Lycoming Reciprocating Engine Division/ Subsidiary of Textron Inc. 652 Oliver Street Williamsport, PA 17701 U.S.A. 717/323-6181 TECHNICAL PUBLICATION 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 corresponding page(s) of the publication indicated above. Previous revisions to this publication This revision consists of: - None February, 1995 Added Figure 19A Slick Pressurized Magnetos Pages 4-2A & 4-2B
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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
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
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
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
* 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
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
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.
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)
* 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
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
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
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