TIO-540-AE2A20Catalog PC-315-7
TIO-540-AE2A20Catalog PC-315-7
TIO-540-AE2A20Catalog PC-315-7
December 2013
All brand and product names referenced in this publication are trademarks or registered
trademarks of their respective companies.
Mailing address:
Lycoming Engines
652 Oliver Street
Williamsport, PA 17701 U.S.A.
Phone:
Factory: U.S. and Canada toll free +1(800) 258-3279
International Customers +1(570) 323-6181
Sales Department: +1(570) 327-7278
Fax: +1(570) 327-7101
Lycoming’s regular business hours are Monday through Friday from 8:00 A.M.
through 5:00 P.M. Eastern Time (-5 GMT)
©2013
TIO-540-AE2A Parts Catalog
RECORD OF REVSIONS
NOTE: Service Documents override parts information in this document.
TABLE OF CONTENTS
Subject Ch-Se-Su Page Date
Frontal ________________________________________________________________________
Record of Revisions ............................................................... ........................... iii ................. 12/13
List of Effective Pages ............................................................ ........................... v ................. 12/13
Table of Contents ................................................................... ........................... vii ................ 12/13
Introduction ............................................................................ ........................... ix ................. 12/13
Abbreviations and Acronyms .................................................. ........................... xiii ............... 12/13
Oversize and Undersize Part Listing ...................................... ........................... xv ................ 12/13
Electrical Power _________________________________ 24-00 _________________________
AC Generation ...................................................................... 24-20
1. Dual-Alternator-Mounting-and-Attaching-Parts ............. ........................... 0-2 .............. 12/13
2. Alternator-Assemblies-and-Belts .................................. ........................... 4-5 .............. 12/13
Reciprocating Engine _____________________________ 72-00 _________________________
Front Section ........................................................................ 72-10
1. Propeller-Governor-Drive-Assembly ............................. ........................... 6-7 .............. 12/13
Power Section ...................................................................... 72-20
1. Crankcase-Assembly .................................................... ........................... 8-9 .............. 12/13
2. Crankcase-Related-Parts ............................................. ........................... 10-11 .......... 12/13
3. Crankshaft,-Counterweight,-Camshaft-and-Related-Parts ........................ 12-13 .......... 12/13
4. Crankshaft-and-Fuel-Pump-Idler-Gears........................ ........................... 14-15 .......... 12/13
5. Crankcase-Attaching-Parts ........................................... ........................... 16-17 .......... 12/13
Cylinder Section ................................................................... 72-30
1. Connecting-Rods,-Pistons-and-Ring-Assemblies ......... ........................... 18-19 .......... 12/13
2. Cylinder-Assembly........................................................ ........................... 20-21 .......... 12/13
3. Valve-Assembly-and-Related-Parts .............................. ........................... 22-24 .......... 12/13
4. Cylinder-Related-Parts ................................................. ........................... 26-27 .......... 12/13
Turbocharger System .......................................................... 72-40
1. Intake-Pipes,-Oil-Suction-Screen,-and-Air-Inlet-Housing .......................... 28-29 .......... 12/13
2. Turbochargers,-Supports-and-Attaching-Parts ............. ........................... 30-31 .......... 12/13
3. Turbocharger-Hoses,-Drain-Tanks-and-Related-Parts.. ........................... 32-34 .......... 12/13
4. Intercoolers,-Controller-and-Air-Inlet-Housing ............... ........................... 36-38 .......... 12/13
INTRODUCTION
DO NOT USE THIS CATALOG AS AN ASSEMBLY OR INSTALLATION
DOCUMENT. THIS CATALOG MUST ONLY BE USED TO IDENTIFY PARTS
IN CONJUNCTION WITH THE APPLICABLE OVERHAUL MANUAL.
Purpose of this Catalog
This Illustrated Parts Catalog (IPC) contains a complete list of spare parts for the Lycoming TIO-
540-AE2A Certified Series wide cylinder flange model engine.
How to use this Catalog
This catalog is based on the Air Transport Association (ATA) Spec100 format.
This catalog is frequently updated by Service Bulletins (SB) and Service Instructions (SI). The
updated information will be incorporated into subsequent full revisions of this catalog.
The ATA two element numbering system provides consistency throughout various manuals. The
bottom of each page (beyond the frontal section) contains a two element number (##-##). In the two
element numbering, the first two digits represent a chapter, and the next two digits subdivide the
material into a more specific section.
The ATA 100 format designates chapters by the numeric code. In the example below, Chapter 74 is
for Ignition with a subsection 20 for Distribution.
EXAMPLE: 74 — 20
Chapter Section
Ignition Distribution
NOTE: Refer to the Table of Contents for the sub-systems listed in each section.
Numerical Index
The Numerical Index is a single list of part numbers, names and their locations within this IPC. It is
useful for locating parts when you only know the number of name of the part.
Description column
Indentation of a part name represents a lower level of assembly. Attaching parts have the same
indentation level and are listed below the parts grouping or assembly they attach to. This column is
often referred to as the “Nomenclature” on other ATA Spec manuals.
Perspective of References
In this manual, all references to locations of various components will be designated as if viewing the
engine from the rear (or anti-propeller) end. The front of the engine is considered to be the propeller
end and the oil sump is considered to be on the bottom of the engine. Cylinders are numbered from
front to rear with the odd-numbered cylinders on the right-hand side. The firing order for this engine
is 1-4-5-2-3-6.
©2013 by Lycoming Engines. “All Rights Reserved.” All Lycoming publications are to
be considered copyrighted and are not to be reproduced without permission of the
company.
A
Adj. Adjustable
C
Cyl. Cylinder
F
Fill. Fillister
H
Hex. Hexagon
I
I.D. Inside Diameter
N
No. Number
O
O.D. Outside Diameter
S
Scav. Scavenge
T
Temp. Temperature
Thd. Thread
V
Vac. Vacuum
66713 ** GUIDE X X X X
69260 INSERT X
69796 DOWEL X
71903-B BUSHING X
72155-S BUSHING X X X
73810 BUSHING X X♦
75656-S BUSHING X X X X
75838 ** GUIDE X X X X
79024-S BUSHING X X X
LW-15628 SEAL X
STD-1065 DOWEL X X X
16T19468 SEAT X X
18B23885 BEARING X X X
18E23886 BEARING X X X
**- See latest revision of Service Instruction No. 1256. Reference Figure 10 items no. 4 and 5 for valve guides
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
18B23885 bearing in .003 in. undersize, order P/N 18B23885-M03. Undersize code letter is
“M” while oversize code letter is “P”. These letters are followed by the number designating the
size in thousandths of an inch.
AR as required
Crankcase Assembly
Figure 4
* Select the appropriate spring to give a minimum of three threads exposed on adjusting screw
to allow field adjustment. Refer to the latest revision of SSP-1776, Part I for spring
identification.
♦ See latest revision of Service Instruction No. 1324 for installation.
P Lycoming proprietary part. Listed for reference purposes only, cannot be purchased.
* Service use only.
Cylinder Assembly
Figure 10
P Lycoming proprietary part. Listed for reference purposes only, cannot be purchased.
* Refer to latest revision of Service Instruction No. 1256 for service valve guides.
AR as required
* Refer to the latest revision of Service Instruction No. 1060 for complete push rod application.
NOTE: Various push rod lengths are used to set valve clearances.
AR as required
* Refer to the latest revision of Service Instruction No. 1060 for complete push rod application.
** Due to the size of the area where the number is stamped, the last five digits may be all that is
shown (21185 or 21186).
NOTE: Various push rod lengths are used to set valve clearances.
FIGURE 13 – INTAKE PIPES, OIL SUCTION SCREEN, AND AIR INLET HOUSING
FIGURE 23 – TURBO SCAVENGE PUMP AND HYDRAULIC PUMP DRIVE AND COVER
FIGURE 25 – FUEL INJECTOR, FUEL LINES, MANIFOLD ASSEMBLY AND PRESSURE LINE
FIGURE 25 – FUEL INJECTOR, FUEL LINES, MANIFOLD ASSEMBLY AND PRESSURE LINE
(CONT.)
* Refer to the latest revision of Lycoming Service Instruction No. 1042 for complete listing of all
approved spark plugs.
V Vendor Prime Manufacturer part
NUMERICAL INDEX
PAGE PAGE
PART NO. PART NAME PART NO. PART NAME
NO. NO.
AN3-11 BOLT 38 LW-12191 PIPE 29
AN3-14 BOLT 38 LW-12192 PIPE 29
AN3-5 BOLT 68 LW-12193 PIPE 29
AN3-7 BOLT 68 LW-12194 PIPE 29
AN565B1032H5 SET SCREW 7 LW-12195 PIPE 29
AN6-12 BOLT 73 LW-12287 ADAPTER 33
AN6-15 BOLT 1 LW-12545 PLUG 29
AN6-15 BOLT 73 LW-12596 BOLT 19
AN6-21 BOLT 1 LW-12681 GASKET 65
AN6-21 BOLT 73 LW-12688 SEAT 21
AN6-34A BOLT 17 LW-12798-4S111 HOSE 65
AN6-44 BOLT 2 LW-12798-4S204 HOSE ASSEMBLY 34
AN6C12A BOLT 31 LW-12798-4S204 HOSE ASSEMBLY 34
AN791-2 ELBOW 59 LW-12798-4S204 HOSE ASSEMBLY 38
AN814-6L PLUG 37 LW-12798-4S204 HOSE 65
AN816-4 NIPPLE 33 LW-12798-4S340 HOSE ASSEMBLY 59
AN816-6 NIPPLE 51 LW-12799-6S070 HOSE ASSEMBLY 33
AN816-6-2 NIPPLE 33 LW-12799-6S070 HOSE ASSEMBLY 34
AN816-8 NIPPLE 53 LW-12799-6S130 HOSE ASSEMBLY 34
AN818-6 NUT 38 LW-12876-4S172 HOSE ASSEMBLY 63
AN821-8 ELBOW 34 LW-12877-6S161 HOSE ASSEMBLY 60
AN826-4 TEE 65 LW-12878-4S200 HOSE ASSEMBLY 33
AN834-8 TEE 34 LW-12878-4S260 HOSE ASSEMBLY 33
AN912-5 REDUCER 51 LW-12878-4S334 HOSE ASSEMBLY 33
AN912-9 BUSHING 33 LW-12975 ADAPTER 38
AN919-6 NIPPLE 63 LW-12988 CYLD & HEAD ASSY 21
AN924-8 NUT 34 LW-13176-8S050 HOSE ASSEMBLY 34
AN960C516 WASHER 31 LW-13176-8S050 HOSE ASSEMBLY 34
AN960C516 WASHER 67 LW-13176-8S134 HOSE ASSEMBLY 34
AN960C616 WASHER 31 LW-13226 NUT 65
AN960C616 WASHER 31 LW-13227 ADAPTER 65
LW-10442 GEAR 7 LW-13321 SEAT 23
LW-10541 GEAR ASSEMBLY 7 LW-13322 SEAT 23
LW-10637 ELBOW 33 LW-13422-S CONN. ROD ASSY 19
LW-10799 SPACER 51 LW-13795 SHAFT 15
LW-11273 CLAMP 43 LW-13807 ADAPTER ASSY 44
LW-11635 SHIELD 2 LW-13896 PLUG 7
LW-11713 SPRING 11 LW-13906 OIL FILTER 57
LW-11796 SPRING 23 LW-13908 CAMSHAFT ASSY 13
LW-11797 SPRING 23 LW-13923 BUSHING 19
LW-11956 GUIDE 21 LW-13926 ADAPTER 65
LW-11958 GUIDE 21 LW-14021 SHAFT 7
LW-12093-3 COUPLING 67 LW-14078 PIN 19
LW-12093-5 COUPLING 67 LW-14326 ALTERNATOR 5
LW-12093-6 COUPLING 68 LW-14326 ALTERNATOR 5
LW-12098-0-170 TUBE ASSEMBLY 59 LW-14445-2 VALVE ASSEMBLY 37
LW-12098-0-210 TUBE ASSEMBLY 59 LW-14820 RING 13
LW-12186 NUT 19 LW-14914 NIPPLE 33