1-1/2 x 5/16 wideSTUD, 1/4-20 x 4.00 longPIN, 1/8 dia. x 1/4 long
WASHER, 5/16 plainWASHER, 5/16 lock, internal teethNUT, 5/16-18 plainGASKET, Hydraulic pumpCOVER. Hydraulic pumpSPACER, Hydraulic pump studWASHER, 1/4 plainWASHER, 1/4 lock, internal teethNUT, 1/4-20 plain
QUALTITYPER
ASSEMBLY
2-9
Lycom
ingT
IO/L
TIO
-540-U2A
P
AR
TS
CA
TA
LO
GW
IDE
CY
LIND
ER
FLA
NG
E C
RA
NK
CA
SE
MO
DE
L EN
GIN
E
Figure 13. HY
DR
AU
LIC
PU
MP
DR
IVE
AN
D C
OV
ER
S
2-10
LycomingLycoming T10/LT10 IO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
ACCESSORY HOUSING AND RELATED PARTSOIL FILTER ASSEMBLY AND OIL COOLER BYPASS VALVE
FIG.REF.14
123456789
PARTNUMBER DESCRIPTION
LW-12795LW-1321577852STD-8STD-160STD-1411STD-18567594425C-10
GASKET, Oil filter adapterOIL FILTER, Short, (spin-on type)BASE ASSY., Oil filterWASHER, 1/4 plainWASHER, 1/4 lock, internal teethNUT, 1/4-20 plainSCREW, 1/4-20 x 1.00 long, hex. hd., self-lockingVALVE ASSY., Temp. control, oil cooler bypassSTUD, 1/4-20 x 1-1/4 long
QUALTITYPER
ASSEMBLY
2-11
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
Figure 14. OIL FILTER ASSEMBLY AND OIL COOLER BYPASS VALVE
2-12
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
CYLINDER, PISTON AND VALVE TRAINCONNECTING RODS, PISTON AND RING ASSEMBLIES
FIG.REF.
15
PARTNUMBER DESCRIPTION
1 LW-134222 LW-139233 LW-125964 LW-121865 LW-13212
LW-13209LW-16143
6 LW-105457 LW-140788 608289 74241
10 73857
CONNECTING ROD ASSEMBLYBUSHING, Connecting rod, upperBOLT, Connecting rodNUT, Connecting rod bolt
BEARING, Connecting rodBEARING, Connecting rod (alternate)BEARING, Connecting rod (alternate)PISTON, Compression ratio, 7.30:1 (finned)PIN, PistonPLUG, Piston pinRING, Piston, top compressionRING, Piston, oil regulating (expander type)
QUALTITYPER
ASSEMBLY
3-1
,
Lycom
ingT
IO/L
TIO
-540-U2A
P
AR
TS
CA
TA
LO
GW
IDE
CY
LIND
ER
FLA
NG
E C
RA
NK
CA
SE
MO
DE
L EN
GIN
E
co
Figure 15. CO
NN
EC
TIN
G
RO
DS, PIST
ON
S AN
D R
ING
ASSE
MB
LIE
S
3-2
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
CYLINDER, PISTON AND VALVE TRAINCYLINDER ASSEMBLY
FIG.REF.
16123456789
1011121314
PARTNUMBER DESCRIPTION
LW-12988LW-1268871894667137583869260STD-187231C-1325C-866670MS20823-6D72343723441102
CYLINDER AND HEAD ASSEMBLYSEAT, Intake valveSEAT, Exhaust valveGUIDE, Valve intakeGUIDE, Valve exhaust (Ni-Resist)INSERT, Spark plug, 18-1.5 MM (long reach)INSERT, 1/8-27 Heli-Coil taper pipe threadSTUD, 5/16-18 x 1-5/8 longSTUD, 1/4-20 x 1.00 longBUSHING, Rocker shaftELBOW, 3/8 flared tube, 1/4 pipe threadSTABILIZER, Cylinder head fins, 15 teethSTABILIZER, Cylinder head fins, 26 teeth
PLUG, 1/8-27 NPT, Allen
QUALTITYPER
ASSEMBLY
* Nitrided cylinder, long reach plug
3-3
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
13
11
Figure 16. CYLINDER ASSEMBLY
3-4
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
CYLINDER, PISTON AND VALVE TRAINVALVE ASSEMBLY
FFIG.REF.
17
PARTNUMBER DESCRIPTION
1 LW-136222 LW-167403 LW-117974 LW-117965 LW-133216 LW-133227 695328 LW-164759 72050
10 6238811 MS13997-312 MS13998-313 7829014 7852415 7225516 LW-1307717 66728*18 6150319 LW-1866120 6292221 73455
73456734577345873555735567355773558
22 6711323 6711424 6711225 6711426 7154927 72626
VALVE, Intake (small diameter intake rotator)VALVE, Exhaust (rotator type)SPRING, Valve, innerSPRING, Valve, outerSEAT, Valve spring, lower intakeSEAT, Valve spring, lower exhaustSEAT, Valve spring, upper intake (rotator)SEAT, Valve spring, upper exhaust (rotator)KEY, Valve intake (rotator)CAP, Valve stem intake (rotator)KEY, Valve exhaust (rotator)CAP, Valve stem, exhaust (rotator)PLUNGER ASSY., Hydraulic tappetSOCKET, Push rod, hydraulic tappetTUBE ASSY., Shroud, push rodSPRING, Shroud tubeWASHER, 25/32 I.D. x 1-1/4 0.D. x 1/32 thickSLEEVE, Shroud tube sealSeal, Shroud tube (w/61503 sleeve)SEAL, Shroud tube (w/crankcase end)ROD ASSY., PushROD ASSY., PushROD ASSY., PushROD ASSY., PushROD ASSY., PushROD ASSY., PushROD ASSY., PushROD ASSY., PushROCKER ASSY., Intake valve
BUSHING, Valve rockerROCKER ASSY., Exhaust valve
BUSHING, Valve rockerWASHER, Valve rocker thrustSHAFT, Valve rocker
QUALTITYPER
ASSEMBLY
* See latest edition of Textron Lycoming Service Instruction No. 1284 for application of Port No. 66728 washer.See latest edition of Textron Lycoming Service Instruction No. 1060 for complete push rod application.
3-5
Lyco
min
gT
IO/L
TIO
-540-U2A
P
AR
TS
CA
TA
LO
GW
IDE
CY
LIND
ER
FLA
NG
E C
RA
NK
CA
SE
MO
DE
L EN
GIN
E
m0
Figure 17. VA
LV
E A
SSEM
BL
Y
3-6
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
CYLINDER, PISTON AND VALVE TRAINCYLINDER RELATED PARTS
FIG.REF.
'18123456789
1011121314151617181920212223242526272829
PARTNUMBER
6673266731STD-160STD-14116719368795STD-192574494714817790674887383-BSTD-2090STD-684STD-2180LW-15592-5-05727027270373027LW-10610LW-10611716107161172834STD-692STD-67065614STD-251STD-1686
DESCRIPTION
GASKET, Cover, valve rocker shaftCOVER, Valve rocker shaftWASHER, 1/4 internal lockNUT, 1/4-20 plainGASKET. Rocker box coverCOVER ASSY., Rocker boxSCREW, 1/4-20 x 5/8 long, pan hd., self-lockingPLATE, Spark plug cautionRING, Oil seal. 3/32 dia. x 4-27/32 I.D.SPACER, 33/64 I.D. x 7/8 O.D. x 1/8 thickSPACER, 33/64 I.D. x 7/8 O.D. x 3/8 thickNUT, 3/8-24 plainNUT, 1/2-20 plainNIPPLE. Straight, 3/8 I.D. hoseHOSE, 3/8 I.D. x 1-13/16 longCLAMP, HoseTUBE ASSY., Cyl. head oil drain. cyl. no. 1TUBE ASSY., Cyl. head oil drain, cyl. no. 2TUBE ASSY., Cyl. head oil drain, cyls. no. 3, 4, 5, 6BAFFLE AND CLIP ASSY., Intercylinder, cyls. no. 1 & 6BAFFLE AND CLIP ASSY., Intercylinder, cyls. no. 2 & 5HOOK, Intercylinder baffle retainerRETAINER, Intercylinder baffleCOVER, Baffle ignition cable holeSCREW, No. 10/32 x 1/2 long, rd. hd.NUT. No. 10/32 self-lockingPLUG, Baffle attachingWASHER, No. 10, internal lockSCREW, 10/32 x 7/16 long, fill. hd.
QUALTITYPER
ASSEMBLY
3-7
Lyco
min
gT
IO/L
TIO
-540-U2A
PA
RT
S C
AT
AL
OG
WID
E C
YLIN
DE
R F
LAN
GE
CR
AN
KC
AS
E M
OD
EL E
NG
INE
U)
N
N
N
N
Figure 18. C
YL
IND
ER
RE
LA
TE
D P
AR
TS
3-8
Lycoming TIO/LT10-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
IGNITION SYSTEMMAGNETOS, MAGNETO DRIVES AND SPARK PLUGS
FIG.REF.
19123456789
101112131415161718192021222324252627282930
PARTNUMBER DESCRIPTION
LW-1213662224LW-12681LW-127077301373636LW-349610-2'LW-349490-2'LW-349510-2'LW-720515-203LW-349610-3LW-349490-3LW-349510-3LW-720515-20375965STD-475STD-1410STD-6961182-K4tLW-16494*67542*LW-18194**67542AN816-4LW-18262MS29512-4LW-13134MS20822-4LW-12784-4-060LW-12784-4-080
CUSHION, Magneto driveGASKET, Magneto adapterGASKET, MagnetoADAPTER, MagnetoCOUPLING, Magneto drive (retard)COUPLING, Magneto drive (right)MAGNETO, Ignition system
MAGNETO, Ignition, S6LN-1258 (25° retard)MAGNETO, Ignition, S6LN-1259HARNESS, Ignition, (3/4-20)
MAGNETO, Ignition systemMAGNETO, Ignition, S6RN-1258 (25° retard)MAGNETO, Ignition, S6RN-1259HARNESS, Ignition (3/4-20)
CLAMP, MagnetoWASHER, 5/16 lock, internal teethNUT, 5/16-18 plainWASHER, 1/4 plainSPARK PLUG, (Champion RHB-36W) (Iridium) long reachGEAR RETAINER ASSY.
BEARING, BallGEAR RETAINER ASSY.
BEARING, BallNIPPLE, 1/4 flared tube, 1/8 NPTADAPTER, Magneto pressurizationSEAL, Oil, 5/64 dia. sect. 23/64 I.D.VALVE ASSY., ReliefELBOW, 1/4 flared tube, 1/8 NPT, 90°
HOSE ASSY., Magneto adapter to left magnetoHOSE ASSY., Magneto adapter to right magneto
QUALTITYPER
ASSEMBLY
t Item No. 19 spork plug is used in current production only. Additional spark plugs are available for this engine. See latest edition of lextronLycoming Service Instruction No. 1042 for complete listing of all approved spark plugs.
* Used on TIO-540-U2A engines.Used on LTIO-540-U2A engines.
NOTE
Individual spark plug leads may be replaced by ordering either 620633-48 (1B, 2B, 3B, 4B, 5B, 6B, 3T, 4T,5T, 6T) or 620633-72 (1T, 2T). Replacement Elbow is P/N 10-320573-2.
4-1
TIO
/LT
IO-540-U
2A P
AR
TS
CA
TA
LO
GW
IDE
CY
LIND
ER
FLA
NG
E C
RA
NK
CA
SE
MO
DE
L EN
GIN
E
Figure 19. M
AG
NE
TO
S, MA
GN
ET
O D
RIV
ES A
ND
SPA
RK
PL
UG
S
4-2
Lycoming TIO, LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
IGNITION SYSTEMPRESSURIZED MAGNETOS (SLICK), MAGNETO DRIVES, HARNESSES AND SPARK PLUGS
FIG.EF. PART9A NUMBER
1 7363673013
2 LW-136413 LW-190964 675425 622246 LW-127077 LW-126818 66LP-OSCNP
66LP-ORCNP9 66LR25SCNP
66LR25RCNP10 67J20608-P11 67J20609-P12 66M2119513 STD-47514 STD-141015 STD-71316 LW-12784-4-10217 AN816-418 LW-12784-4-06019 LW-1826220 66N2102021 MS29512-0422 MS20822-423 1182-L7*
DESCRIPTIONQTY.
PER ASSY.TIO LTIO
2222222
COUPLING; Magneto driveCOUPLING. Magneto driveCUSHION; Magneto driveGEAR RETAINER ASSY.
BEARING. BallGASKET. Magneto adapterADAPTER. MagnetoGASKET. MagnetoMAGNETO. Right. Slick Model No. 6360MAGNETO. Right. Slick Model No. 6340MAGNETO. Left. (Retard). Slick Model No. 6365MAGNETO. Left, (Retard). Slick Model No. 6391HARNESS ASSY.. Right. Slick P/N M-2966HARNESS ASSY.. Left. Slick P/N M-2965CLAMP. MagnetoWASHER. 5/16 lock, internal teethNUT. 5/16-18 plainCOTTER PIN. 3/32 dla. x 3/4 longHOSE. Right magneto to ninnleNIPPLE. 1/4 flared tube. 1/8 NPTHOSE, Left magneto to nippleADAPTER, Magneto pressurizationVALVE ASSY.. ReliefSEAL. Oil. 5/64 dia. section x 23/64 I.D.ELBOW. 1/4 flared tube. 1/8 NPT. 90°
SPARK PLUG. Champion (RHB36S) orAuburn (281)
* Item No. 23 spark plugs are used in current production. See latest edition of Textron LycomingService Instruction No. 1042 for complete listing of all approved spark plugs.
Added February, 1995 4-2A
11
Part No.
LW-M-237676734LW- 16266-25-25LW-14060LW- 16266-25-44LW-16266-10-75
Lycoming TIO, LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
Part Name
PLATE, 3 WireZIP STRAPCLIP, One wire for 1/4 screwCLIP, Two wire for 1/4 screwCLAMP, Three wireCLAMP, Six wire
212242
Qty.
ATTACHING -IARDWARE
Figure 19A. PRESSURIZED MAGNETOS (SLICK), MAGNETO DRIVES, HARNESSESAND SPARK PLUGS
4-2B Added February, 1995
FIG.REF.
201
2
Lycomlng TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
ELECTRICAL COMPONENTSALTERNATOR AND BELT
PARTNUMBER DESCRIPTION
QUALTITYPER
ASSEMBLYLW-14324
74519
ALTERNATOR, 24 volt, 70 amp., externally grounded(ALU-8421)
BELT, Alternator drive, 3/8 wide
NOTE
See latest edition of Textron Lycoming Service Instruction No. 1154 for complete listing of FAA approvedstarters generators, alternators. requlators and relays.
2
0
o
Figure 20. ALTERNATOR AND BELT
5-1
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
ELECTRICAL COMPONENTSSTARTER MOTOR AND ATTACHING PARTS
FIG.REF.
21
PARTNUMBER DESCRIPTION
1 LW-15572*
LW-14214**
2 STD-353 STD-4754 STD-21565 STD-1410
STARTER, 24 volt (3.38:1 internal reduction) (12/14 p. pinion)(MHB-4016)
STARTER, 24 volt, 3.38:1, ratio - 12/14 pitch(MHB-4014)
WASHER, 5/16 plainWASHER, 5/16 internal lockBOLT, 5/16-18 x 1-5/32 long, hex hd.NUT, 5/16-18 plain
QUALTITYPER
ASSEMBLY
* Used on TIO-540-U2A engines.** Used on LTIO-540-U2A engines.
NOTE
See latest edition of Textron Lycoming Service Instruction No. 1154 for complete listing of FM approved starters,generators, alternators, regulators and relays.
Figure 21. STATER MOTOR AND ATTACHING PARTS
5-2
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
ELECTRICAL COMPONENTSALTERNATOR MOUNTING AND ATTACHING PARTS
FIG.REF.
22123456789
101112131415161718192021222324252627282930
PARTNUMBER
7775673383STD-183877757STD-1727LW-14637*LW-14649'STD-1889786397861478629MS16625-1125786177676876769STD-669STD-676STD-1727LW-14637STD-1889LW- 10952'STD-690AN6-12STD-872STD-71376534AN6-16STD-690STD-872STD-713
DESCRIPTION
BRACKET, AlternatorLOCKPLATE, 5/16 bolt x 1.00 spacingBOLT, 5/16-18 x 5/16 long, hex hd.BRACKET, Alternator belt adlustingWASHER, Plain, 3/4 O.D. x 11/32 I.D. x 1/8 thickSHIM, 13/16 O.D. x 11/32 I.D. x .005 thickSHIM, 13/16 O.D. x 11/32 I.D. x .010 thickBOLT, 15/16-18 x 1-7/32 long, hex hd., drilledPULLEY & SHAFT ASSY., Alternator belt adlusting
PULLEY, Alternator belt adlustingBEARING, Ball, alternator idler pulleyRING, Internal retaining, 1-1/8 diameterIDLER SHAFT, Alternator belt adlustingWASHER, Lock, alternator idler pulley bearingLOCKNUT, Alternator idler pulley bearing
WASHER, 33/64 I.D. x 1.00 O.D. x 1/8NUT, 1/2-20 self-locking, 39/64 thickWASHER, Plain, 3/4 O.D. x 11/32 I.D. x 1/8 thickSHIM, 13/16 O.D. x 11/32 I.D. x .005 thickBOLT, 5/16-18 x 1-7/32 long, hex hd., drilledSHIM, 13/16 O.D. x 13/32 I.D. x .005 thickWASHER, 13/16 O.D. x 25/64 I.D. x 1/16 thickBOLT, 3/8-24 x 1-21/64 long, hex hd., drilled endNUT, 3/8-24 slottedPIN, Cotter, 3/32 dia. x 3/4 longSHIM, 1-1/8 O.D. x 13/32 I.D. x .005 thickBOLT, 3/8-24 x 1-53/64 long, hex hd., drilled endWASHER, 13/16 O.D. x 25/64 I.D. x 1/16 thickNUT, 3/8-24 slottedPIN, Cotter, 3/32 dia. x 3/4 long
QUALTITYPER
* Shim as required for belt alignment between crankcase, idler adj. bracket, alternator and alternator bracket.
5-3
Lyco
min
gT
IO/LT
IO-540-U
2A
PA
RT
S C
AT
ALO
GW
IDE
CY
LIN
DE
R FL
AN
GE
CR
AN
KC
ASE
MO
DE
L EN
GIN
E
Figure 22. AL
TE
RN
AT
OR
M
OU
NT
ING
AN
D A
TT
AC
HIN
G
PAR
TS
5-4
TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
OIL SUMP AND INDUCTION SYSTEMOIL SUMP AND INDUCTION HOUSING ASSEMBLY
FIG.REF. PART23 NUMBER
1 LW-133832 LW-133843 LW-133854 STD-4255 STD-16866 LW-133067 LW-149468 LW-182919 STD-514
10 7217911 72167
7216872169
12 LW-1127313 25C-914 25C-1115 38-1716 7270617 STD-9118 110219 STD-78420 STD-35521 STD-822 STD-16023 STD-164624 STD-168825 STD-141126 STD-58927 7296028 STD-187529 STD-830 STD-16031 STD-141932 STD-168833 STD-141134 STD-551
DESCRIPTION
BAFFLE, Oil sumpSUPPORT, Oil sump baffleSUPPORT, Oil sump baffleWASHER, 7/16 O.D. x 13/64 I.D. x 1/16 thickSCREW, 10-32 x 7/16 long, fill. hd.GASKET, Oil sumpHOUSING ASSY., Oil sump and induction
COVER, Induction housingDOWEL, 5/16 dia. x 1/2 longSTUD, Intake pipe extensionPIPE, Extension, intake cylinder, no. 1 & 2PIPE, Extension, intake cylinder, no. 3 & 4PIPE, Extension, intake cylinder, no. 5 & 6CLAMP, Intake pipe extensionSTUD, 1/4-20 N. form x 1-1/8 longSTUD, 1/4-20 x 1-3/8 longSTUD, 3/8-16 x 2-1/8 longINSERT, Heli-Coil 1/4-20 x 3/8 long, self-lockPLUG, 1/2-14 NPT, Allen headPLUG, 1/8 NPT, Allen headPLUG, 3/8-18 NPT, Allen headPLUG, 3/4-14 NPT, Allen headWASHER, 1/4 plainWASHER, Lock, internal teethBOLT, 1/4-20 x 2.00 long, hex. headBOLT, 1/4-20 x 1.00 long, hex. headNUT, 1/4 plainGASKET, Annular, 1-1/8 O.D. x 29/32 I.D. x 1/16PLUG, 7/8-14 x 5/8 hex. headBOLT, 1/4-20 x 13/16 long
WASHER, 1/4 plainWASHER, Lock, internal teethBOLT, 1/4-20 x 1-1/8 long, hex. headBOLT, 1/4-20 x 1.00 long, hex. headNUT, 1/4-20 plainPLUG, 1/2-14 NPT, sq. hd., drilled
QUALTITYPER
ASSEMBLY
6-1
1
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
1
14-
1
-16
17
-16
-8
1
16- 928
Figure 23. OIL SUMP AND INDUCTION HOUSING ASSEMBLY
6-2
Lycomlng TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
OIL SUMP AND INDUCTION SYSTEMINTAKE PIPES AND AIR INLET HOUSING
FIG.REF.
24123456789
1011121314151617181920
PARTNUMBER DESCRIPTION
72711LW-12191LW-12192LW-12193LW-12194LW-121957197374360STD-8STD-160STD-121572210LW-18981STD-11641102STD-8STD-187560422STD-111LW-12545
RING, Seal, intake pipesPIPE, Intake, cylinder no. 1PIPE, Intake, cylinder no. 2PIPE, Intake, cylinder no. 3PIPE, Intake, cylinder no. 4 & 5PIPE, Intake, cylinder no. 6GASKET, 2 bolt flange, 1-7/8 I.D.FLANGE, Intake pipe, upperWASHER, 1/4 plainWASHER, 1/4 lock, internal teethBOLT, 1/4-20 x 1-1/4 long, hex. headGASKET, Air throttle housingHOUSING ASSY.. Air inlet
INSERT, Heli-coil 5/16-18 x 5/8 longPLUG. 1/8 pipe, Allen head
WASHER, 1/4 plainBOLT. 1/4-20 x 13/16 long, hex. headSCREEN. Oil suctionGASKET, 1.00 I.D. x 1-1/4 O.D. x 3/32PLUG, 5/8 Hex head x 1 00, 20 thread
QUALTITYPER
ASSEMBLY
6-3
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
-2
2
14
Figure 24. INTAKE PIPES AND AIR INLET HOUSING
6-4
TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
OIL SUMP AND INDUCTION SYSTEMFUEL INJECTOR, FUEL MANIFOLD AND AIR BLEED NOZZLES
FIG.REF. PART25 NUMBE1 730322 LW-181573 MS29512-64 AN919-65 STD-17276 STD-357 STD-4758 STD-18289 79007
10 MS20823-411 AN780-212 7544713 LW-1818214 7396615 7396516 STD-25117 STD-8218 LW-12098-0-20019 LW-12098-0-17020 LW-16266-10-7521 LW-16266-10-1322 STD-86023 STD-42524 STD-67025 7313626 LW-12876-4S33427 7315228 LW 16266-25-6329 STD-86030 STD-42531 STD-67032 LW-12877-6S-04533 MS20822-6-834 LW-1802835 LW-1659936 LW-1872437 LW-15592-5-0438 LW-16266-25-38'39 STD-133940 STD-160*41 STD-1688
ER DESCRIPTION
GASKET, Air inlet housingFUEL INJECTOR (2524880-1)SEAL, OilREDUCER, Flared tube (3/8 O.D. to 1/4 O.D.)WASHER, 5/16 thickWASHER. 5/16 plainWASHER, 5/16 internal toothBOLT, 5/16-18x 1-5/16 long, hex hd.MANIFOLD ASSY., Fuel
ELBOW, 1/4 tube x 1/8 NPT, 45°
NIPPLE, Union 1/8 NPTNIPPLE. 3/16 tube to 1/8 NPT, restricted
NOZZLE ASSY . Manifold air bleedSPACER. Fuel manifold bracketBRACKET. Fuel manifoldWASHER. No. 10 lock. internal teethSCREW, No. 10-24 x 1/2 long. fill. hd. driveTUBE ASSY., Fuel manifold to nozzle cyls. 1, 2, 5 & 6TUBE ASSY . Fuel manifold to nozzle cyls. 3 & 4CLAMPCLAMPSCREW, No. 10-32 x 5/8 long, fill. hd.WASHER. No. 10, plainNUT. No. 10-32. self-lockingBRACKET, 90°
HOSE ASSY.. Fuel injector to fuel manifoldBRACKET. Support clampCLAMPSCREW, No. 10-32 x 5/8 long, fill. hd.WASHER, No. 10, plainNUT. No. 10-32. self-lockingHOSE ASSY., Fuel pump to inlectorELBOW, 3/8 flared tube with 1/2 NPT. 90° fuel pump outletMANIFOLD, Right. outer, injector nozzle ventMANIFOLD, Left. outer, injector nozzle ventHOSE. 3/16 I.D. x 7/16 O.D. x 3-1/4 longCLAMP. 7/16 I.D. x 5/16 wideCLIP, 3/8 I.D. x 1/4 screwPLUG, 1/16-27 NPT, AllenWASHER, 1/4 lock, internal teethBOLT. 1/4-20 x 1.00 long, hex. hd.
QUALTITYPER
* Assemble 1 each at top forward boss on cylinders 2, 3, 5 & 6.
6-5
33-
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
Figure 25. FUEL INJECTOR, FUEL MANIFOLD AND AIR BLEED NOZZLES
6-6
FIG.REF.
26123
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
TURBOCHARGER AND EXHAUST SYSTEMSINTERCOOLER ASSEMBLY AND RELATED PARTS
PARTNUMBER
LW-18821MS29513-138LW-14445-2
DESCRIPTION
INTERCOOLER, Harrison (HR800159)SEAL, "0" Ring, 2-7/64 x 7/64 sectionVALVE ASSY., Absolute pressure relief
QUALTITYPER
ASSEMBLY
2-
3-
U
Figure 26. INTERCOOLER ASSEMBLY AND RELATED PARTS
7-1
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
TURBOCHARGER AND EXHAUST SYSTEMS
NOTE
The Turbocharger and Control Com-ponents for this engine shall be sup-plied by the Airframe Manufacturer.
7-2
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
SERVICE KIT SECTION
SEAL AND GASKET SETWIDE CYLINDER FLANGE MODELS
Part NamePart No. Qty.
LW-18072MS16625-1081MS29512-6MS29513-138STD-111STD-208STD-213STD-294STD-589STD-1045STD-173783136118362224LW-186616673267193LW-186386831569164695517045570457711937148171667719737205372091722107231272711730327381877611LW-12681LW-12795LW-13306LW-14260LW-15628
SEAL AND GASKET SETRING, Internal retainingSEAL, OilSEAL, OilGASKETSEAL, OilSEAL, Oil (fuel pump drive)GASKETGASKETGASKETRINGGASKET, Vacuum pumpGASKET, Accessory adapterGASKET, MagnetoSEAL, Shroud tubeGASKET, Valve rocker shaft coverGASKET, Rocker box coverLOCKPLATE, Crankshaft gearGASKET, Acc. drive adapterGASKET, Fuel pump adapterGASKET, Acc. pad coverGASKETGASKETBOXRING, Oil sealLOCKPLATE, Crankshaft idler gearGASKET, Intake flangeGASKET, Governor drive padRING, Oil sealGASKET, Oil throttle housingRING, Oil sealRING, Oil seal, intake pipeRING, Air inlet housingGASKET, Acc. housingGASKET, Exhaust flangeGASKET, MagnetoGASKETGASKET, Oil sumpSEAL, TachometerSEAL, Crankshaft
11112212111214
2412611111116261211611621111
8-1
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
SERVICE KIT SECTION
CYLINDER, PISTON AND RING KITWIDE CYLINDER FLANGE MODELS
Part NamePart No. Qty.
LW-180697205060828LW-186616673166732671126711367193LW-1332168795711957148171549726267385773112 or LW-13322LW-1362274241LW-11167LW-1647569532LW-11775LW-11796LW-11797LW-10545SLW-13446 or LW-14077LW-12988MS13997-3MS13998-3STD-160STD-1411STD-1215STD-19256238874494
CYLINDER, PISTON AND RING KITKEY, ValvePLUG, Piston pinSEAL, Shroud tubeCOVER, Valve rocker shaftGASKET, Valve rocker shaft coverROCKER ASSY., Exhaust valveROCKER ASSY., Intake valveGASKET, Rocker box coverSEAT, Valve spring, lowerCOVER ASSY., Rocker boxBOX, Set upRING, Oil sealWASHER, Valve rockerSHAFT, Valve rockerRING, Oil regulatorSEAT, Valve spring, lowerVALVE, IntakeRING, PistonVALVE, Exhaust, nimonicSEAT, Valve springSEAT, Valve springPLUG, Piston pinSPRING, Valve, outerSPRING, Valve, auxiliaryPISTONPIN, PistonCYLINDER ASSY.KEY, Valve (rotator type)CAP, Valve stemWASHER, Internal lockNUT, PlainBOLTSCREWCAPPLATE, Spark plug caution
122422111111122111211122211121442921
8-2
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
NUMERICAL INDEX
PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO.
AN380C4-2AN565B1032H5AN6-12AN6- 16AN6-34AAN780-2AN816-4AN844 16DAN919-6LW-10442LW-10541LW-10545LW-10610LW 10611LW- 10641LW 10799LW-10806LW 10807LW-10952LW-11273LW-11713LW-11796LW-11797LW-1 2098-0-170LW-12098-0-200LW-12136LW-12186LW 12191LW-12192LW-1 2193LW-12194LW-12195LW-12201LW-12545LW 12596LW-12681LW- 12688LW-12707LW-12784-4-060LW-1 2784-4-080LW-12795LW- 12876-4S334LW 12877-6S-045LW-12988LW-13077LW-13134LW-13209LW-13212LW-13215LW-13306
PinSet ScrewBoltBoltBoltNippleNippleElbowReducerGearGear Assy.PistonBaffle Assy.Baffle Assy.Housing Assy.SpacerSpacerAdapter Assy.ShimClampSpringSpringSpringTube Assy.Tube Assy.CushionNutPipePipePipePipePipeCamshaftPlugBoltGasketSeatAdapterHose Assy.Hose Assy.GasketHose Assy.Hose Assy.Cylinder & Head Assy.SpringValve Assy.BearingBearingOil FilterGasket
2-31-115-35-31-156-54-12-76-51-111-113-13-73-72-12-52-92-95-36-11-53-53-56-56-54-13-16-36-36-36-36-31-96-33-14-13-34-14-14-12-116-56-53-33-54-13-13-12-116-1
LW-1 3321LW-1 3322LW-1 3383LW- 13384LW-1 3385LW-1 3422LW-1 3622LW- 13794LW-1 3795LW-1 3885LW- 13896LW-1 3909LW-1 3923LW- 14021LW- 14078LW-14214LW-14260LW-14324LW- 14444LW-14445-2LW-14637LW-14649LW-14820LW- 14830LW-14946LW-15572LW-15592 5-04LW- 15592-5-05LW- 15628LW-16143LW-16266-10-13LW-16266-10-75LW-16266-25-38LW-16266 25-63LW-16475LW- 16494LW-16599LW-16718LW- 16740LW- 16783-3LW-17763LW-17764LW-17788LW-17789LW-18028LW- 18157LW- 18182LW-18194LW- 18208LW- 18262
SeatSeatBaffleSupportSupportConnecting Rod Assy.ValveStudShaftBearingPlugPumpBushingShaftPinStarterSealAlternatorPumpValve Assy.ShimShimRingBearingHousing Assy.StarterClampClampSealBearingClampClampClipClampSeatGear Retainer Assy.ManifoldBody Assy.ValveGage Assy.CrankshaftCrankshaftCrankshaftCrankshaftManifoldFuel InjectorNozzle Assy.Gear Retainer Assy.Crankcase Assy.Adapter
3-53-56-16-16-13-13-51-11-131-51-112-53-11-113-15-22-35-12-57-15-35-31-71-56-15-26-53-71-53-16-56-56-56-53-54-16-52-33-51-31-71-71-71-76-56-56-54-11-14-1
9-1
Textron Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
NUMERICAL INDEX (Cont.)
PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO.
LW-18291LW- 18309LW-18461LW- 18638LW- 18661LW 18724LW- 18821LW-18981LW-349490-2LW-349490-3LW 349510-2LW-349510-3LW 349610-2LW-349610-3LW 720515-203MS13997-3MS13998-3MS16625-1081MS16625 1125MS20822 4MS20822 6-8MS20822-6-8MS20823-4MS20823-6DMS20823-8MS29512-4MS29512-6MS29513-138STD-8STD-8STD-8STD-8STD-8STD-8STD-8STD 19STD-33STD-33STD-35STD-35STD-35STD-35STD-35STD-35STD-82STD-91STD-111STD- 160STD-160STD-160
CoverHousing Assy.Pump Assy.LockplateSealHoseIntercoolerHousing Assy.MagnetoMagnetoMagnetoMagnetoMagnetoMagnetoHarnessKeyCapRingRingElbowElbowElbowElbowElbowElbowSealSealSealWasherWasherWasherWasherWasherWasherWasherDowelWasherWasherWasherWasherWasherWasherWasherWasherScrewPlugGasketWasherWasherWasher
6-12-12-51-73-56-57-16-34-14-14-14-14-14-14-13-53-51-95-34-12-56-56-53-32-74-16-57-11-152-32-72-92-116-16-31-111-31-151-112-32-52-95-26-56-56-16-31-152-32-7
STD- 160STD- 160STD-160STD-160STD-160STD-160STD-208STD-208STD-213STD-251STD-251STD-294STD-355STD-425STD-425STD-475STD-475STD-475STD-475STD-475STD-475STD-514STD-514STD-551STD-557STD-589STD-596STD-596STD-669STD-670STD-670STD-676STD-678STD-678STD-684STD-690STD-692STD-696STD-705STD-713STD-714STD-783STD-784STD-784STD-798STD-860STD-872STD-872STD-1045STD- 1065
WasherWasherWasherWasherWasherWasherSealSealSealWasherWasherGasketPlugWasherWasherWasherWasherWasherWasherWasherWasherDowelDowelPlugDowelGasketNutNutWasherNutNutNutWasherWasherNippleWasherScrewWasherScrewPinPinPlugPlugPlugDowelScrewNutNutGasketDowel
2-92-113-76-16-36-52-72-91-133-76-52-76-16-16-51-112-52-94-15-26-51-16-16-11-16-11-31-155-33-76-55-31-31-153-75-33-74-11-135-32-32-12-16-11-116-51-155-31-51-7
9-2
Lycomlng TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
NUMERICAL INDEX (Cont.)
PART NO.
STD- 1164STD-1204STD-1211STD- 1215STD 1227STD-1339STD-1339STD-1339STD-1409STD-1409STD-1410STD-1410STD-1410STD-1410STD-1410STD-1411STD-1411STD-1411STD-1411STD--1411STD-1411STD-1414STD-1416STD-1419STD-1419STD-1419STD-1420STD-1646STD-1686STD-1686STD-1688STD-1688STD-1727STD-1727STD-1737STD-1774STD-1774STD-1774STD-1828STD-1838STD-1856STD-1872STD-1875STD-1875STD-1889STD-1904STD-1925STD 1931STD-2084STD-2090
PART NAME
InsertBoltPlugBoltWasherPlugPlugPlugNutNutNutNutNutNutNutNutNutNutNutNutNutBoltBoltBoltBoltBoltNutBoltScrewScrewBoltBoltWasherWasherRingPinDowelPinBoltBoltScrewInsertBoltBoltBoltBoltScrewBoltBoltNut
PAGE NO.
6-32-31-76-32-31-12-36-51-152-31-112-52-9415-21-152-72-92-113-76-11-151-151-152-36-12-361376-16-16-55-36-51-131-132-7296-55-32-113-36-16-35-32-33-72-31-153-7
PART NO.
STD-2156STD-2167STD-2168STD-2180STD-220925C-825C-925C-1025C-1125C-2125C-3231 C-1231C-1231C-1331C-1331C-1431C-1931C-2131CD-1931 CD-2031CD-2438-1338-1638-1738-2238D-1750-15383-B1028B110211021102110211021182-K48313831360329604226043060430608036082860945611836129761298615036222462388
PART NAME
BoltScrewNutHoseBoltStudStudStudStudStudStudStudStudStudStudStudStudStudStudStudStudStudStudStudStudStudStudNutBallPlugPlugPlugPlugPlugSpark PlugGasketGasketShaftScreenCoverCoverStrapPlugPlugGasketImpellerImpellerSleeveGasketCap
PAGE NO.
5-21-131-133-71-73-36-12-116-12-12-91-12-11-13-31-12-12-12-12-12-11-11-16-11-11-11-13-71-51-12-13-36-16-34-12-72-92-36-32-72-91-153-11-72-72-32-33-54-13-5
9-3
Lycomlng TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
NUMERICAL INDEX (Cont.)
PART NO.
6241762922650076561466670667136672866731667326711267113671146719367530675366754268315687956915969164692606953269796704557045770474714817154971596715967161071611716647166771668718947190371907719737205072053720597209172155721587216772168721697217972210
PART NAME
PlugSealRetainerPlugBushingGuideWasherCoverGasketRocker Assy.Rocker Assy.BushingGasketBushingAdapter Assy.BearingGasketCover Assy.Adapter Assy.GasketInsertSeatDowelGasketGasketWasherRingWasherWasherWasherHookRetainerGear Assy.LockplateGear Assy.SeatBushingWasherGasketKeyGasketGasketRingBushingBushingPipePipePipeStudGasket
PAGE NO.
2-73-51-13-73-33-33-53-73-73-53-53-53-71-132-74-12-93-71131-133-33-51-11-111-31-13373-52-72-93-7371-131-131-13331-71-76-33-51-111-31-51-71-16-16-16-16-16-3
PART NO.
7224672255723067234372344723787262672702727037270672711728347287772960729647297272974730137302773032731367315273249732507325173252733837345573456734577345873555735567355773558736367364473772738107381873857739657396674241743607449474519748877528775447
PART NAME
ShaftTube Assy.BracketStabiizerStabilizerCoverShaftTube Assy.Tube Assy.InsertRingCoverBodyPlugGear Assy.Shaft Gear Assy.Gear Assy.CouplingTube Assy.GasketBracketBracketWasherWasherWasherWasherLockplateRod Assy.Rod Assy.Rod Assy.Rod Assy.Rod Assy.Rod Assy.Rod Assy.Rod Assy.CouplingCounterweight Assy.Nozzle Assy.BushingGasketRingBracketSpacerRingFlangePlateBeltSpacerBody Assy.Nipple
PAGE NO.
1-133-51-33-33-31-113-53-73-76-16-33-71-56-12-91-132-74-13-76-56-56-51-111-111-111-115-33-53-53-53-53-53-53-53-54-11-71-11-72-13-16-56-53-16-33-75-13-72-32-5
9-4
Lycoming TIO/LTIO-540-U2A PARTS CATALOGWIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE
NUMERICAL INDEX (Cont.)
PART NO.
7544775656757377583875944759657611876148761557615676220764227653476768767697678476786
PART NAME
NippleBushingExtensionGuideValve Assy.ClampSpacerCamshaftShaft Assy.ShieldStudElbowShimWasherLocknutShaftGear
PAGE NO.
6-51-71-33-32-114-11-91-91-92-11-152-55-35-35-32-31-7
PART NO.
767877678877309777567775777808778527787277906782907836878524786147861778629786397900779024
PART NAME
RollerRollerBushingBracketBracketValve Assy.Base Assy.BushingSpacerPlunger Assy.PinSocketPulleyIdler ShaftBearingPulley & Shaft Assy.Manifold Assy.Bushing
PAGE NO.
1-71-71-135-35-31-52-111-113-73-51-93-55-35-35-35-36-51-7
9-5