O 540 F1B5 Parts Catalog PC 515 2
O 540 F1B5 Parts Catalog PC 515 2
O 540 F1B5 Parts Catalog PC 515 2
INTRODUCTION
This illustrated parts catalog contains a complete parts listing for the Lycoming O-540-F1B5 series wide
cylinder flange crankcase model aircraft engines.
Major assembly and sub-assembly parts of the engine are listed in the Group Assembly sections in the
general sequence of engine build-up.
An Oversize and Undersize Parts List are included to aid in ordering parts as necessary during overhaul.
The Numerical Index is provided for convenience in finding parts when only the part number is known.
Parts coverage of Vendor Accessories used on Lycoming engines may be found in the appropriate
Vendor’s Parts Catalog. A list of addresses of where to obtain these publications appears in the latest
revision of Service Letter No. L114.
NOTE
This catalog when used in conjunction with the appropriate overhaul manual, is only to
be used for parts identification.
Any reference in this document to the suppliers/parts manufacturer’s product, by name, trademark, part
number or other description is solely for the purposes of identification and does not indicate or infer that
Lycoming accepts responsibility for quality control and/or airworthiness of parts which do not pass through
the Lycoming quality control system.
Although the information contained in this parts catalog is up-to-date at time of publication, users are
advised to procure current information through all Lycoming distributors or from the factory by
subscription. Consult the latest revision of Service Letter No. L114 for subscription information.
In ordering parts for your engine, observe the following instructions which will expedite shipment of
correct parts required without delay.
i PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
TABLE OF CONTENTS
SECTION PAGE
Introduction ........................................................................................................................................................ i
Table of Contents .............................................................................................................................................. ii
Oversize and Undersize Parts Listing .............................................................................................................. iii
4. IGNITION SYSTEM
Magnetos, Magneto Drives, Harnesses and Spark Plugs .......................................................................... 4-1
5. ELECTRICAL COMPONENTS
Starter Attaching Parts .............................................................................................................................. 5-1
Alternator Assembly ................................................................................................................................. 5-2
Alternator Mounting and Attaching Parts ................................................................................................. 5-3
PC-515-2 ii
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
72057 SEAT X X X X
72058 SEAT X X X
72155-S BUSHING X X X X
73810 BUSHING See latest revision of Service Instruction No. 1142.
75656-S BUSHING X X X X
75657-S BUSHING X X X
LW-13792 SEAL See latest revision of Service Instruction No. 1324.
18D23135 BEARING X X X X
STD-1065 DOWEL X X X X
18A19441 BEARING X X X X
In addition to the above, studs are available in P03, P07 & P12.
NOTE
When ordering oversize and undersize parts, be sure to specify the required oversize and undersize dimension
along with the proper part number. For example, to order bearing P/N 18D23135 in .003 undersize, order P/N
18D23135-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 an inch.
iii PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
1 NUMBER DESCRIPTION ASSEMBLY
1 11E24004-S1* CRANKCASE ASSEMBLY 1
* - This part is not available as a service item. Refer to Service Kits, Section 7 for applicable Crankcase Assembly and Governor
Stud Kit Part Number.
PC-515-2 1-1
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
1-2 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
2 NUMBER DESCRIPTION ASSEMBLY
1 LW-18481 GASKET, Oil filler adapter 1
PC-515-2 1-3
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
1-4 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
3 NUMBER DESCRIPTION ASSEMBLY
1 1028-B BALL, 11/16 diameter 1
* - Select spring to give a maximum of three threads exposed on adjusting screw to allow field adjustment. Reference latest
revision of Lycoming Table of Limits, SSP-1776, Part I for spring identification.
PC-515-2 1-5
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
1-6 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
4 NUMBER DESCRIPTION ASSEMBLY
1 13E27622 CRANKSHAFT ASSEMBLY 1
* - See latest revision of Lycoming Service Bulletin No. 475 for application.
PC-515-2 1-7
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
1-8 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
5 NUMBER DESCRIPTION ASSEMBLY
1 LW-19340 CAMSHAFT ASSEMBLY 1
PC-515-2 1-9
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
6 NUMBER DESCRIPTION ASSEMBLY
1 78589 PLUG, Propeller governor idler shaft 1
1-10 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
7 NUMBER DESCRIPTION ASSEMBLY
1 71652 GEAR ASSEMBLY, Crankshaft idler 1
PC-515-2 1-11
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
1-12 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
8 NUMBER DESCRIPTION ASSEMBLY
1 LW-25-1.50 BOLT, 1/4-20 x 1-1/2 long, hex. head 11
PC-515-2 1-13
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
1-14 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
9 NUMBER DESCRIPTION ASSEMBLY
1 73818 GASKET, Accessory housing 1
2-1 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
10 NUMBER DESCRIPTION ASSEMBLY
1 78531 BODY ASSEMBLY, Oil pump 1
2 74641 SHAFT, Oil pump drive 1
3 LW-18110* IMPELLER ASSEMBLY, Oil pump driven 1
4 LW-18108 IMPELLER, Oil pump, driven 1
5 78530 SHAFT, Oil pump drive 1
6 LW-18109* IMPELLER, Oil pump, driven 1
7 STD-35 WASHER, 5/16 plain 3
8 STD-1420 NUT, 5/16-18 slotted 3
9 LW-14260 SEAL, Tachometer shaft, oil 1
10 STD-8 WASHER, 1/4 plain 12
11 STD-160 WASHER, 1/4 lock, internal teeth 12
12 LW-25-0.94 BOLT, 1/4-20 x 15/16 long, hex. head 9
13 LW-25-1.13 BOLT, 1/4-20 x 1-1/8 long, hex. head 1
14 LW-25-1.44 BOLT, 1/4-20 x 1-7/16 long, hex. head 2
FIGURE 10. OIL PUMP ASSEMBLY AND ACCESSORY HOUSING ATTACHING PARTS
2-2 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
11 NUMBER DESCRIPTION ASSEMBLY
1 60096 GASKET, Fuel pump 1
PC-515-2 2-3
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
12 NUMBER DESCRIPTION ASSEMBLY
1 61183 GASKET, Accessory adapter 1
2 60430 COVER, Vacuum pump 1
3 STD-8 WASHER, 1/4 plain 4
4 STD-160 WASHER, 1/4 lock, internal teeth 4
5 STD-1411 NUT, 1/4-20 plain 4
6 69551 GASKET, Accessory drive adapter 1
7 69106 COVER, Governor drive adapter pad 1
8 STD-35 WASHER, 5/16 plain 4
9 STD-475 WASHER, 5/16 lock, internal teeth 4
10 STD-1410 NUT, 5/16-18 plain 4
2-4 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
13 NUMBER DESCRIPTION ASSEMBLY
1 STD-8 WASHER, 1/4 plain 4
2 STD-1856 SCREW, 1/4-20 x 1.00 long, hex. head 4
3 53E22144* VALVE ASSEMBLY, Temperature control oil cooler bypass 1
4 76510* GASKET, Valve assembly 1
5 06E19769-0.63 GASKET, 5/8 I.D. annular 1
6 62417 PLUG, Oil cooler bypass 1
7 STD-784 PLUG, 3/8-18 NPT, Allen head 2
8 72996 FITTING, Breather 1
9 61173 GASKET, Oil pressure housing 1
PC-515-2 2-5
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
14 NUMBER DESCRIPTION ASSEMBLY
1 62817 SCREEN ASSEMBLY, Oil pressure 1
FIGURE 14. OIL PRESSURE SCREEN ASSEMBLY AND OIL COOLER BYPASS VALVE
2-6 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
15 NUMBER DESCRIPTION ASSEMBLY
1 LW-11750 CONNECTING ROD ASSEMBLY 6
PC-515-2 3-1
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
3-2 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
16 NUMBER DESCRIPTION ASSEMBLY
1 LW-13870 CYLINDER ASSEMBLY 6
PC-515-2 3-3
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
3-4 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
17 NUMBER DESCRIPTION ASSEMBLY
1 17A23938 VALVE, Intake 6
2 17B23936 VALVE, Exhaust 6
3 65441 SEAT, Valve spring, lower intake 6
4 LW-13323 SEAT, Valve spring, lower exhaust 6
5 LW-10077 SEAT, Valve spring, upper intake 6
6 LW-16475 SEAT, Valve spring, upper exhaust 6
7 60009 KEY, Valve, intake 12
8 17C21191 KEY, Valve, exhaust 12
9 17C19386 CAP, Valve stem, exhaust 6
10 LW-11795 SPRING, Valve, auxiliary 12
11 LW-11800 SPRING, Valve, outer 12
12 15B26066 PLUNGER ASSEMBLY, Hydraulic tappet 12
13 15B21319 SOCKET, Push rod, hydraulic tappet 12
14 LW-11485 SHROUD TUBE ASSEMBLY 12
15 15G23461♦ SHROUD TUBE ASSEMBLY 12
16 LW-14995 SPRING, Shroud tube 6
17 LW-12272 LOCKPLATE, Shroud tube 6
18 STD-1411 NUT, 1/4-20 plain 6
19 01L23459♦ WASHER, 25/32 I.D. x 1-3/8 O.D. x 1/32 thick 12
20 LW-18661 SEAL, Shroud tube 12
21 06A23493♦ SEAL, Shroud tube 12
22 70310■ SEAL, Shroud tube 12
23 15F19957-28*♦ ROD ASSEMBLY, Push (A total of 12 required) AR
15F19957-29*♦ ROD ASSEMBLY, Push (A total of 12 required) AR
15F19957-30*♦ ROD ASSEMBLY, Push (A total of 12 required) AR
15F19957-31*♦ ROD ASSEMBLY, Push (A total of 12 required) AR
15F19957-32*♦ ROD ASSEMBLY, Push (A total of 12 required) AR
15F19957-33*♦ ROD ASSEMBLY, Push (A total of 12 required) AR
15F19957-34*† ROD ASSEMBLY, Push (A total of 12 required) AR
15F19957-35* ROD ASSEMBLY, Push (A total of 12 required) AR
15F19957-36* ROD ASSEMBLY, Push (A total of 12 required) AR
15F19957-37* ROD ASSEMBLY, Push (A total of 12 required) AR
24 17F19357** ROCKER ASSEMBLY, Valve 12
25 74637 BUSHING, Valve rocker 12
26 LW-13790 SHAFT, Valve rocker 6
27 LW-12892 THRUST BUTTON, Rocker shaft 12
* - Refer to the latest revision of Service Instruction No. 1060 for complete push rod application.
** - Due to the size of the area where the part number is stamped, the last five digits may be all that is shown (19357).
♦ - These parts are used on roller tappet engines only.
† - This push rod can be used on both roller tappet engines and flat tappet engines.
■ - This seal needs to be installed on both roller tappet engines and flat tappet engines.
PC-515-2 3-5
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
3-6 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
18 NUMBER DESCRIPTION ASSEMBLY
1 75906 GASKET, Rocker box cover 6
PC-515-2 3-7
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
3-8 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
IGNITION SYSTEM
MAGNETOS, MAGNETO DRIVES, HARNESSES AND SPARK PLUGS
FIG. QUANTITY
REF. PART PER
19 NUMBER DESCRIPTION ASSEMBLY
1 68H22624 CUSHION, Magneto drive 4
* - Refer to the latest revision of Service Instruction No. 1042 for complete listing of all approved spark plugs.
PC-515-2 4-1
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
4-2 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
ELECTRICAL COMPONENTS
STARTER ATTACHING PARTS
FIG. QUANTITY
REF. PART PER
20 NUMBER DESCRIPTION ASSEMBLY
1 STD-35 WASHER, 5/16 plain 4
PC-515-2 5-1
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
ELECTRICAL COMPONENTS
ALTERNATOR ASSEMBLY
FIG. QUANTITY
REF. PART PER
21 NUMBER DESCRIPTION ASSEMBLY
1 32B19549 ALTERNATOR ASSEMBLY, 12 volt, 70 amp. 1
NOTE
Refer to the latest revision of Service Instruction No. 1154 for complete listing of FAA approved starters,
generators, alternators, regulators and relays.
5-2 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
ELECTRICAL SYSTEM
ALTERNATOR MOUNTING AND ATTACHING PARTS
FIG. QUANTITY
REF. PART PER
22 NUMBER DESCRIPTION ASSEMBLY
1 07A19474 BRACKET, Alternator 1
PC-515-2 5-3
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
5-4 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
23 NUMBER DESCRIPTION ASSEMBLY
1 06B21326 GASKET, Oil sump 1
PC-515-2 6-1
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
6-2 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
24 NUMBER DESCRIPTION ASSEMBLY
1 70485 PIPE, Intake 6
PC-515-2 6-3
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
FIG. QUANTITY
REF. PART PER
25 NUMBER DESCRIPTION ASSEMBLY
1 66224 GASKET, Carburetor 1
6-4 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
PC-515-2 7-1
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
7-2 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
PC-515-2 7-3
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
SECTION 8
NUMERICAL INDEX
PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO.
8-1 PC-515-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
PC-515-2 8-2
O-540-F1B5 SERIES PARTS CATALOG
WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINES
NUMERICAL INDEX
PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO.