PARTS CATALOG

PC-315-3

TIO-540-AB1AD

Wide Cylinder Flange Model

MAY 1985
 LYCOMIING TIO-540-ABIAD CATALOG
PARTS
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

INTRODUCTION

This illustrated parts catalog contains a complete parts listing for the Avco Lycoming TIO-540-ABlAD wide
cylinder flange model aircraft engines.
Major assembly and sub-assembly parts of the engines are listed in the Group Assembly sections in the
general sequence of engine build up.

A Service Kits section and 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 Avco Lycoming engines may be found in the appropriate Ven-
dor's Parts Catalog. A list of these publications appear in the latest edition of Service Letter No. L114.

NOTE

The illustrations, pictures and drawings shown in this publication are typical of the subject matter they por-
tray.

This catalog, when used in conjunction with the appropriate overhaul manual, shall be used forparts identifica-
tion only. Under no circumstances shall this catalog be used as an assembly or installation document.

Any reference in this document to a suppliers/parts manufacturers' product, by name, trademark; part
number or other description is solely for the purposes of identification and does not indicate or infer that Avco
Lycoming accepts responsibility for quality control and/or airworthiness of parts which do not pass through the
Avco Lycoming quality control system.

SERVICE BULLETINS, INSTRUCTIONS AND LETTERS

Although the information contained in this parts catalog is up-to-date at time of publication, users are urged to
keep abreast of later information through all Avco Lycoming distributors or from the factory by subscription.
Consult the latest edition of Service Letter No. L114 for subscription information.

HOW TO ORDER PARTS

In ordering parts for your engine, observe the following instructions which will expedite shipment of correct
parts required without delay.

a. Always specify the model and serial number of your engine.

b. Always specify Part Number, Nomenclature and quantity required.

i
 LYCOMIING PARTS
TIO-540-AB1AD CATALOG
CYLINDER
WIDE CRANKCASE
FLANGE MODEL
ENGINE

TABLE OF CONTENTS

SECTION PAGE

Introduction ................................................................................. i
Table of Contents .................................................................. ii
Oversize and Undersize Parts ........................................ ......................... iii

1. CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP

Crankcase A ssem bly ................................................................... 1-1
Oil Level Gage and Engine Mounting Brackets ................................................ 1-3
Crankcase Related Parts ................................................................ 1-5
Crankshaft and Related Parts .................................................... ........ 1-7
Camshaft and Related Parts ............................................................... 1-9
Propeller Governor Drive Assembly ................................................... 1-11
Crankshaft and Fuel Pump Idler Gears ..................................................... 1-13
Crankcase Attaching Parts ............................................................... 1-15

2. ACCESSORY HOUSING AND RELATED PARTS

Accessory Housing Assembly ....................... .................................... 2-1
Oil Pump Assy. and Accessory Housing Attaching Parts ...................................... 2-3
Fuel Pum p Assem bly ..................................................................... 2-5
Oil Filter Assembly and Oil Cooler Bypass Valve .............................................. 2-6
Vacuum Pump Drive, Oil Cooler and Breather Fittings ......................................... 2-7
Turbo Scavenge Pump and Adapter Assembly ................................................ 2-9

3. CYLINDER, PISTON AND VALVE TRAIN

Connecting Rods, Pistons and Ring Assemblies ............................................... 3-1
Cylinder A ssembly ....................................................................... 3-3
Valve A ssem bly ......................................................................... 3-5
Cylinder Related Parts .................................................................... 3-7

4. IGNITION SYSTEM
Magneto, Magneto Drive and Spark Plugs ................................... 4-1

5. ELECTRICAL COMPONENTS
Alternator, Belt, Starter Motor and Attaching Parts ...................................... 5-1
Alternator Mounting and Attaching Parts ................................................... 5-3

6. OIL SUMP AND INDUCTION SYSTEM

Oil Sump Assembly ...................................................................... 6-1
Intake Pipes and Air Inlet Housing ........................................................ 6-3
Fuel Injector, Fuel Manifold and Air Bleed Nozzles ............... ................... ...... 6-5
Nozzle Vent Manifolds and Attachments ............................................ 6-7

7. TURBOCHARGER AND EXHAUST SYSTEMS

Exhaust Pipes and Transition Assembly ..................................................... 7-1
Turbocharger, Support and Attaching Parts ...................... ......................... 7-3
Drain Tank, Density Controller and Related Parts ............................................. 7-5
Differential Pressure Controller, Hoses and Related Parts ...................................... 7-7

8. SERVICE KIT SECTION .................................................................. 8-1

9. NUMERICAL INDEX .................................................................... 9-1

ii
 LYCOMING TIO-540-ABIAD
PARTSCATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

OversizeandUndersize
PartsListing

PARTNO. DESCRIPTION OVERSIZE UNDERSIZE

P02 P05 P10 P15 P20 P30 P40 P50 M03 M06 M10
.002 .005 .010 .015 .020 .030 .040 .050 .003 .006 .010
61681 GUIDE X X X X X
66610 BUSHING X X
69260 INSERT X
69796 DOWEL X
71903 BUSHING SEELATEST
EDITION
OFSERVICE
INSTRUCTION
NO.1143FORAPPLICATION.
72057 SEAT X X X
72058 SEAT X X X
72060S BUSHING X X X X
72061S BUSHING X X X X
72062S BUSHING X X X
73810 BUSHING SEELATEST
EDITION
OFSERVICE
INSTRUCTION
NO.1142FORAPPLICATION.
73857 RING X X
74230 GUIDE X X X X X
74241 RING X
LW-13521 BEARING X X X X
LW-13792 SEAL X
LW-13884 BEARING X X X X
LW-16711 BEARING X X X
STD-2078 DOWEL X X X X

In additionto the above,studsare availablein P01, P02, P03, P05, P07, P10& P12.

NOTE

Whenorderingoversizeand undersizeparts, besureto specifythe requiredoversizeand undersizedimensionalongwiththe proper

part number. Forexample,to order bearingLW-13884in .003 undersize,orderpart numberLW-13884-M3.Oversizecodeletter is
"P" while undersizecodeletter is "M". Theselettersare then followedby the numberdesignatingthe size in thousandthsof an
inch.

iii
 LYCOIVIIIG PARTS
TIO-540-AB1AD CATALOG
WIDE FLANGE
CYLINDER MODEL
CRANKCASE ENGINE
CRANKCASE,
CRANKSHAFT
ANDCAMSHAFT
GROUP
CRANKCASE
ASSEMBLY

FIG. QUANTITY
REF. PART PER
1 NUMBER DESCRIPTION ASSEMBLY

1 11E20000-D1 CRANKCASE ASSEMBLY

2 31C-12 STUD,5/16-18x 1-1/2 long
3 31C-13 STUD,5/16-18x 1-5/8 long
4 38-13 STUD,3/8-16x 1-5/8 long
5 38-16 STUD,3/8-16x 2.00long
6 38-22 STUD,3/8-16x 2-3/4 long
7 38D-17 STUD,3/8-16x 2-1/8 long,drilled
8 50-15 STUD,1/2-20x 1-7/8 long
9 69796 DOWEL, Crankshaftbearing
10 STD-514 DOWEL, 5/16 x 1/2 long
11 STD-557 DOWEL, 1/2 dia.x 11/16 long
12 STD-1339 PLUG,1/16-27pipe,Allenhead
13 1102 PLUG, 1/8 pipex 3/8 long,Allenhead
14 65007 RETAINER, Shroudtubeseal
15 72158 BUSHING, Gov.driveidlershaft
16 31C-16 STUD,5/16-18x 2.00long
17 73772 NOZZLEASSY.,Pistoncooling

1-1
 LYCOMING TIO-540-AB1AD
PARTSCATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

10

13

Figure 1. CRANKCASEASSEMBLY
1-2
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANI(CASE
MODEL
ENGINE
CRANKCASE, CRANKSHAFT
ANDCAMSHAFTGROUP
OIL LEVELGAGEANDENGINEMOUNTING
BRACKETS

FIG. QUANTITY
REF. PART PER
2 NUMBER DESCRIPTION ASSEMBLY
1 70457 GASKET,Oilfillerextension
2 75675 EXTENSION,Oilfiller (short)
3 74065 "0" RING,Oillevelgage
4 LW-14771 GAGEASSY.,Oillevel(short)
5 72306 BRACKET, Engine mounting (Dynafocal)
76790 BRACKET, Engine mounting (Dynafocal)
lowerleft
6 STD-33 WASHER, 3/8 plain
7 STD-678 WASHER, 3/8 internallock
8 STD-596 NUT,3/8-24 plain

1-3
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

3-

Figure 2. OIL LEVEL GAGE AND ENGINE MOUNTING BRACKETS

1-4
 LYCOIVIING TIO-540-ABIAD CATALOG
PARTS
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
ANDCAMSHAFT
CRANKSHAFT
CRANKCASE, GROUP
CRANKCASE
RELATED
PARTS

FIG. QUANTITY
REF. PART PER
3 NUMBER DESCRIPTION ASSEMBLY

1 1028-B BALL,11/16dia.
2 LW-11713 SPRING,Oilpressure reliefvalve
3 STD-1045 GASKET, 1-1/4 I.D. x 1-1/2 O.D.x 3/32 annular
4 77808 VALVEASSY.,Oilpressurerelief,adjustable
5 LW-16711 BEARING,Crankshaft
6 LW-13884 BEARING,Crankshaft, front
7 LW-13792 SEAL,Crankshaft, oil
8 72091 RING,Oilseal,23/64 I.D. x 7/64 dia.section
9 72877 BODY,Hydraulic tappet

1-5
LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

Figure 3. CRANKCSE RELATED PARTS

1-6
 LYCOMING TIO-540-ABIAD CATALOG
PARTS
CRANKCASE
FLANGE
WIDECYLINDER ENGINE
MODEL
CRANKCASE, ANDCAMSHAFT
CRANKSHAFT GROUP
PARTS
ANDRELATED
CRANKSHAFT

FIG. QUANTITY
REF. PART PER
4 NUMBER DESCRIPTION ASSEMBLY

1 LW-17680 CRANKSHAFT ANDCOUNTERWEIGHT ASSEMBLY

2 LW-17651 CRANKSHAFT ANDPLUG ASSEMBLY
3 STD-1211 PLUG, 2.00dia. expansion
4 73810 BUSHING, Crankshaft dynamiccounterweight
5 71640 PLUG, 1-3/8 dia.
6 72062 BUSHING, Propeller flange,long
7 72061 BUSHING, Propeller flange,short
8 72060 BUSHING, Propeller flange,indexing
9 STD-2078 DOWEL, 3/8 O.D.x 1/2 long
10 72801 COUNTERWEIGHT ASSEMBLY
11 71903 BUSHING, Dynamic counterweight
12 72797 ROLLER, Dynamic counterweight,6.3 order
13 72965 ROLLER, Dynamic counterweight,5.1 order
14 LW-14820 RING,Internalretaining
15 71907 WASHER, Dynamic counterweight
16 LW-10284 Crankshaft
GEAR,
17 LW-10332 LOCKPLATE,Crankshaft gear
18 AN8-14A BOLT,1/2-20x 1-19/32long
19 77579 SUPPORTASSY.,Starterring gear,12/14 pitch
20 72566 GEAR, Starterring, 12/14 pitch

1-7
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

19
3-

6 7
5
1
16

18
11
3
15
14

Figure 4. CRANKSHAFTAND RELATEDPARTS

1-8
 LYCOIVIING PARTSCATALOG
TIO-540-ABIAD
WIDE FLANGE
CYLINDER MODEL
CRANKCASE ENGINE
ANDCAMSHAFT
CRANKSHAFT
CRANKCASE, GROUP
CAMSHAFT
ANDRELATED
PARTS

FIG. QUANTITY
REF. PART PER
5 NUMBER DESCRIPTION ASSEMBLY

1 LW-19340 CAMSHAFT ASSEMBLY

2 76118 SPACER, Tachometer shaftcentering
3 76155 SHAFT ASSY.,Tachometer
4 LW-18667 PIN,3/16 dia.x 2-21/64long
5 MS16625-1081 RING,Internalretaining

1-9
 LYCOMING TIO-540-ABIAD
PARTSCATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

4-

-1

-2
3

-5
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
CRANKCASE,
CRANKSHAFT
ANDCAMSHAFT GROUP
PROPELLER
GOVERNOR
DRIVEASSEMBLY

FIG. QUANTITY
REF. PART PER
6 NUMBER DESCRIPTION ASSEMBLY

1 LW-10442 GEAR,
Governordrive
2 LW-14021 SHAFT,Propeller
governoridlergear
3 LW-10541 GEARASSY.,Propellergovernordrive
4 77872 BUSHING,Propellergovernoridlergear
5 STD-19 DOWEL,3/32 dia.x 7/32 long
6 STD-798 DOWEL,3/32 dia.x 9/32 long
7 73249 WASHER,Thrust
73250 WASHER,Thrust
73251 WASHER,Thrust
73252 WASHER,Thrust
8 AN565B1032H5 SETSCREW,No.10/32 x 5/16 long
9 70455 GASKET,
25/32 I.D.x 1-1/8 O.D.x 1/16 thick
10 LW-13896 PLUG,
3/4-16 hex.head

1-11
LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

100
9

Figure 6. PROPELLER GOVERNOR DRIVE ASSEMBLY

1-12
 LYCOIVIING PARTSCATALOG
TIO-540-ABIAD
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
CRANKCASE,
CRANKSHAFT
ANDCAMSHAFT GROUP
ANDFUELPUMPIDLERGEARS
CRANKSHAFT

FIG. QUANTITY
REF. PART PER
7 NUMBER DESCRIPTION ASSEMBLY

1 LW-10292 GEARASSY.,Crankshaft idler, plain

2 LW-10299 SHAFT, Crankshaftidlergear
3 LW-10297 GEARASSY.,Crankshaft idler(heavy)
4 LW-10325 SPACER, Idlergear
5 LW-10324 GEARASSY.,Fuelpumpidler
6 LW-10299 SHAFT, Crankshaftidlergear
7 LW-10325 SPACER, Idlergear
8 LW-10329 SHAFTGEAR ASSY.,Fuelpumpdrive
9 61166 THRUST BUTTON
10 69164 GASKET,Fuelpumpadapter
11 69159 ADAPTERASSY.,Fuelpumpdrive
12 STD-1774 PIN,1/8 dia.x 1/4 long
13 STD-213 SEAL,Oil,3/4 I.D. x 1-3/8 O.D.

1-13
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

12

1
13

Figure 7. CRANKSHAFTAND FUEL PUMP IDLER GEARS

1-14
 LYCOMING PARTSCATALOG
TIO-540-AB1AD
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
CRANKCASE,
CRANKSHAFT
ANDCAMSHAFTGROUP
CRANKCASE
ATTACHING
PARTS

FIG. QUANTITY
REF. PART PER
8 NUMBER DESCFIIPTION ASSEMBLY

1 STD-1414 BOLT,1/4-20x 1-1/2 long,hex.hd.

2 STD-1646 BOLT,1/4-20x 2.00 long,hex.hd.
3 STD-8 WASHER, 1/4 plain
4 60803 STRAP,Lifting
5 STD-2084 BOLT,1/4-20x 1-3/4 long,hex.hd.
6 STD-1419 BOLT,1/4-20x 1-1/8 long,hex.hd.
7 STD-160 WASHER, 1/4 lock, internalteeth
8 STD-1411 NUT,1/4-20 plain
9 STD-1416 BOLT,1/4-20x 1-1/2 long,hex.hd., dr. end
10 STD-8 WASHER, 1/4 plain(18 max.)
11 STD-1409 NUT,1/4-20 slottedshear
12 STD-33 WASHER, 3/8 plain
13 STD-872 NUT,3/8-24 slotted
14 AN6-34A BOLT,3/8-24 x 3-37/64long,hex.hd.
15 STD-33 WASHER, 3/8 plain
16 STD-678 WASHER, 3/8 lock, internalteeth
17 STD-596 NUT,3/8-24 plain
18 76220 STUD,1/2-20x 10-45/64long

1-15
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE FLANGE
CYLINDER MODEL
CRANICASE ENGINE

2,3,7,8

/ 0

15,16,17- 12,13

18

14,15,1

9.10,11

Figure 8. CRANKCASEATTACHING PARTS

1-16
 LYCOMING TIO-540-ABIAD CATALOG
PARTS
FLANGE
CYLINDER
WIDE CRANKCASE ENGINE
MODEL
ACCESSORY
HOUSING
ANDRELATED
PARTS
ACCESSORY
HOUSING
ASSEMBLY

FIG. QUANTITY
REF. PART PER
9 NUMBER DESCRIPTION ASSEMBLY

1 73818 GASKET,Accessory housing

2 LW-10920 HOUSING ASSEMBLY, Accessory
3 25C-12 STUD,1/4-20 x 1-1/2 long
4 31C-19 STUD,5/16-18x 2-3/8 long
5 31CD-20 STUD,5/16-18x 2-1/2 long,drilled
6 31C-13 STUD,5/16-18x 1-5/8 long,(Mag.Pad)
7 76156 SHIELD, Oilaccessorybreather
8 STD-1339 PLUG, 1/16 NPTAllenhead
9 LW-10341 INSERT, 1.00-14Heli-Coil
x 3/8 long
10 MS-124703 INSERT, 3/4-16 Heli-Coil
x 1-1/8 long
11 LW-12589 INSERT, 5/8-18 Heli-Coil
x 3/8 long
12 25C-39 STUD,1/4-20x 4-7/8 long
13 25C-19 STUD,1/4-20 x 2-3/8 long
14 31C-12* STUD,5/16-18x 1-1/2 long

* Installin extreme
lowerleft cornerof accessory
housing.

2-1
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

10

Figure 9. ACCESSORYHOUSING ASSEMBLY

2-2
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
CYLINDER
WIDE CRANKCASE
FLANGE MODEL
ENGINE
ACCESSORYHOUSING
ANDRELATED
PARTS
OILPUMPASSEMBLYANDACCESSORY
HOUSING
ATTACHING
PARTS

FIG. QUANTITY
REF. PART PER
10 NUMBER DESCRIPTION ASSEMBLY

1 LW-10344 BODY ASSY.,Oilpump

2 60329 SHAFT, Oilpumpidler
3 STD-714 PIN,1/8 dia.x 1.00long,cotter
4 LW-10318 GEAR ASSY.,Oilpumpdrive
5 61166 THRUST BUTTON, Oil pumpdrivegear
6 61297 IMPELLER, Oilpumpdriving
7 61298 IMPELLER, Oilpumpdriven
8 STD-35 WASHER, 5/16 plain
9 STD-1420 NUT,5/16-18slotted
10 LW-14260 SEAL,Tachometer drive,oil
11 STD-8 WASHER, 1/4 plain
12 STD-160 WASHER, 1/4 lock,internal
13 STD-1204 BOLT,1/4-20x 15/16 long,hex.hd.
14 STD-1215 BOLT,1/4-20x 1-1/4 long,hex.hd.
15 STD-1875 BOLT,1/4-20x 13/16 long,hex.hd.

2-3
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

1 1,1 2,13

8-

Figure 10. OIL PUMP ASSEMBLYAND ACCESSORYHOUSING ATTACHING PARTS

2-4
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
ACCESSORY
HOUSING
ANDRELATED
PARTS
FUELPUMPASSEMBLY

FIG. QUANTITY
REF. PART PER
11 NUMBER DESCRIPTION ASSEMBLY
1 LW-10799 SPACER,Fuelpumpinsulating
2 LW-12534 PUMP,Fuel(RG17980P)
3 STD-35 WASHER, 5/16 plain
4 STD-475 WASHER, 5/16 lock,internalteeth
5 STD-1410 NUT,5/16-18plain

4
-5

Figure 11. FUEL PUMP ASSEMBLY

2-5
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER CRANKCASE
FLANGE ENGINE
MODEL
ACCESSORYHOUSING
ANDRELATEDPARTS
OIL FILTERASSEMBLYANDOILCOOLER
BYPASSVALVE

FIG. QUANTITY
REF. PART PER
12 NUMBER DESCRIPTION ASSEMBLY

1 LW-10321 SPRING,Oilfilterbypassvalve
2 76539 SEAT,Oil reliefvalve
3 LW-10320 SLEEVE,Oilfilterbypassvalve
4 MS16625-1100 RING,Internalretaining
5 LW-13905 OILFILTER, Long(spin-ontype)Champion
6 LW-13904 KIT,Converter plate,oil filter
7 75944 VALVE ASSY.,Temp.control,oil coolerbypass
8 76510 GASKET, Valveassembly

Figure 12. OIL FILTER ASSEMBLYAND OIL COOLER BYPASSVALVE

2-6
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE FLANGE
CYLINDER MODEL
CRANKCASE ENGINE
ACCESSORYHOUSING ANDRELATED
PARTS
VACUUMPUMPDRIVE,OIL COOLER
ANDBREATHER
FITTINGS

FIG. QUANTITY
REF. PART PER
13 NUMBER DESCRIPTION ASSEMBLY

1 LW-10307 GEARASSY.,Accessory driven

2 61166 THRUST BUTTON, Vacuum pumpgear
3 71596 WASHER, Accessory drivegear
4 STD-2217 SEAL,Oil,7/8 I.D.x 1-1/2 O.D.x 5/16 wide
5 8313 GASKET,Vacuumpump
6 60430 COVER,Vacuum pump
7 STD-8 WASHER, 1/4 plain
8 STD-160 WASHER, 1/4 lock, internalteeth
9 STD-1411 NUT,1/4-20 plain
10 71651 FITTING,
Breather
11 STD-294* GASKET,7/8 I.D. x 5/8 I.D. x 3/32 annular
12 1540* PLUG,Thermometer well
13 MS29512-10** SEAL,Oil,3/32 sectionx 45/64 I.D.
14 LW-14828* REDUCER, 1/2 tubingto 5/8 tubing

* Assemble
in accessory
housing
at oiltemperature
boss.
** Usedat oil coolerinlet and outlet.

2-7
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

10-
1

2-

3-

Figure 13. VACUUM PUMP DRIVE, OIL COOLER AND BREATHERFITTINGS

2-8
 LYCOMING TIO-540-AB1AD
PARTSCATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
ACCESSORY
HOUSINGANDRELATEDPARTS
TURBOSCAVENGE
& VACUUMPUMPDRIVEASSEMBLY

FIG. QUANTITY
REF. PART PER
14 NUMBER DESCRIPTION ASSEMBLY

1 LW-16448 GEAR ASSY.,Accessory driven

2 71596 WASHER, Accessory drivengear
3 8313 GASKET,Turboscavenge & vac.pumpdriveassy.
4 LW-19069 DRIVEASSY.,Turboscavenge & vacuumpump
5 LW-19068 ADAPTER ASSY.,Vacuumpump
6 25C-12 STUD,1/4-20 x 1-1/2 long
7 78612 SHAFT, Hydraulicpump
8 STD-95 KEY,1/8 x 1/2 Woodruff
9 LW-15550 PUMP,Gerotor
10 LW-19066 ADAPTER, Turboscavenge pump
11 70474 WASHER, Retaining, hydraulic
pumpdriveshaft
12 STD-1737 RING,External retaining,
9/16 dia.
13 AN-500-10-16 SCREW, No.10-24x 1-1/8 long,fill. hd.
14 STD-122 WASHER, 13/64 I.D.x 5/16 O.D.
15 STD-178 WASHER, No. 10springlock
16 STD-2217 SEAL,Oil7/8 I.D. x 1-1/2 0.D.
17 STD-8 WASHER, 1/4 plain
18 STD-160 WASHER, 1/4 internallock
19 STD-1411 NUT,1/4-20 plain
20 8313 GASKET,Hydraulic pump
21 60430 COVER,Hydraulic pump
22 STD-8 WASHER, 1/4 plain
23 STD-160 WASHER, 1/4 internallock
24 STD-1411 NUT,1/4-20plain

2-9
 LYCOMING T10-540-ABIAD
PARTSCATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

10

16-

Figure 14. TURBO SCAVENGE& VACUUM PUMP DRIVE ASSEMBLY

2-10
 LYCOMING T10-540-AB1AD CATALOG
PARTS
WIDE FLANGE
CYLINDER MODEL
CRANKCASE ENGINE
PISTONANDVALVETRAIN
CYLINDER,
ANDRINGASSEMBLIES
RODS,PISTONS
CONNECTING

FIG. QUANTITY
REF. PART PER
15 NUMBER DESCRIPTION ASSEMBLY

1 LW-11750 CONNECTING RODASSEMBLY

2 LW-13923 BUSHING, Connecting rod,upper
3 75061 BOLT,Connecting rod
4 LW-12186 NUT,Connecting rod bolt
5 LW-13521 BEARING,Connecting rod
6 LW-12733 PISTON,Compression ratio8.00:1
7 LW-14077 PIN,Piston
8 LW-11775 PLUG,Pistonpin
9 74241 RING,Piston,topcompression
10 73857 RING,Piston,oil regulating
(expander
type)

3-1
 LYCOMING TIO-54D-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

Figure 15. CONNECTING RODS, PISTONSAND RING ASSEMBLIES

3-2
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE FLANGE
CYLINDER ENGINE
MODEL
CRANI(CASE
CYLINDER, ANDVALVETRAIN
PISTON
CYLINDERASSEMBLY

FIG. QUANTITY
REF. PART PER
16 NUMBER DESCRIPTION ASSEMBLY

1 LW-12429* CYLINDERANDHEAD ASSEMBLY

2 72057 SEAT,Intakevalve
3 72058 SEAT,Exhaustvalve
4 61681 GUIDE,Valveintake
5 74230 GUIDE,Valveexhaust
6 69260 INSERT,Sparkplug, 18-1.5MM(longreach)
7 STD-1872 INSERT,1/8-27helicoiltaperpipethread
8 31C-12 STUD,5/16-18x 1-1/2 long
9 25C-9 STUD,1/4-20x 1-1/8 long
10 MS20823-6D ELBOW,45° , 3/8 flared tube
11 66610 BUSHING,Rockershaft
12 1102 PLUG,
1/8-27 NPT,Allen(assemble
in cyl. heads1, 2, 3, 4 & 6)

* Nitridedcylinder,longreachplug.

3-3
LYCOMING TIO-540-AB1AD
PARTSCATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

Figure 16. CYLINDER ASSEMBLY

3-4
 LYCOIVIING TIO-540-AB1AD CATALOG
PARTS
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
CYLINDER,
PISTONANDVALVETRAIN
VALVEASSEMBLY

FIG. QUANTITY
REF. PART PER
17 NUMBER DESCRIPTION ASSEMBLY

1 73938 VALVE,Intake
2 LW-19001 VALVE,Exhaust (rotatortype)
3 LW-10077 SEAT,Valvespring,upperintake
4 LW-13323 SEAT,Valvespring,lowerexhaust& intake
5 LW-16475 SEAT,Valvespring,exhaust(rotatortype)
6 60009 KEY,Valveintake
7 MS13997-3 KEY,Valveexhaust (rotatortype)
8 MS13998-3 CAP,Valvestemexhaust(rotatortype)
9 LW-11795 SPRING,Valve,inner
10 LW-11800 SPRING,Valve,outer
11 AN823-3 ELBOW,1/8 NPTto 3/16 tube, 45°
12 78290 PLUNGERASSY.,Hydraulictappet
13 78524 SOCKET,Pushrod, hydraulic
tappet
14 LW-11485 TUBE,Shroud,pushrod
15 LW-14995 SPRING,Shroudtube
16 LW-12272 LOCKPLATE,Shroudtube
17 STD-1411 NUT,1/4-20 plain
18 LW-18661 SEAL,Shroudtube
19 70310 SEAL,Shroudtube
20 73434* RODASSY.,Push
73435* RODASSY.,Push
73436* RODASSY.,Push
73437* RODASSY.,Push
21 LW-18790 ROCKERASSY.,Valve
22 74637 BUSHING, Valverocker
23 LW-13790 SHAFT,Valverocker
24 LW-12892 THRUSTBUTTON, Rockershaft

* Seelatesteditionof AvcoLycoming
ServiceInstruction
No. 1060for complete
pushrodapplication.

3-5
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

-13

-16
17

10

1 9

-5

22
21

-24

Figure 17. VALVE ASSEMBLY

3-6
 LYCOMING TIO-540-AB1AD
PARTSCATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
CYLINDER,
PISTONANDVALVETRAIN
CYLINDERRELATED
PARTS

FIG. QUANTITY
REF. PART PER
18 NUMBER DESCRIPTION ASSEMBLY
1 75906 GASKET, Rockerboxcover
2 61247 COVER, Rockerbox
3 STD-1925 SCREW, 1/4-20x 5/8 long,panhd. (selflocking)
4 STD-1874 SCREW, 1/4-20x 13/16 long,fill. hd. (selflocking)
5 74494 PLATE,Sparkplugcaution
6 71481 RING,Oilseal,3/32 dia. sect.x 4-27/32I.D.
7 77906 SPACER, 33/64 I.D. x 7/8 O.D.x 1/8 thick
8 74887 SPACER, 33/64 I.D. x 7/8 O.D.x 3/8 thick
9 383-B NUT,3/8-24 plain
10 STD-2090 NUT,1/2-20 plain
11 STD-684 NIPPLE,Straight,3/8 I.D. hose
12 STD-1821 HOSE,3/8 I.D. x 2-1/2 long
13 LW-15592-5-05 CLAMP, Hose
14 68759 TUBEASSY.,Cyl.headoildrain,cyl. no. 1
15 71737 TUBEASSY.,Cyl.headoil drain,cyl. no. 2
16 68761 TUBEASSY.,Cyl.headoil drain,cyls.no.3, 4, 5, 6
17 75339 BAFFLEASSY.Intercylinder
18 73975 BAFFLEASSY.,Intercylinder
19 71611 RETAINER,Intercylinderbaffle
20 71610 HOOK,Intercylinder
baffleretainer
21 AN931-12S17 GROMMET, 3/4 I.D.x 1-3/8 O.D.x 3/8 thick

3-7
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

-8

-5
18

14,15,16-

Figure 18. CYLINDER RELATEDPARTS

3-8
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
IGNITION
SYSTEM
MAGNETO,
MAGNETO DRIVEANDSPARKPLUGS

FIG. QUANTITY
REF. PART PER
19 NUMBER DESCRIPTION ASSEMBLY

1 LW-13642 GEAR, Retainer,magneto drive

2 LW-13641 CUSHION, Magneto drive
3 LW-12681 GASKET, Magneto
4 LW-685126-107 MAGNETO, Ignitionsystem(DL6N-3000)
5 LW-682560-13 MAGNETO, Ignition
6 LW-684602-303 HARNESS, Ignition
7 66M19385 CLAMP, Magneto
8 STD-475 WASHER, 5/16 lock,internalteeth
9 STD-1410 NUT,5/16-18plain
10 LW-620029-6 CLIP,3 wirefor 10/32screw(bottomlead)
11 LW-620037-4 CLIP,6 wirefor 10/32screw
12 76734 ZIPSTRAP
13 STD-1925 SCREW, 1/4-20 selflocking
14 LW-620026-2 CLIP,1 wirefor no. 10screw(4 bottom& 2 topleads)
15 LW-620028-2 CLIP,2 wirefor 1/4 screw(1 bottom& 2 topleads)
16 STD-8 WASHER, 1/4 plain
17 LW-16266-25-19 CLAMP, Cushion type(standoffof nozzleventman.)
18 LW-620029-5 CLIP,3 wirefor 1/4 screw(bottomleads)
19 LW-620036-4 CLIP,6 wirefor no.10 screw
20 LW-620032-7 CLAMP, Ignitionharness
21 LW-14875 BRACKET, Extension
22 STD-692 SCREW, 10/32 x 1/2 long,rd. head
23 STD-670 NUT,10/32 selflocking
24 LW-16266-10-75 CLAMP, Cushion type
25 STD-696 WASHER, 17/64 I.D.x 1/2 O.D.x 1/32 thick
26 STD-1411 NUT,1/4-20 plain
27 STD-8 WASHER, 1/4 plain
28 STD-1874 SCREW, 1/4-20x 13/16 long,self locking,fill. hd.
29 1182-W5* SPARK PLUG, Champion (RHB-37E) longreach
30 LW-382698 KIT,Magneto groundterminal

* ItemNo.29sparkplugis usedin currentproduction

only.Additional sparkplugsareavailable
for this engine.Seelatesteditionof Avco
LycomingServiceInstruction
No. 1042for complete
listingof all approved
sparkplugs.

NOTE
Individualspark plug leadsmay be replacedby orderingeither 10-720633-48
(4B, 6B, 4T, 6T) or
10-720633-78(1B, 2B,3B,5B, 1T,2T, 3T, 5T).

4-1
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

14 17 15 29 16,27

22

11,19 21 12 -20
24 10,18

Figure 19. MAGNETO, MAGNETO DRIVE AND SPARKPLUGS

4-2
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE FLANGE
CYLINDER MODEL
CRANKCASE ENGINE
ELECTRICAL
COMPONENTS
ALTERNATOR,
BELT,STARTER
MOTOR
ANDATTACHING
PARTS

FIG. QUANTITY
REF. PART PER
20 NUMBER DESCRIPTION ASSEMBLY

1 LW-14316 ALTERNATOR, 12volt, 70amp.externally grounded(ALX-8421)

2 76026 BELT,Alternator
drive,3/8 wide
3 LW-15571 STARTER, 12volt (3.38:1internalreduction),
(12/14 pitchpinion),
(MZ-4222)
4 STD-35 WASHER, 5/16 plain
5 STD-475 WASHER, 5/16 lock,internalteeth
6 LW-31-1.16 BOLT,5/16-18x 1-5/32 long,hex.hd.
7 STD-1410 NUT,5/16-18plain

NOTE
Seelatesteditionof Lycoming
ServiceInstruction
No. 1154for complete
listingof FAAapproved
starters,
generators,
alternators,
regulators
andrelays.

5-1
 LYCOMIING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

Figure 20. ALTERNATOR, BELT, STARTERMOTOR AND ATTACHING PARTS

5-2
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER CRANKCASE
FLANGE ENGINE
MODEL
ELECTRICAL
COMPONENTS
ALTERNATOR
MOUNTING
ANDATTACHING
PARTS

FIG. QUANTITY
REF. PART PER
21 NUMBER DESCRIPTION ASSEMBLY

1 LW-13039 BRACKET, Alternator

2 73383 LOCKPLATE, 5/16 boltx 1.00spacing
3 STD-1838 BOLT,5/16-18x 15/16 long,hex.hd.
4 75380 LINK,Alternatoradjusting
5 STD-35 WASHER, 5/16 plain
6 LW-31H.75 BOLT,5/16-18x 3/4 long,hex.hd. drive
7 STD-1727 WASHER, Plain,3/4 O.D.x 11/32 I.D. x 1/8 thick
8 LW-31H.75 BOLT,5/16-18x 3/4 long,hex.hd. drive
9 74323 STRUT,Alternator support
10 LW-31H.75 BOLT,5/16-18x 3/4 long,hex.hd. drive
11 STD-690 WASHER, 13/16 O.D.x 25/64 I.D. x 1/16 thick
12 AN6-14 BOLT,3/8-24 x 1-37/64long,hex.hd., drilledend
13 STD-690 WASHER, 13/16 O.D.x 25/64 I.D. x 1/16 thick
14 STD-872 NUT,3/8-24, slotted
15 STD-713 PIN,Cotter,3/32 dia. x 3/4 long
16 AN6-16 BOLT,3/8-24x 1-53/64long,hex.hd., drilledend
17 76534 SHIM,1-1/8 O.D.x 13/32I.D. x .005thick
18 STD-690 WASHER, 13/16O.D.x 25/64 I.D.x 1/16 thick
19 STD-872 NUT,3/8-24, slotted
20 STD-713 PIN,Cotter,3/32 dia. x 3/4 long

5-3
LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

10
-13
-

Figure 21. ALTERNATOR MOUNTING AND ATTACHING PARTS

5-4
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
OIL SUMPANDINDUCTION
SYSTEM
OILSUMPASSEMBLY

FIG. QUANTITY
REF. PART PER
22 NUMBER DESCRIPTION ASSEMBLY
1 LW-13306 GASKET, Oilsump
2 LW-19168 SUMPASSY.,Oil
3 71699 CONNECTION, Intakepipe
4 25C-11 STUD,1/4-20x 1-3/8 long
5 25C-14 STUD,1/4-20x 1-3/4 long
6 STD-1164 INSERT,5/16-18Heli-Coilx 5/8 long
7 38-15 STUD,3/8-16 x 1-7/8 long
8 STD-1173 INSERT,1/4-20 Heli-Coil
x 1/2 long
9 STD-1171 INSERT,3/8-16 Heli-Coil
x 3/4 long
10 1102 PLUG,1/8-27 NPT,Allen
11 STD-8 WASHER, 1/4 plain
12 STD-160 WASHER, 1/4 internallock
13 STD-1419 BOLT,1/4-20x 1-1/8 long,hex.hd.
14 STD-1688 BOLT,1/4-20x 1.00long,hex.hd.
15 STD-1411 NUT,1/4-20plain
16 STD-551 PLUG,1/2-14NPTsq. hd., drilled
17 STD-1885 BOLT,1/4-20x 1-41/64long
18 74655 SPACER,Exhaust manifoldbracket
19 LW-19240 BRACKET,Cable,exhaust manifold
20 70484 SCREEN,Oilsuction
21 STD-111 GASKET,1.001.D.x 1-1/4 O.D.x 3/32 annular
22 LW-12545 PLUG,5/8 hex.hd. x 1.00-20thread

6-1
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

22

Figure 22. OIL SUMP ASSEMBLY

6-2
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
OIL SUMPANDINDUCTION SYSTEM
INTAKEPIPESANDAIR INLETHOUSING

FIG. QUANTITY
REF. PART PER
23 NUMBER DESCRIPTION ASSEMBLY
1 70485 PIPE,Intake
2 69603 HOSE, 1-3/4 I.D. x 2-3/16O.D.x 1-3/4 long
3 LW-15592-8-28 CLAMP, Hose
4 71973 GASKET, 2 boltflange,1-7/8 I.D.
5 73346 FLANGE, Intakepipe,upper
6 STD-8 WASHER, 1/4 plain
7 STD-160 WASHER, 1/4 internallock
8 STD-1215 BOLT,1/4-20 x 1-1/4 Ig., hex.hd.
9 78366 HEATSHIELD, (1, 2, 4 & 6) intakepipes
10 LW-15592-8-24 CLAMP, 1-13/16dia.x 9/16 wide
11 LW-19108 HOSE, Air inlethousing,2-1/2 I.D.
12 LW-15858-62-294 CLAMP, "T" Bolt
13 77504 GASKET, Fuelinlector
14 LW-19088 HOUSING, Air inlet
15 MS29512-6 "O" RING,15/32 I.D. x 5/64 section
16 AN-893-2 BUSHING, Reducer, 9/16-18to 7/16-20
17 75948 TEE,1/4 tubewithst. threadon side
18 STD-678 WASHER, 3/8 internallock
19 STD-33 WASHER, 3/8 plain
20 LW-38-0.59 BOLT,3/8-16 x 19/32long,hex.hd.(in air inlethsg.)
21 LW-13807 ADAPTER ASSY.,Fueldrainvalve

6-3
LYCOMING T1O-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

4
9
10

-11
13

6
1

21

Figure 23. INTAKE PIPESAND AIR INLET HOUSING

6-4
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
OIL SUMPANDINDUCTION
SYSTEM
FUELINJECTOR,FUELMANIFOLD
ANDAIR BLEEDNOZZLES

FIG. QUANTITY
REF. PART PER
24 NUMBER DESCRIPTION ASSEMBLY

1 66224 GASKET,Fuelinlector
2 LW-19379 FUELINJECTOR, Bendix(2524979-1)
3 STD-35 WASHER, 5/16 plain
4 STD-475 WASHER, 5/16 internallock
5 LW-31-1.25 BOLT,5/16-18x 1-1/4 long,hex.head
6 LW-18854 NOZZLEASSY.,Manifoldair bleed(2524917)
7 75283 MANIFOLD ASSY.,Fuel
8 MS20823-4 ELBOW,1/4 tube to 1/8 NPT,45°
9 STD-148 NIPPLE,
Union,1/8 NPT
10 LW-12604 NIPPLE,
1/8 tubeto 1/8 NPT(restricted)
11 73966 SPACER,Fuelmanifoldbracket
12 73965 BRACKET,Fuelmanifold
13 STD-251 WASHER,No.10 lock,internalteeth
14 STD-82 SCREW,No. 10-24x 1/2 long,hd. dr.
15 LW-12098-0-200 TUBEASSY.,Fuelmanifold to nozzle,cyls.1, 2, 5 & 6
16 LW-12098-0-170 TUBEASSY.,Fuelmanifoldto nozzle,cyls.3 & 4
17 LW-16266-10-75 CLAMP
18 LW-16266-10-13 CLAMP
19 STD-860 SCREW,No.10-32x 5/8 long,fill. hd.
20 STD-425 WASHER,No. 10plain
21 STD-670 NUT,No.10-32self-locking
22 73136 90°
BRACKET,
23 LW-12798-4S-274 HOSEASSY.,Fuelinjectorto fuelmanifold
24 74278 BRACKET ASSY.,Fuellinesupport
25 STD-1891 NUT,Clinch,10-32selflocking
26 LW-16266-10-63 CLAMP,Bracket
27 STD-860 SCREW,No.10-32x 5/8 long,fill. hd.
28 STD-692 SCREW,No. 10-32x 1/2 long,rd. hd.
29 STD-425 WASHER, No.10 plain
30 STD-670 NUT,No. 10-32self locking
31 LW-12799-6S-300 HOSEASSY.,Fuelpumpto inlector
32 LW-16266-25-75 CLAMP,Attachto sump
33 STD-8 WASHER, 1/4 plain
34 STD-1874 SCREW,1/4-20x 13/16 long,fill. head
35 MS20823-3 ELBOW,1/4 tube, 45° , fuel pump vent
36 MS20823-6 ELBOW,3/8 tube, 45° , fuel pump outlet
37 MS20822-6* ELBOW,3/8 flared tube with 1/4 NPT,90° angle

* Assemble
horizontally
infuel pumpinlet.

6-5
 LYCOMING TIO-540-ABIAD
PARTSCATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

36

Figure 24. FUEL INJECTOR, FUEL MANIFOLD AND AIR BLEED NOZZLES
6-6
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
SYSTEM
OIL SUMPANDINDUCTION
NOZZLE
VENTMANIFOLDSANDATTACHMENTS

FIG. QUANTITY
REF. PART PER
25 NUMBER DESCRIPTION ASSEMBLY

1 78109 MANIFOLD, Right(inlectornozzlevent)

2 78110 MANIFOLD, Left(injectornozzlevent)
3 LW-18737 HOSE, 3/16 I.D. x 7/16 O.D.x 2.00 long
4 LW-15592-5-04 CLAMP, 7/16 I.D. x 5/16 wide
5 78127 TUBE,Crossover, inlectornozzleventmanifold
6 STD-2048 HOSE, 1/4 I.D. x 19/32O.D.x 2-7/16 long
7 LW-15592-5-04 CLAMP, 7/16 I.D.x 5/16 wide
8 STD-2049 CLIP,1/4 dia.tubeor 1/4 dia.screw
9 STD-1916 SCREW, 1/4-20 x 1-1/8 long,fill. hd., selflocking
10 STD-2044 NUT,1/4-20self locking
11 LW-16266-25-25 CLAMP
12 78753 BRACKET, Injectornozzleventcrossover
13 STD-692 SCREW, 10-32x 1/2 long,fill. hd.
14 STD-425 WASHER, No.10 plain
15 STD-670 NUT,10-32self locking
16 STD-1339 PLUG,1/16-27NPT,Allen
17 AN815-4 NIPPLE,1/4 tube(between hose& venttube)
18 LW-12784-4-310 HOSEASSY.,(Nozzleventto air inlethousing)
19 LW-16266-25-31 CLAMP, (Attachto bracket)
20 73136 BRACKET, Supportclamp(attachto sump)
21 STD-860 SCREW, 10-32x 5/8 long,fill. hd.
22 STD-425 WASHER, No. 10plain
23 STD-670 NUT,10-32self locking

6-7
LYCOMING TIO-540-ABIAD
PARTSCATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

-17

2-

1
5-

1,19

18 -23

Figure 25. NOZZLE VENT MANIFOLDS AND ATTACHMENTS

6-8
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
ANDEXHAUST
TURBOCHARGER SYSTEMS
EXHAUST
PIPESANDTRANSITION
ASSEMBLY

FIG. QUANTITY
REF. PART PER
26 NUMBER DESCRIPTION ASSEMBLY

1 77611 GASKET,Exhaust flange

2 LW-12728 ADAPTER,Exhaust pipe,cylinderno.2
3 LW-19112 PIPE,Exhaust,
cylinderno. 2
4 LW-19114 PIPE,Exhaust,
cylinderno.4
5 LW-19116 PIPE,Exhaust,
cylinderno.6
6 LW-19111 PIPE,Exhaust,
cylindersno. 1 and3
7 LW-12728 ADAPTER,Exhaust pipe,cylinderno.3
8 LW-19115 PIPE,Exhaust,
cylinderno. 5
9 LW-19276 CROSSOVER, Exhaust pipe,right
10 LW-19239 CROSSOVER, Exhaust pipe,left
11 LW-12093-5* COUPLING,V-Band,2.00tube
12 78084* GASKET,V-Band coupling,2.00tube
13 78064** FLANGE,Exhaust
14 LW-12093-6* COUPLING,V-Band,2-1/4 tube
15 78246** GASKET,V-Bandcoupling,2-1/4 tube
16 STD-2043 NUT,5/16-18self locking
17 LW-19084 TRANSITION,Exhaust
18 STD-1932 BUSHING,1/4 to 1/8 NPT
19 STD-405 PLUG,1/8 NPT,sq. hd.
20 LW-19189 CABLE,Exhaustmanifoldretainer
21 LW-14525 CLAMP, Exhaustpipe
22 STD-1411 NUT,1/4-20 plain
23 STD-705 BOLT,1/4-20x 11/16long,hex.hd.
24 STD-2044 NUT,1/4-20self locking

* Assemble
at crossover
pipe.
** Assemble
at exhaust
transition.

7-1
 LYCOIVIING TIO-540-AB1AD
PARTSCATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

1
20

-14
15

18
1

Figure 26. EXHAUST PIPESAND TRANSITION ASSEMBLY

7-2
 LYCOIVIING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
TURBOCHARGER
ANDEXHAUSTSYSTEMS
TURBOCHARGER,
SUPPORTANDATTACHING
PARTS

FIG. QUANTITY
REF. PART PER
27 NUMBER DESCRIPTION ASSEMBLY

1 LW-19106 BRACKET, Turbocharger mounting

2 STD-33 WASHER, 3/8 plain
3 STD-678 WASHER, 3/8 internallock(bracketto sump)
4 LW-38-2.50 BOLT,3/8-16 x 2-1/2 long,hex.hd. (bracket to sump)
5 LW-38-3.50 BOLT,3/8-16x 3-1/2 long,hex.hd.(bracketto sump)
6 LW-19107 STRUT,Turbocharger, adjustable
7 STD-678 WASHER, 3/8 internallock(strutto sump)
8 STD-1957 BOLT,3/8-16x 1.00long,hex.hd. (strutto sump)
9 LW-19330 TURBOCHARGER (TE0659)
10 AN960C-616 WASHER, 3/8 plain
11 AN6C-13A BOLT,3/8-24 x 1-7/16 long,hex.hd.(turboto transition)
12 AN6C-11A BOLT,3/8-24 x 1-13/64long,hex.hd. (turboto transition)
13 MS20500-624 NUT,3/8-24 selflocking(turboto transition)
14 LW-18861 VALVE,Exhaust bypass
15 72376 ELBOW, 1/4 tube,90° (bypass drain)
16 LW-12125-3 COUPLING, V-Band,2-1/4 O.D.tube
17 75845 GASKET,V-Bandcoupling,2-1/4 O.D.tube
18 LW-19277 HEATSHIELD

7-3
 LYCOIVIING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

13

10

16

14-

-9

10

Figure 27. TURBOCHARGER, SUPPORTAND ATTACHING PARTS

7-4
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
TURBOCHARGERANDEXHAUST
SYSTEMS
DRAINTANK,DENSITY
CONTROLLER
ANDRELATEDPARTS

FIG. QUANTITY
REF. PART PER
28 NUMBER DESCRIPTION ASSEMBLY

1 LW-11999 REDUCER,
7/8-14 to 9/16-18(acc.hsg.-oildrain)
2 74070 ELBOW,3/8 tube, 45° (acc. hsg.-oildrain)
3 LW-10466 ELBOW, 3/16 tubex 1/8 NPT,90° restricted (oil press.gage)
4 LW-12056 SPACER, Oilpressure fitting
5 LW-15596 BOLT,Oilpressure fitting(turbo& wastegateoil supply)
6 AN901-8A GASKET, 3/4 I.D. x 1.00O.D.(turbo& wastegate oil supply)
7 MS20822-4 ELBOW, 1/4 tubex 1/8 NPT,90°
8 LW-12798-4S-313 HOSEASSY.,Spacerto turbooil inlet
9 76734 ZIPSTRAP
10 LW-12690 ELBOW, 90° tubeto malepipe(turbooil inlet)
11 STD-949 BUSHING, 1/8 NPTto 1/4 NPT(in turbooil inletadapt.)
12 75371 GASKET, Turbooil inletadapter
13 76889 ADAPTER, Turbooil inlet
14 STD-33 WASHER, 3/8 plain
15 STD-678 WASHER, 3/8 internallock
16 LW-38-.75 BOLT,3/8-16 x 3/4 long,hex.hd.
17 LW-18038 GASKET, Turbooil drainadapter
18 58B19497 TANKASSY.,Turbooil drain
19 AN816-4 NIPPLE,1/4 tubex 1/8 NPT
20 MS20823-8 ELBOW,1/2 tube x 3/8 NPT,45°
21 STD-33 WASHER, 3/8 plain
22 STD-678 WASHER, 3/8 internallock
23 LW-38-.88 BOLT,3/8-16x 7/8 long,hex.hd.
24 LW-11999 REDUCER, 7/8-14to 33/64-18(in acc.hsg.tankvent)
25 76304 ELBOW, 1/4 tubex 9/16-18,adjustable 45°
26 MS29512-8 "0" RING,41/64 I.D.x 3/32 wall
27 LW-10637 ELBOW, 1/2 tubex 3/4-16,90° (in scavenge pump)
28 LW-12798-4S-274 HOSEASSY.,(Tankto acc. hsg.vent)
29 LW-13176-8S-220 HOSEASSY.,(Tankto scavenge pump)
30 76734 ZIPSTRAP
31 LW-19346 BRACKET, Turbooil draintank
32 LW-19160 SHIELD,Heat,turbooil drain
33 STD-425 WASHER, No. 10plain
34 STD-670 NUT,10-32self locking
35 STD-860 SCREW, 10-32x 5/8 long
36 STD-692 SCREW, 10-32x 1/2 long,roundhd.
37 73314 GASKET, Densitycontroller
38 LW-10682 CONTROLLER, Density
39 STD-28 WASHER, No.10 plain
40 STD-1566 SCREW, 10-24x 3/4 long,fill. hd., dr. hd.
41 STD-1928 SEAL,Wire
42 STD-8 WASHER, 1/4 plain
43 STD-160 WASHER, 1/4 internallock
44 STD-1204 BOLT,1/4-20x 15/16 long,hex.hd. (usedw/diff. cont.bracket)
45 LW-25-.75 BOLT,1/4-20x 3/4 long,hex.hd.
46 MS20822-3 ELBOW, 1/4 tube,90° (fuelpumpvent)
47 LW-12786-3-250 HOSEASSY.,(Fuelpumpventto air inlethousing)

7-5
LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

30
3 9.30

Figure 28. DRAIN TANK, DENSITY CONTROLLERAND RELATEDPARTS

7-6
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE
TURBOCHARGER
ANDEXHAUST
SYSTEMS
DIFFERENTIAL
PRESSURE
CONTROLLER,
HOSESANDRELATED
PARTS

FIG. QUANTITY
REF. PART PER
29 NUMBER DESCRIPTION ASSEMBLY

1 73944 ELBOW, 1/4 tube,adjustable 45° (bypass valveinlet)

2 LW-12798-4S-242 HOSE ASSY.,(Acc.housing to bypassvalveinlet)
3 LW-16266-25-63 CLAMP, Hose(attachto sump)
4 72377 ELBOW, 3/8 tube,adjustable 90° (bypass valve& densityoutlet)
5 LW-12799-6S-222 HOSE ASSY.,(Bypass valveoutletto densityinlet)
6 76355 TEE,3/8 tube,adj.st. thd. onrun (densityinlet)
7 LW-10446 ELBOW, 3/8 tube,90° (ondensityinlettee)
8 LW-12799-6S-082 HOSE ASSY.,(Densityinletto diff. inlet)
9 LW-19109 BRACKET, Differentialpressurecontroller
10 LW-19193 CONTROLLER, Differential
pressure
11 LW-11201 WASHER, 11/16O.D.x 9/32 I.D. x 1/16 thick
12 STD-8 WASHER, 1/4 plain
13 LW-25-.75 BOLT,1/4-20x 3/4 long,hex.hd.
14 STD-1685 NUT,1/4-20selflocking
15 LW-11883 ELBOW, 3/8 tube,adl.90° restricted(diff. controlinlet)
16 AN893-12 BUSHING, Reducer, 1/2 tubeto 3/8 tube(diff. cont.outlet)
17 MS-29512-8 SEAL,Oil,3/32 dia.sect.x 41/64 dia. (diff. cont.outlet)
18 77461 TEE,3/8 tube,adj.st. thd. onside(diff. cont.outlet)
19 LW-12799-6S-110 HOSE ASSY.,(Differentialcontroloutletto densityoutlet)
20 LW-12799-6S-160 HOSE ASSY.,(Differentialcontroloutletto acc.hsg.)
21 STD-949 BUSHING, Reducer, 1/4 to 1/8 NPT(lowpress.portin diff. press.cont.)
22 LW-10466 ELBOW, 3/16 tube,90° (lowpress.portin diff. press.cont.)
23 AN893-2 REDUCER, 9/16 to 7/16 thread
24 MS29512-6 SEAL,Oil,5/64 dia. sect.x 15/32 dia.
25 74200 ELBOW, 3/8 tube,adj. 90° restricted (highpress.port,diff. cont.)
26 LW-12784-4-.060 HOSE ASSY.,(Highpress.portto air inlethousing)
27 LW-162M-10-75 CLAMP, 3/4 I.D. for #10screw(wastegate/cont., fuel/inject.)
28 STD-602 SCREW, 10-32x 1/2 long,rd. hd. (wastegate/cont., fuel/inject.)
29 STD-670 NUT,10-32selflocking(wastegate/cont., fuel/inlect.)
30 LW-12796-3-250 HOSE ASSY.,No.5 cyl. to diff. press.cont.
31 LW-14432 BRACKET
32 LW-16268-10-25 CLAMP, Cushion type
33 STD-800 SCREW, 10-32x 5/8 long,fill. hd.
34 STD-670 NUT,10-32selflocking

7-7
 LYCOMING T10-540-ABIAD
PARTS
CATALOG
WIDE FLANGE
CYLINDER MODEL
CRANKCASE ENGINE

19

8 18
16 15

a
0

Figure 29. DIFFERENTIALPRESSURE

CONTROLLER, HOSESAND RELATEDPARTS
7-8
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
FLANGE
CYLINDER
WIDE MODEL
CRANKCASE ENGINE

SERVICE KIT SECTION

SEAL AND GASKET SET

WIDE CYLINDER FLANGE MODELS
Part No. Part Name Qty.
05K19387 SEAL AND GASKET SET 1
AN-901-8A GASKET 1
MS-16625-1081 RING, Internal retaining 1
MS-16625-1100 RING, Internal retaining 1
MS-29512-8 "O" RING 2
MS-29512-10 SEAL, Oil 2
STD-111 GASKET 1
STD-213 SEAL, Oil 1
STD-294 GASKET, Thermometer plug 1
STD-1045 GASKET 1
STD-2217 SEAL, Oil 1
8313 GASKET, Vac. pump 2
66224 GASKET, Fuel injector 1
69164 GASKET, Fuel pump adapter 1
70310 SEAL, Shroud tube 12
70455 GASKET 1
70457 GASKET, Oil filler ext. 1
71193 BOX 1
71481 RING, Oil seal 6
71973 GASKET, Int. pipe flange 6
72053 GASKET, Governor 1
72091 RING, Oil seal 2
73314 GASKET, Density cont. 1
73383 LOCKPLATE 1
73818 GASKET, Accessory housing 1
74065 "O" RING, Oil level gauge 1
75371 GASKET, Turbo inlet adapter 1
75845 GASKET, V-Band coupling 1
75906 GASKET, Rocker box cover 6
77504 GASKET, Fuel injector 1
77611 GASKET, Exh. flange 12
78084 GASKET, V-Band coupling 1
78246 GASKET, V-Band coupling 1
LW-10332 LOCKPLATE 1
LW-12272 LOCKPLATE, Shroud tube 6
LW-12681 GASKET, Magneto 1
LW-13306 GASKET, Oil sump 1
LW-13792 SEAL, Crankshaft oil 1
LW-14260 SEAL, Oil, tach. shaft 1
LW-14995 SPRING, Shroud tube 6
LW-18038 GASKET, Turbo oil drain adapter 1
LW-18661 SEAL, Shroud tube 12

8-1
 LYCOMING PARTS
T10-540-AB1AD CATALOG
WIDE
CYLINDER
FIANGE
CRANKCASE
MODEL
ENGINE

SERVICE KIT SECTION

CYLINDER, PISTON AND RING KIT

WIDE CYLINDER FLANGE MODELS
Part No. Part Name Qty.
LW-19179 CYLINDER, PISTON AND RING KIT 1
LW-10077 SEAT, Valve spring 1
LW-11775 PLUG, Piston pin 2
LW-11795 SPRING, Valve, auxiliary 2
LW-11800 SPRING, Valve, outer 2
LW-12272 LOCKPLATE, Shroud tube 1
LW-12429* CYLINDER AND HEAD ASSEMBLY 1
LW-12733 PISTON, 3 ring 1
LW-12892 THRUST BUTTON 2
LW-13323 SEAT, Valve spring, lower exh. 1
LW-13790 SHAFT, Valve rocker 1
LW-14077 PIN, Piston 1
LW-14995 SPRING, Shroud tube 1
LW-16475 SEAT, Valve spring 1
LW-18661 SEAL, Shroud tube 2
LW-18790 ROCKER ASSEMBLY, Valve 2
LW-19001 VALVE, Exhaust 1
MS-13997-3 KEY, Valve 2
MS-13998-3 CAP, Valve stem 1
SSP-2272 TAG 1
SSP-2472 TAG 1
STD-1874 SCREW, 1/2-20 x 13/16 long 1
STD-1925 SCREW, 1/4-20 x 5/8 long 5
60009 KEY, Valve 2
60828 PLUG, Piston pin 2
61247 COVER, Rocker box 1
65441 SEAT, Valve spring, lower 1
70310 SEAL, Shroud tube 2
71195 BOX, Set up 1
71481 SEAL, Cylinder base 1
73857 RING, Oil regulator 1
73938 VALVE, Intake 1
74241 RING, Piston 2
75906 GASKET, Rocker box cover 1

* Nitrided cylinder, long reach plug.

8-2
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

NUMERICAL INDEX
PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO.

AN500-10-16 Screw 2-9 LW-12056 Spacer 7-5

AN565B1032H5 Set Screw 1-11 LW-12093-5 Coupling 7-1
AN6-14 Bolt 5-3 LW-12093-6 Coupling 7-1
AN6-16 Bolt 5-3 LW-12098-0-170 Tube Assy. 6-5
AN6-34A Bolt 1-15 LW-12098-0-200 Tube Assy. 6-5
AN6C-11A Bolt 7-3 LW-12125-3 Coupling 7-3
AN6C-13A Bolt 7-3 LW-12186 Nut 3-1
AN8-14A Bolt 1-7 LW-12272 Lockplate 3-5
AN815-4 Nipple 6-7 LW-12429 Cylinder & Head Assy. 3-3
AN816-4 Nipple 7-5 LW-12534 Pump 2-5
AN823-3 Elbow 3-5 LW-12545 Plug 6-1
AN893-2 Bushing 6-3 LW-12589 Insert 2-1
AN893-2 Bushing 7-7 LW-12604 Nipple 6-5
AN893-12 Bushing 7-7 LW-12681 Gasket 4-1
AN901-8A Gasket 7-5 LW-12690 Elbow 7-5
AN931-12S17 Grommet 3-7 LW-12728 Adapter 7-1
AN960C-616 Washer 7-3 LW-12733 Piston 3-1
LW-10077 Seat 3-5 LW-12784-4-.060 Hose Assy. 7-7
LW-10284 Gear 1-7 LW-12784-4-310 Hose Assy. 6-7
LW-10292 Gear Assy. 1-13 LW-12786-3-250 Hose Assy. 7-5
LW-10297 Gear Assy. 1-13 LW-12786-3-250 Hose Assy. 7-7
LW-10299 Shaft 1-13 LW-12798-4S-242 Hose Assy. 7-7
LW-10307 Gear Assy. 2-7 LW-12798-4S-274 Hose Assy. 6-5
LW-10318 Gear Assy. 2-3 LW-12798-4S-274 Hose Assy. 7-5
LW-10320 Sleeve 2-6 LW-12798-4S-313 Hose Assy. 7-5
LW-10321 Spring 2-6 LW-1 2799-6S-082 Hose Assy. 7-7
LW-10324 Gear Assy. 1-13 LW-12799-6S-110 Hose Assy. 7-7
LW-10325 Spacer 1-13 LW-12799-6S-1 60 Hose Assy. 7-7
LW-10329 Shaftgear Assy. 1-13 LW-12799-6S-222 Hose Assy. 7-7
LW-10332 Lockplate 1-7 LW-12799-6S-300 Hose Assy. 6-5
LW-10341 Insert 2-1 LW-12892 Thrust Button 3-5
LW-10344 Body Assy. 2-3 LW-13039 Bracket 5-3
LW- 10442 Gear 1-11 LW-13176-8S-220 Hose Assy. 7-5
LW- 10446 Elbow 7-7 LW-13306 Gasket 6-1
LW-10466 Elbow 7-5 LW-13323 Seat 3-5
LW-10466 Elbow 7-7 LW-13521 Bearing 3-1
LW-10541 Gear Assy. 1-11 LW-13641 Cushion 4-1
LW-10637 Elbow 7-5 LW-13642 Gear 4-1
LW-10682 Controller 7-5 LW-13790 Shaft 3-5
LW-10799 Spacer 2-5 LW-13792 Seal 1-5
LW-10920 Housing Assy. 2-1 LW-13807 Adapter Assy. 6-3
LW-11201 Washer 7-7 LW-13884 Bearing 1-5
LW-11485 Tube 3-5 LW-1 3896 Plug 1-11
LW-11713 Spring 1-5 LW-1 3904 Kit 2-6
LW-11750 Rod Assy. 3-1 LW-1 3905 Oil Filter 2-6
LW-11775 Plug 3-1 LW-1 3923 Bushing 3-1
LW-11795 Spring 3-5 LW-14021 Shaft 1-11
LW-11800 Spring 3-5 LW-14077 Pin 3-1
LW-11883 Elbow 7-7 LW-14260 Seal 2-3
LW-11999 Reducer 7-5 LW-14316 Alternator 5-1

9-1
 LYCOMING TIO-540-ABIAD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

NUMERICAL INDEX (Cont.)

PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO.

LW-14432 Bracket 7-7 LW-19114 Pipe 7-1

LW-14525 Clamp 7-1 LW-19115 Pipe 7-1
LW-14771 Gage Assy. 1-3 LW-19116 Pipe 7-1
LW-14820 Ring 1-7 LW-19160 Shield 7-5
LW-14828 Reducer 2-7 LW-19168 Sump Assy. 6-1
LW-14875 Bracket 4-1 LW-19189 Cable 7-1
LW-14995 Spring 3-5 LW-19193 Controller 7-7
LW-15550 Gerotor 2-9 LW-19239 Crossover 7-1
LW-15571 Starter 5-1 LW-19240 Bracket 6-1
LW-15592-5-04 Clamp 6-7 LW-19276 Crossover 7-1
LW-15592-5-05 Clamp 3-7 LW-19277 Shield 7-3
LW-15592-8-24 Clamp 6-3 LW-19330 Turbocharger 7-3
LW-15592-8-28 Clamp 6-3 LW-19340 Camshaft Assy. 1-9
LW-15858-62-294 Clamp 6-3 LW-19346 Bracket 7-5
LW-15996 Bolt 7-5
LW-16266-10-13 Clamp 6-5 LW-19379 Fuel Injector 6-5
LW-16266-10-25 Clamp 7-7 LW-25-.75 Bolt 7-5
LW-16266-10-63 Clamp 6-5 LW-25-.75 Bolt 7-7
LW-16266-10-75 Clamp 4-1 LW-31-1.16 Bolt 5-1
LW-16266-10-75 Clamp 6-5 LW-31-1.25 Bolt 6-5
LW-16266-10-75 Clamp 7-7 LW-31 H.75 Bolt 5-3
LW-1 6266-25-19 Clamp 4-1 LW-38-0.59 Bolt 6-3
LW-16266-25-25 Clamp 6-7 LW-38-.75 Bolt 7-5
LW-16266-25-31 Clamp 6-7 LW-38-.88 Bolt 7-5
LW-16266-25-63 Clamp 7-7 LW-38-2.50 Bolt 7-3
LW-16266-25-75 Clamp 6-5 LW-38-3.50 Bolt 7-3
LW-16448 Gear Assy. 2-9 LW-382698 Kit 4-1
LW-16475 Seat 3-5 LW-620026-2 Clip 4-1
LW-16711 Bearing 1-5 LW-620028-2 Clip 4-1
LW-17651 Crankshaft & Plug Assy. 1-7 LW-620029-5 Clip 4-1
LW-17680 Crankshaft Assy. 1-7 LW-620029-6 Clip 4-1
LW-18038 Gasket 7-5 LW-620032-7 Clamp 4-1
LW-18661 Seal 3-5 LW-620036-4 Clip 4-1
LW-18667 Pin 1-9 LW-620037-4 Clip 4-1
LW-18737 Hose 6-7 LW-682560-13 Magneto 4-1
LW-18790 Rocker Assy. 3-5 LW-684602-303 Harness 4-1
LW-18854 Nozzle Assy. 6-5 LW-685126-107 Magneto 4-1
LW-18861 Valve 7-3 MS124703 Insert 2-1
LW-1 9001 Valve 3-5 MS13997-3 Key 3-5
LW-19066 Adapter 2-9 MS13998-3 Cap 3-5
LW-19069 Adapter Assy. 2-9 MS16625-1081 Ring 1-9
LW-19068 Drive Assy. 2-9 MS16625-1100 Ring 2-6
LW-1 9084 Transition 7-1 MS20500-624 Nut 7-3
LW-19088 Housing 6-3 MS20822-3 Elbow 7-5
LW-19106 Bracket 7-3 MS20822-4 Elbow 7-5
LW-19107 Strut 7-3 MS20822-6 Elbow 6-6
LW-19108 Hose 6-3 MS20823-3 Elbow 6-6
LW-19109 Bracket 7-7 MS20823-4 Elbow 6-5
LW-19111 Pipe 7-1 MS20823-6 Elbow 6-6
LW-19112 Pipe 7-1 MS20823-6D Elbow 3-3

9-2
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

NUMERICAL INDEX (Cont.)

PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO.

MS20823-8 Elbow 7-5 STD-475 Washer 5-1

MS29512-6 Seal 6-3 STD-475 Washer 6-5
MS29512-6 Seal 7-7 STD-514 Dowel 1-1
MS29512-8 Seal 7-5 STD-551 Plug 6-1
MS29512-8 Seal 7-7 STD-557 Dowel 1-1
MS29512-10 Seal 2-7 STD-596 Nut 1-3
STD-8 Washer 1-15 STD-596 Nut 1-15
STD-8 Washer 2-3 STD-670 Nut 4-1
STD-8 Washer 2-7 STD-670 Nut 6-5
STD-8 Washer 2-9 STD-670 Nut 6-7
STD-8 Washer 4-1 STD-670 Nut 7-5
STD-8 Washer 6-1 STD-670 Nut 7-7
STD-8 Washer 6-3 STD-678 Washer 1-3
STD-8 Washer 6-6 STD-678 Washer 1-15
STD-8 Washer 7-5 STD-678 Washer 6-3
STD-8 Washer 7-7 STD-678 Washer 7-3
STD-19 Dowel 1-11 STD-678 Washer 7-5
STD-28 Washer 7-5 STD-684 Nipple 3-7
STD-33 Washer 1-3 STD-690 Washer 5-3
STD-33 Washer 1-15 STD-692 Screw 4-1
STD-33 Washer 6-3 STD-692 Screw 6-5
STD-33 Washer 7-3 STD-692 Screw 6-7
STD-33 Washer 7-5 STD-692 Screw 7-5
STD-35 Washer 2-3 STD-692 Screw 7-7
STD-35 Washer 2-5 STD-696 Washer 4-1
STD-35 Washer 5-1 STD-705 Bolt 7-1
STD-35 Washer 5-3 STD-713 Pin 5-3
STD-35 Washer 6-5 STD-714 Pin 2-3
STD-82 Screw 6-5 STD-798 Dowel 1-11
STD-95 Key 2-9 STD-860 Screw 6-5
STD-111 Gasket 6-1 STD-860 Screw 6-7
STD-122 Washer 2-9 STD-860 Screw 7-5
STD-148 Nipple 6-5 STD-860 Screw 7-7
STD-160 Washer 1-15 STD-872 Nut 1-15
STD-160 Washer 2-3 STD-872 Nut 5-3
STD-160 Washer 2-7 STD-949 Bushing 7-5
STD-160 Washer 2-9 STD-949 Bushing 7-7
STD-160 Washer 6-1 STD-1045 Gasket 1-5
STD-160 Washer 6-3 STD-1164 Insert 6-1
STD-160 Washer 7-5 STD-1171 Insert 6-1
STD-178 Washer 2-9 STD-1173 Insert 6-1
STD-213 Seal 1-13 STD-1204 Bolt 2-3
STD-251 Washer 6-5 STD-1 204 Bolt 7-5
STD-294 Gasket 2-7 STD-1211 Plug 1-7
STD-405 Plug 7-1 STD-1215 Bolt 2-3
STD-425 Washer 6-5 STD-1215 Bolt 6-3
STD-425 Washer 6-7 STD-1339 Plug 1-1
STD-425 Washer 7-5 STD-1339 Plug 2-1
STD-475 Washer 2-5 STD-1339 Plug 6-7
STD-475 Washer 4-1 STD-1409 Nut 1-15

9-3
 LYCOMING TIO-540-ABIAD CATALOG
PARTS
WIDE FLANGE
CYLINDER MODEL
CRANKCASE ENGINE

NUMERICALINDEX (Cont.)
PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO.

STD-1410 Nut 2-5 25C-12 Stud 2-9

STD-1410 Nut 4-1 25C-14 Stud 6-1
STD-1410 Nut 5-1 25C-19 Stud 2-1
STD-1411 Nut 1-15 25C-39 Stud 2-1
STD-1411 Nut 2-7 31C-12 Stud 1-1
STD-1411 Nut 2-9 31C-12 Stud 2-1
STD-1411 Nut 3-5 31C-12 Stud 3-3
STD-1411 Nut 4-1 31C-13 Stud 1-1
STD-1411 Nut 6-1 31C-13 Stud 2-1
STD-1411 Nut 7-1 31C-16 Stud 1-1
STD-1414 Bolt 1-15 31C-19 Stud 2-1
STD-1416 Bolt 1-15 31CD-20 Stud 2-1
STD-1419 Bolt 1-15 38-13 Stud 1-1
STD-1419 Bolt 6-1 38-15 Stud 6-1
STD-1420 Nut 2-3 38-16 Stud 1-1
STD-1566 Screw 7-5 38-22 Stud 1-1
STD-1646 Bolt 1-15 38D-17 Stud 1-1
STD-1685 Nut 7-7 50-15 Stud 1-1
STD-1688 Bolt 6-1 383-B Nut 3-7
STD-1727 Washer 5-3 1028B Ball 1-5
STD-1737 Ring 2-9 1102 Plug 1-1
STD-1774 Pin 1-13 1102 Plug 3-3
STD-1821 Hose 3-7 1102 Plug 6-1
STD-1838 Bolt 5-3 1182-W5 Spark Plug 4-1
STD-1872 Insert 3-3 1540 Plug 2-7
STD-1874 Screw 3-7 8313 Gasket 2-7
STD-1874 Screw 4-1 8313 Gasket 2-9
STD-1874 Screw 6-6 60009 Key 3-5
STD-1875 Bolt 2-3 60329 Shaft 2-3
STD-1885 Bolt 6-1 60430 Cover 2-7
STD-1891 Nut 6-5 60430 Cover 2-9
STD-1916 Screw 6-7 60803 Strap 1-15
STD-1925 Screw 3-7 61166 Thrust Button 1-13
STD-1925 Screw 4-1 61166 Thrust Button 2-3
STD-1928 Seal 7-5 61166 Thrust Button 2-7
STD-1932 Bushing 7-1 61247 Cover 3-7
STD-1957 Bolt 7-3 61297 Impeller 2-3
STD-2043 Nut 7-1 61298 Impeller 2-3
STD-2044 Nut 6-7 61681 Guide 3-3
STD-2044 Nut 7-1 65007 Retainer 1-1
STD-2048 Hose 6-7 66224 Gasket 6-5
STD-2049 Clip 6-7 66610 Bushing 3-3
STD-2078 Dowel 1-7 68759 Tube Assy. 3-7
STD-2084 Bolt 1-15 68761 Tube Assy. 3-7
STD-2090 Nut 3-7 69159 Adapter Assy. 1-13
STD-2217 Seal 2-7 69164 Gasket 1-13
STD-2217 Seal 2-9 69260 Insert 3-3
25C-9 Stud 3-3 69603 Hose 6-3
25C-11 Stud 6-1 69796 Dowel 1-1
25C-12 Stud 2-1 70310 Seal 3-5

9-4
 LYCOMING TIO-540-AB1AD
PARTSCATALOG
WIDE
CYLINDER CRANKCASE
FLANGE ENGINE
MODEL

NUMERICAL INDEX (Cont.)

PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO.

70455 Gasket 1-11 73944 Elbow 7-7

70457 Gasket 1-3 73965 Bracket 6-5
70474 Washer 2-9 73966 Spacer 6-5
70484 Screen 6-1 73975 Baffle Assy. 3-7
70485 Pipe 6-3 74065 "0" Ring 1-3
71481 Ring 3-7 74070 Elbow 7-5
71596 Washer 2-7 74200 Elbow 7-7
71596 Washer 2-9 74230 Guide 3-3
71610 Hook 3-7 74241 Ring 3-1
71611 Retainer 3-7 74278 Bracket Assy. 6-5
71640 Plug 1-7 74323 Strut 5-3
71651 Fitting 2-7 74494 Plate 3-7
71699 Connection 6-1 74637 Bushing 3-5
71737 Tube Assy. 3-7 74655 Spacer 6-1
71903 Bushing 1-7 74887 Spacer 3-7
71907 Washer 1-7 75061 Bolt 3-1
71973 Gasket 6-3 75283 Manifold Assy. 6-5
72057 Seat 3-3 75339 Baffle Assy. 3-7
72058 Seat 3-3 75371 Gasket 7-5
72060 Bushing 1-7 75380 Link 5-3
72061 Bushing 1-7 75675 Extension 1-3
72062 Bushing 1-7 75845 Gasket 7-3
72091 Ring 1-5 75906 Gasket 3-7
72158 Bushing 1-1 75944 Valve Assy. 2-6
72306 Bracket 1-3 75948 Tee 6-3
72376 Elbow 7-3 76026 Belt 5-1
72377 Elbow 7-7 76118 Spacer 1-9
72566 Gear 1-7 76155 Shaft Assy. 1-9
72797 Roller 1-7 76156 Shield 2-1
72801 Counterweight Assy. 1-7 76220 Stud 1-15
72877 Body 1-5 76304 Elbow 7-5
72965 Roller 1-7 76355 Tee 7-7
73136 Bracket 6-5 76510 Gasket 2-6
73136 Bracket 6-7 76534 Shim 5-3
73249 Washer 1-11 76539 Seat 2-6
73250 Washer 1-11 76734 Zip Strap 4-1
73251 Washer 1-11 76734 Zip Strap 7-5
73252 Washer 1-11 76790 Bracket 1-3
73314 Gasket 7-5 76889 Adapter 7-5
73346 Flange 6-3 77461 Tee 7-7
73383 Lockplate 5-3 77504 Gasket 6-3
73434 Rod Assy. 3-5 77579 Support Assy. 1-7
73435 Rod Assy. 3-5 77611 Gasket 7-1
73436 Rod Assy. 3-5 77808 Valve Assy. 1-5
73437 Rod Assy. 3-5 77872 Bushing 1-11
73772 Nozzle Assy. 1-1 77906 Spacer 3-7
73810 Bushing 1-7 78064 Flange 7-1
73818 Gasket 2-1 78084 Gasket 7-1
73857 Ring 3-1 78109 Manifold 6-7
73938 Valve 3-5 78110 Manifold 6-7

9-5
 LYCOMING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

NUMERICAL INDEX (Cont.)

PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO.

78127 Tube 6-7 78612 Shaft 2-9

78246 Gasket 7-1 78753 Bracket 6-7
78290 Plunger Assy. 3-5 11E20000-D1 Crankcase Assy. 1-1
78366 Shield 6-3 66M19385 Clamp 4-1
78524 Socket 3-5 58B19497 Tank Assy. 7-5

9-6
LYCOMIING TIO-540-AB1AD
PARTS
CATALOG
WIDE
CYLINDER
FLANGE
CRANKCASE
MODEL
ENGINE

Intentionally
Left
Blank