Lycoming Aircraft Engines Parts Catalog

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1 Aircraft Engines Parts Catalog TIO/LTIO-540-V2AD Wide Cylinder Flange Model Part No. PC Oliver Street Williamsport, PA 770

2 Aircraft Engines Parts Catalog TIO/LTIO-540-V2AD Wide Cylinder Flange Model Part No. PC Oliver Street Williamsport, PA 770

4 Lycoming Reciprocating Engine Division/ Subsidiary o Textron Inc. 652 Oliver Street Williamsport, PA 770 U.S.A. TECHNICAL PUBLICATION REVISION REVISION No. PC35-2A ENGINE MODEL TIO/LTIO-540-V2AD PUBLICATION No. PC35-2 PUBLICATION DATE December, 983 The page(s) furnished herewith are intended to replace the corresponding page(s) of the publication indicated above. Remove I Insert December, 983 July, 986-3, -4, 5-2, 5-0, 6-3, 6-4, -3, -4, 5-2, 5-0, 6-3, 6-4, 9-, 9-2, , 9-2, 9-3 Reprinted Jan. 993 Including This Revision

6 INTRODUCTION This illustrated parts catalog contains a complete parts listing for the Lycoming TIO /LTIO-540-V2AD flange model aircraft engines. wide cylinder Major assembly and sub-assembly sequence of engine build up. parts of the engines are listed in the Group Assembly sections in the general 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 Lycoming engines may be found in the appropriate Vendor's Parts Catalog. A list of these publications appear in the latest edition of Service Letter No. L4. NOTE The illustrations, pictures and drawings shown in this publication are typical of the subject matter they portray. This catalog, when used in conjunction with the appropriate overhaul manual, shall be used for parts identification 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 Lycoming accepts responsibility for quality control and/or airworthiness of parts which do not pass through the 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 Lycoming distributors or from the factory by subscription. Consult the latest edition of Service Letter No. L4 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

7 TABLE OF CONTENTS SECTION PAGE Introduction T able of C ontents... ii iii Oversize and Undersize Parts iv. CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP Crankcase Assembly... - Oil Level Gage and Engine Mounting Brackets Crankcase Related Parts Crankshaft and Related Parts Camshaft and Related Parts Propeller Governor Drive Assembly... - Crankshaft and Fuel Pump Idler Gears Crankcase Attaching Parts ACCESSORY HOUSING AND RELATED PARTS Accessory Housing Assembly Oil Pump Assy. and Accessory Housing Attaching Parts Fuel Pump Assemblies Vacuum Pump Drive, Oil Cooler and Breather Fittings Oil Filter Assembly and Oil Cooler Bypass Valve Turbo Scavenge, Vacuum Pump Drive and Covers CYLINDER, PISTON AND VALVE TRAIN Connecting Rods, Pistons and Ring Assemblies Cylinder Assembly V alve A ssem bly Cylinder Related Parts IGNITION SYSTEM Magnetos, Magneto Drives and Spark Plugs ELECTRICAL COMPONENTS Alternator and Belt Starter Motor and Attaching Parts AMP Alternator Mounting and Attaching Parts AMP Alternator Mounting and Attaching Parts AMP Alternator Mounting and Attaching Parts Compressor Mounting, Attachments and Linkage OIL SUMP AND INDUCTION SYSTEM Oil Sump and Induction Housing Assembly Intake Pipes and Air Inlet Housing Fuel Injector, Fuel Manifold and Air Bleed Nozzles Cylinder Head and Manifold Fuel Drains TURBOCHARGER AND EXHAUST SYSTEMS Exhaust Manifold and Transition Assembly Turbocharger, Support and Attaching Parts ii

8 T0/LT0-540-V2AD PARTS CATALOG TABLE OF CONTENTS (Cont.) SECTION PAGE 7. TURBOCHARGER AND EXHAUST SYSTEMS (Cont.) Turbocharger Tank Assembly, Hoses and Related Parts Intercooler Assembly and Related Parts SERVICE KIT SECTION NUMERICAL INDEX iii

9 TIO/LT0-540-V2AD PARTS CATALOG Oversize and Undersize Parts Listing PART NO S S S LW-2688 LW-322 LW-3885 LW-4830 LW-5628 LW-8856 STD-2078 DESCRIPTION BUSHING INSERT DOWEL SEAT BUSHING, COUNTERWEIGHT BUSHING BUSHING RING RING BUSHING GUIDE BUSHING SEAT BEARING BEARING BEARING SEAL GUIDE DOWEL P02 P OVERSIZE P0 P5 P UNDERSIZE P30 P40 P50 M03 M06 M SEE LATEST EDITION OF SERVICE INSTRUCTIONO. 43 FOR APPLICATION. SEE LATEST EDITION OF SERVICE INSTRUCTIONO. 42 FOR APPLICATION. Studs available in P03, P07 and P2. * Also available in P0 oversize. 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 LW-3885 in.003 undersize, order part number LW-3885-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. iv

11 CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP CRANKCASE ASSEMBLY FIG. REF. LW C-2 3 3C D STD STD STD C PART NUMBER DESCRIPTION CRANKCASE ASSEMBLY STUD, 5/6-8 x -/2 long STUD, 5/6-8 x -5/8 long STUD, 3/8-6 x -5/8 long STUD, 3/8-6 x 2.00 long STUD, 3/8-6 x 2-3/4 long STUD, 3/8-6 x 2-/8 long, drilled STUD, /2-3 x -7/8 long STUD, 0-32 x.00 long DOWEL, /2 dia. x /6 long, hollow PLUG, /8 pipe x 3/8 long RETAINER, Shroud tube seal PLUG, /6-27 pipe, Allen head DOWEL, Crankshaft bearing DOWEL, 5/6 dia. x /2 long BUSHING, Governor drive idler shaft STUD, 3/8-6 x -5/8 long STUD, 3/8-6 x -7/8 long STUD, 5/6-8 x 2-/4 long NOZZLE ASSY., Piston cooling NIPPLE, 3/8 tube QUANTITY PER ASSEMBLY * Install in left case at top and lower front position of front pad. ** Install at front pads. -

12 7 Figure. CRANKCASE ASSEMBLY -2

13 CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP OIL LEVEL GAGE AND ENGINE MOUNTING BRACKETS FIG. QUANTITY REF. DESCRIPTION PER 2 ASSEMBLY LW-848 GASKET, Oil filler adapter 2 LW-8482 ADAPTER. Oil fillter tube 3 STD-28 WASHER, #0 plain 4 STD-25 WASHER, #0 internal lock 5 STD-63 NUT plain GASKET. Oil filler extension EXTENSION, Oil filler GASKET, Oil filler extension "0" RING, Oil level gauge EXTENSION, Oil filler GAUGE ASSY., Oil level 2 LW-4688 BRACKET, Engine mounting (Dynafocal), bottom 3 LW-8626 BRACKET ASSY., Engine mounting, upper left 4 STD-7 INSERT, 3/8-6 Heli-Coil x 3/4 long 5 LW-8624 BRACKET ASSY., Engine mounting, upper right 6 STD-7 INSERT, 3/8-6 Hell-Coil x 3/4 long 7 STD-33 WASHER. 3/8 plain 8 STD-678 WASHER. 3/8 internal lock 9 STD-596 NUT, 3/8-24 plain 20 STD-33 WASHER, 3/8 plain (assemble between lifting eye and engine mount) 2 LW-8760 EYE. Lifting (rear) 22 STD-678 WASHER. 3/8 internal lock 23 STD-275 BOLT. 3/8-6 x -/8 long, hex. head -3

14 Figure 2. OIL LEVEL GAGE AND ENGINE MOUNTING BRACKETS -4

15 FIG. REF B 2 LW-73 3 STD LW LW LW CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP CRANKCASE RELATED PARTS DESCRIPTION BALL. /6 dia. SPRING. Oil pressure relief valve GASKET, -/4 I.D. x -/2 O.D. x 3/32 annular VALVE ASSY., Oil pressure relief, adjustable BEARING. Crankshaft BEARING, Crankshaft (front) SEAL, Crankshaft, oil RING. Oil seal, 23/64 I.D. x 7/64 dia. BODY, Hydraulic tappet QUANTITY PER ASSEMBLY -5

16 Figure 3. CRANKCASE RELATED PARTS -6

17 CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP CRANKSHAFT AND RELATED PARTS FIG. REF. 4 LW-7790 LW LW-7765 LW STD STD LW LW LW AN8-4A * * 77579* * 23 LW * 25 LW-572'* PART NUMBER 26 LW-055"* 27 LW-8679** 28 LW-055** DESCRIPTION CRANKSHAFT AND COUNTERWEIGHT ASSEMBLY CRANKSHAFT AND COUNTERWEIGHT ASSEMBLY CRANKSHAFT AND PLUG ASSEMBLY CRANKSHAFT AND PLUG ASSEMBLY PLUG, 2.00 dia. expansion BUSHING. Crankshaft dynamic counterweight PLUG, -/4 diameter BUSHING. Propeller flange, long BUSHING, Propeller flange, short BUSHING. Propeller flange, indexing DOWEL. 3/8 0.D. x /2 long COUNTERWEIGHT ASSEMBLY BUSHING. Dynamic counterweight ROLLER, Dynami counterweight. 6.3 order ROLLER, Dynami counterweight, 5 order RING, Internal retaining WASHER. Dynami counterweight GEAR. Crankshaft LOCKPLATE. Crankshaft gear BOLT. /2-20 x -9/32 long SUPPORT ASSY.. Starter ring gear, 2/4 pitch. with de-icing provision (standard rotation) GEAR. Starter ring. 2/4 pitch SUPPORT ASSY. Starter ring gear, 2/4 pitch, without de-icing provision (standard rotation) GEAR. Starter ring, 2/4 pitch SUPPORT ASSY, Starter ring gear, 2/4 pitch, 24V -00 Amp. alternator (standard rotation) GEAR, Starter ring, 2/4 pitch SUPPORT ASSY.. Starter ring gear, 2/4 pitch. 24V -00 Amp. alternator (reverse rotation) GEAR, Starter ring, 2/4 pitch SUPPORT ASSY, Starter ring gear, 2/4 pitch, 24V.-70 Amp alternator (reverse rotation) GEAR. Starter ring, 2/4 pitch QUANTITY PER * Used on TIO-540-V2AD engines ** Used on LTIO-540-V2AD engines -7

18 Figure 4. CRANKSHAFT AND RELATED PARTS -8

19 Lycomlng CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP CAMSHAFT AND RELATED PARTS FIG. REF ' LW-220** MS DESCRIPTION CAMSHAFT CAMSHAFT (Reverse rotation) SHAFT ASSY.. Tachometer PIN, 3/6 x 2-2/64 long SPACER. Tachometer shaft centering RING. Internal retaining QUANTITY PER ASSEMBLY * Used on TIO-540-V2AD engines ** Used on LTIO-540-V2AD engines. -9

20 Lycomlng 5 Figure 5. CAMSHAFT AND RELATED PARTS -0

21 CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP PROPELLER GOVERNOR DRIVE ASSEMBLY FIG. REF DESCRIPTION LW-0442 GEAR, Governor drive LW-402 SHAFT, Propeller governor idler gear LW-054 GEAR ASSY., Propeller governor idler BUSHING, Propeller governor idler gear STD-9 DOWEL, 3/32 dia. x 7/32 long STD-798 DOWEL, 3/32 dia. x 9/32 long WASHER, Thrust WASHER, Thrust 7325 WASHER, Thrust WASHER, Thrust AN565B032H5 SET SCREW, No. 0/32 x 5/6 long GASKET, 25/32 I.D. x -/8 0.D. x /6 thick LW-3896 PLUG, 3/4-6 hex. hd. QUANTITY PER ASSEMBLY --

22 Figure 6. PROPELLER GOVERNOR DRIVE ASSEMBLY -2

23 Lycomlng CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP CRANKSHAFT AND FUEL PUMP IDLER GEARS FIG. REF. 7 PART NUMBER DESCRIPTION QUANTITY PER ASSEMBLY LW LW LW LW STD STD-23 9 LW LW-0299 LW LW GEAR ASSY., Crankshaft idler, plain SHAFT, Crankshaft idler gear GEAR ASSY., Crankshaft idler (heavy) SPACER, Idler gear GASKET, Fuel pump adapter ADAPTER ASSY., Fuel pump drive PIN, /8 dia. x /4 long SEAL, Oil, 3/4 I.D. x -3/8 O.D. GEAR ASSY., Fuel pump idler SHAFT, Crankshaft idler gear SPACER, Idler gear SHAFTGEAR ASSY., Fuel pump drive THRUST BUTTON Revised July, 986-3

24 Figure 7. CRANKSHAFT AND FUEL PUMP IDLER GEARS -4 Revised July, 986

25 CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP CRANKCASE ATTACHING PARTS FIG. REF. 8 PART NUMBER DESCRIPTION QUANITITY PER ASSEMBLY LW STD STD-44 5 STD-49 6 STD-8 7 STD-60 8 STD-4 9 STD-46 0 STD-8 STD STD-33 3 STD AN6-34A 5 STD-33 6 STD STD STD-646 STRAP, Lifting BOLT, /4-20 x 2-/4 long, hex. head BOLT, /4-20 x -3/4 long, hex. head BOLT, /4-20 x -/2 long, hex. head BOLT, /4-20 x -/8 long, hex. head WASHER, /4 plain WASHER, /4 internal lock NUT, /4-20 plain BOLT, /4-20 x -/2 long, hex. head, drive end WASHER, /4 plain (maximum 6) NUT, /4-20, slotted shear WASHER, 3/8 plain NUT, 3/8-24 slotted BOLT, 3/8-24 x 3-37/64 long, hex. head WASHER, 3/8 plain (2 req. under head of AN6-34A) WASHER, 3/8 internalock NUT, 3/8-24 plain STUD, /2-20 x 0-45/64 long BOLT, /4-20 x 2.00 long, hex. hd. -5

26 0 co : Figure 8. CRANKCASE ATTACHING PARTS -6

27 ACCESSORY HOUSING AND RELATED PARTS ACCESSORY HOUSING ASSEMBLY FIG. REF LW-0909 LW C C-2 PART NUMBER 5 25C-9 6 3C-9 7 3CD C STD-339 LW MS LW-2589 DESCRIPTION GASKET. Accessory housing HOUSING ASSEMBLY. Accessory HOUSING ASSEMBLY, Accessory STUD. /4-20 x 4-7/8 long STUD. /4-20 x -/2 long STUD. /4-20 x 2-3/8 long STUD. 5/6-8 x 2-3/8 long STUD. 5/6-8 x 2-/2 long, drilled STUD, 5/6-8 x -5/8 long, (Mag. pad) SHIELD. Oil accessory breather PLUG. /6 NPT Allen head INSERT Hell-Coil x 3/8 long INSERT. 3/4-6 Heli-Coil x -/8 long INSERT. 5/8-8 Heli-Coil x 3/8 long QUANTITY PER * Used on TIO-540-V2AD engines Used on LTIO-540-V2AD engines. 2-

28 Lycomlng WIDE CYLIINDER FLANGE CRANKCASE MODEL ENGINE Figure 9. ACCESSORY HOUSING ASSEMBLY 2-2

29 ACCESSORY HOUSING AND RELATED PARTS OIL PUMP ASSEMBLY AND ACCESSORY HOUSING ATTACHING PARTS TIO/LT0-540-V2AD PARTS CATALOG FIG. QUANTITY REF. DESCRIPTION PER 0 ASSEMBLY LW-0344 BODY ASSY., Oil pump LW-253 BODY ASSY., Oil pump SHAFT, Oil pump idler 3 STD-74 PIN, /8 dia. x.00 long, cotter 4 STD-768' PLUG. 43/64 dia. x 9/32 long 5 LW-038 GEAR ASSY., Oil pump drive THRUST BUTTON, Oil pump drive gear IMPELLER, Oil pump. driving IMPELLER. Oil pump. driving 9 STD-35 WASHER. 5/6 0 STD-420 NUT, 5/6-8 slotted STD-69 BOLT, 5/6-8 x 2 00 long. hex. hd., drilled 2 STD-229* BOLT. 5/6-8 x 2-/2 long, hex. hd.. drilled 3 LW-4260 SEAL, Tachometer drive, oil 4 STD-8 WASHER, /4 plain 5 STD-60 WASHER, /4-20 lock, internal teeth 6 STD-204 BOLT. /4-20 x 5/6 long, hex. hd 7 STD-25 BOLT. /4-20 x -/4 long, hex. hd 8 STD-875 BOLT. /4-20 x 3/6 long, hex hd. Used on TIO-540-V2AD engines. Used on LTIO-540-V2AD engines 2-3

30 Figure 0. OIL PUMP ASSEMBLY AND ACCESSORY HOUSING ATTACHING PARTS 2-4

31 Lycomlng FIG. REF. PART NUMBER LW LW-8536* LW-8589** 3 LW-3920* LW-5740* 4 LW-87 5 MS STD-35 8 STD STD-40 0 LW LW S-30 ACCESSORY HOUSING AND RELATED PARTS FUEL PUMP ASSEMBLIES DESCRIPTION SPACER. Fuel pump insulating PUMP ASSY.. Fuel PUMP ASSY, Fuel PUMP. Fuel (RG9080-J7A) PUMP, Fuel (RG9080-J8A) ELBOW. Tube to male pipe (inlet) ELBOW, 3/8 tube x /2 NPT, 90 (outlet) ELBOW. /4 tube x /8 NPT, restricted WASHER. 5/6 plain WASHER, 5/6 internal lock NUT. 5/6-8 plain HOSE ASSY., Fuel pump to vent HOSE ASSY, Fuel pump to injector QUANTITY PER ASSEMBLY * Used on TIO-540-V2AD engines. " Used on LTIO-540-V2AD engines. 2-5

32 4-7 0 Figure. FUEL PUMP ASSEMBLIES 2-6

33 ACCESSORY HOUSING AND RELATED PARTS VACUUM PUMP DRIVE, OIL COOLER AND BREATHER FITTINGS FIG. REF. 2 PART NUMBER LW STD STD-8 8 STD-60 9 STD-4 0 LW-8575 AN MS DESCRIPTION GEAR ASSY., Accessory housing THRUST BUTTON, Vacuum pump gear WASHER, Accessory drive gear SEAL, Oil 7/8 I.D. x -/2 0.D. x 5/6 GASKET, Vacuum pump COVER, Vacuum pump WASHER, /4 plain WASHER. /4 lock, internal teeth NUT. /4-20 plain NIPPLE. Hose, 3/4 tube (short) NIPPLE. 7/8-4 x /2 tube (oil cooler) SEAL. Oil. 3/4 0.D. x 7/64 section QUANTITY PER 2-7

34 TIO/LT0-540-V2AD PARTS CATALOG 9 2 Figure 2. VACUUM PUMP DRIVE, OIL COOLER AND BREATHER FITTINGS 2-8

36 ACCESSORY HOUSING AND RELATED PARTS OIL FILTER ASSEMBLY AND OIL COOLER BYPASS VALVE WIDE CYLINDER FLANGE CRANKCASE MODEL ENIGINE FIG. REF PART NUMBER LW LW-0320 MS LW-3904 LW DESCRIPTION SPRING, Oil filter bypass valve SEAT, Oil relief valve SLEEVE, Oil filter bypass valve RING, Internal retaining KIT, Converter plate, oil filter OIL FILTER, Long, spin-on type (Champion) VALVE ASSY., Temperature control GASKET, Valve assembly QUANTITY PER ASSEMBLY 8 Figure 3. OIL FILTER ASSEMBLY AND OIL COOLER BYPASS VALVE 2-9

37 ACCESSORY HOUSING AND RELATED PARTS TURBO SCAVENGE, VACUUM PUMP DRIVE AND COVERS FIG. REF. 4 PART NUMBER LW LW-5580 LW LW-5579 LW C-2 7 STD STD-95 0 LW-5550 MS LW-5568 LW STD AN STD-22 7 STD-78 8 STD STD-8 20 STD-60 2 STD STD-8 25 STD STD-4 DESCRIPTION GEAR ASSY., Accessory driven WASHER, Accessory driven gear GASKET, Turbo scavenge and vacuum pump drive DRIVE ASSY., Turbo scavenge and vacuum pump DRIVE ASSY., Turbo scavenge and vacuum pump ADAPTER ASSY., Vacuum pump ADAPTER ASSY., Vacuum pump STUD, /4-20 x -/2 long DOWEL, Oil, 3/6 I D. x /2 long SHAFT, Pump KEY, /8 x /2, Woodruff PUMP, Gerotor RING, Oil seal, 7/32 I.D. x /6 dia. ADAPTER, Turbo scavenger pump ADAPTER, Turbo scavenger pump WASHER, Retaining, pump drive shaft RING, External.retaining, 9/6 dia. SCREW, No. 0/24 x -/8 long, fill. hd. WASHER, 3/64 I.D. x 5/6 O.D. WASHER, No. 0 spring lock OIL SEAL, 7/8 I.D. x -/2 O.D. WASHER, /4 plain WASHER, /4 internal lock NUT, /4-20 plain GASKET, Pump COVER, Pump WASHER, /4 plain WASHER, /4 internal lock NUT, /4-20 plain QUANTITY PER ASSEMBLY * Used on TIO-540-V2AD engines. Used on LTIO-540-V2AD engines. 2-0

38 N Figure 4. TURBO SCAVENGE, VACUUM PUMP DRIVE AND COVERS 2-

39 CYLINDER, PISTON AND VALVE TRAIN CONNECTING RODS, PISTONS AND RING ASSEMBLIES FIG. REF. 5 LW LW LW LW LW-322 LW-3209 LW LW LW PART NUMBER DESCRIPTION CONNECTING ROD ASSEMBLY BUSHING, Connecting rod, upper BOLT, Connecting rod NUT, Connecting rod bolt BEARING, Connecting rod BEARING, Connecting rod (alternate) BEARING. Connecting rod (alternate) PISTON, Compression ratio, 7.30: (finned) PIN, Piston PLUG, Piston pin RING, Piston, top compression RING, Piston, oil regulating (expander type) QUANTITY PER ASSEMBLY 3-

40 Figure 5. CONNECTING RODS, PISTONS AND RING ASSEMBLIES 3-2

41 CYLINDER, PISTON AND VALVE TRAIN CYLINDER ASSEMBLY FIG. REF. 6 LW-8852' 2 LW LW C C-8 AN STD-48 PART NUMBER DESCRIPTION CYLINDER AND HEAD ASSEMBLY SEAT, Intake valve SEAT, Exhaust valve GUIDE, Valve intake GUIDE, Valve exhaust (Ni-Resist) INSERT, Spark plug, 8-.5 MM (long reach) INSERT, Heli-Coil, /4-20 x 3/8 long (self-locking) STUD, /4-20 x -/4 long BUSHING, Rocker shaft STUD, /4-20 x -/8 long NIPPLE, 3/8 tube x /4 NPT NIPLE, Union, /8 tube (fuel drain) QUANTITY PER ASSEMBLY * Nitrided cylinder, long reach plug. 3-3

42 Lycomlng Figure 6. CYLINDER ASSEMBLY 3-4

43 CYLINDER, PISTON AND VALVE TRAIN VALVE ASSEMBLY FIG. REF. 7 LW LW LW LW LW LW LW MS MS LW LW LW STD-4 9 LW * 73464* 73465* 73466* 22 LW LW-665 PART NUMBER DESCRIPTION VALVE, Intake, hollow stem (rotator type) VALVE, Exhaust (rotator type) SPRING, Valve, inner SPRING, Valve, outer SEAT, Valve spring, lower intake SEAT, Valve spring, lower exhaust SEAT, Valve spring, upper intake (rotator) SEAT, Valve spring, upper exhaust (rotator) KEY, Valve intake (rotator) CAP, Valve stem intake (rotator) KEY, Valve exhaust (rotator) CAP, Valve stem, exhaust (rotator) PLUNGER ASSY., Hydraulic tappet SOCKET, Push rod, hydraulic tappet TUBE, Shroud, push rod SPRING, Shroud tube LOCKPLATE, Shroud tube NUT, /4-20 plain SEAL, Shroud tube SEAL, Shroud tube ROD ASSY., Push ROD ASSY., Push ROD ASSY., Push ROD ASSY., Push ROCKER ASSY., Valve BUSHING, Valve rocker WASHER, Valve rocker thrust SHAFT, Valve rocker THRUST BUTTON, Rocker shaft QUANTITY PER ASSEMBLY * See latest edition of Lycoming Service Instruction No. 060 for complete push rod application. 3-5

44 N T Figure 7. VALVE ASSEMBLY 3-6

45 CYLINDER, PISTON AND VALVE TRAIN CYLINDERELATED PARTS FIG. REF. 8 PART NUMBER LW STD B STD STD STD LW LW LW LW LW STD-8 23 STD-925 DESCRIPTION GASKET, Cover, valve rocker shaft COVER, Valve rocker shaft SCREW, /4-20 x 5/8 long, self-sealing GASKET, Rocker box cover COVER ASSY., Rocker box SCREW, /4-20 x /6 long, pan hd. (self-locking) RING, Oil seal, 3/32 dia. sect. x 4-27/32 I.D. SPACER, 33/64 I.D. x 7/8 O.D. x 3/8 thick (front) SPACER, 33/64 I.D. x 7/8 O.D. x /8 thick (rear) NUT, 3/8-24 plain NUT, /2-20 plain PLATE, Caution, spark plug reach NIPPLE, Straight, 3/8 I.D. hose HOSE, 3/8 I.D. x -3/6 long CLAMP, Hose TUBE ASSY., Cyl. head oil drain, cyl. no. TUBE ASSY., Cyl. head oil drain, cyl. no. 2 TUBE ASSY., Cyl. head oil drain, cyls. no. 3, 4, 5, 6 BAFFLE ASSY., Intercylinder HOOK, Intercylinder baffle retainer RETAINER, Intercylinder baffle WASHER, /4 plain SCREW, /4-20 x 5/8 long, pan hd. (self-locking) QUANTITY PER ASSEMBLY 3-7

46 ,7, 9 Figure 8. CYLINDER RELATED PARTS 3-8

47 IGNITION SYSTEM MAGNETOS, MAGNETO DRIVES AND SPARK PLUGS T0/LTIO-540-V2AD PARTS CATALOG FIG. REF. 9 PART NUMBER LW LW LW LW LW * 6 LW LW ** 8 LW LW LW-8378 STD STD-40 3 STD STD LW LW STD-33 8 MS AN LW LW MS STD U5t 26 LW LW DESCRIPTION GEAR, Retainer, magneto drive CUSHION, Magneto drive GASKET, Magneto MAGNETO, Ignition system (D6LN-3230) MAGNETO, Ignition ( retard), rotation (CCW) HARNESS, Ignition MAGNETO, Ignition system (D6RN-3230) MAGNETO, Ignition ( retard), rotation (CW) HARNESS, Ignition CLAMP, Magneto WASHER, 5/6 internal lock NUT, 5/6-8 plain SCREW, /4-20 x 5/8 long, pan hd. (self-locking) WASHER, 3/8 dia. seal ADAPTER, Magneto pressurization NUT, 3/8-6 plain WASHER, 3/8 plain ELBOW, /4 tube x /8 NPT, 90 NIPPLE, /4 tube x /8 NPT HOSE ASSY., Magneto pressurization adapter ZIP STRAP VALVE ASSY., Relief SEAL, Oil, 5/64 dia. sect. x 23/64 I.D. HOSE, Split SPARK PLUG (Champion RHB-32E) long reach KIT, Magneto ground terminal KIT, Magneto retard terminal QUANTITY PER * Used on TIO-540-V2AD engines. ** Used on LTIO-540-V2AD engines. t Item No. 25 spark plug is used in current production only. Additional spark plugs are available for this engine. See latest edition of Lycoming Service Instruction No. 042 for complete listing of all approved spark plugs. NOTE Individual spark plug leads may be replaced by ordering either (2B, 4B, 5B, 6B, 2T, 4T, 5T, 6T) or (B, 3B, T, 3T). Replacement elbow is P/N or

48 3-4,5,7, Figure 9. MAGNETOS, MAGNETO DRIVES AND SPARK PLUGS 4-2

49 ELECTRICAL COMPONENTS ALTERNATOR AND BELT FIG. REF. 20 LW LW-4325* 3 LW LW * LW-097 DESCRIPTION ALTERNATOR, 24 volt, 70 AMP, externally grounded (ALU-842) ALTERNATOR, 24 volt, 70 AMP, externally grounded (ALU-842), with thermocouples ALTERNATOR ASSY., 24 volt, 00 AMP ALTERNATOR, 24 volt, 00 AMP (ALV-8402-L) PULLEY, Alternator, dual belt BELT, Alternator drive, 3/8 wide BELT, Alternator drive, 3/8 wide, w/idler pulley BELT, Alternator, dual idler (2 matched belts) QUANTITY PER * Used on TIO-540-V2AD engines only. NOTE See latest edition of Lycoming Service Instruction No. 54 for complete listing of FAA approved starters, generators, alternators, regulators and relays Figure 20. ALTERNATOR AND BELT 5-

50 Lycomlng FIG. REF. 2 PART NUMBER LW-5572* LW-424** 2 STD-35 3 STD STD STD-40 ELECTRICAL COMPONENTS STARTER MOTOR AND ATTACHING PARTS DESCRIPTION STARTER, 24 volt (3.38: internal reduction) (2/4 p. pinion) (MHB-406) STARTER, 24 volt. 3.38: ratio - 2/4 pitch (MHB-404) WASHER, 5/6 plain WASHER, 5/6 internal lock BOLT. 5/6-8 x -5/32 long, hex. hd. NUT. 5/6-8 plain QUANTITY PER ASSEMBLY * Used on TIO-540-V2AD engines ** Used on LTIO-540-V2AD engines. NOTE See latest edition of Avco Lycoming Service Instruction No. 54 for complete listing of FAA approved starters, generators, alternators. regulators and relays. - Figure 2. STARTER MOTOR AND ATTACHING PARTS 5-2 Revised July, 986

51 ELECTRICAL COMPONENTS 00 AMP ALTERNATOR MOUNTING AND ATTACHING PARTS FIG. REF. 22 LW-44 2 LW STD LW-47 6 STD LW LW STD LW MS LW STD STD STD STD LW LW LW-3H LW-4650* 25 AN STD AN STD AN STD AN STD-76 DESCRIPTION BRACKET, Alternator, front BRACKET, Alternator, rear LOCKPLATE, 5/6 bolt x.00 spacing BOLT, 5/6-8 x 5/6 long, hex. hd. BRACKET, Alternator belt adjusting WASHER, Plain 3/4 0.D. x /32 I.D. x /8 thick SHIM, 3/6 O.D. x /32 I.D. x.005 thick SHIM, 3/6 O.D. x /32 I.D. x.00 thick BOLT, 5/6-8 x -7/32 long, hex. hd., drilled PULLEY & SHAFT ASSY., Alternator dual belt adjusting PULLEY, Alternator idler, dual BALL BEARING, Double row, alt. idler pulley RING, Internal retaining, -/4 diameter SHAFT, Alternator dual belt idler LOCKWASHER, Alternator idler pulley bearing LOCKNUT, Alternator idler pulley bearing WASHER, 33/64 I.D. x.00 O.D. x /8 thick NUT, /2-20, self-locking, 39/64 thick WASHER, Plain 3/4 0.D. x /32 I.D. x /8 thick BOLT, 5/6-8 x -7/32 long, hex. hd., drilled SHIM, 3/6 O.D. x /32 I.D. x.005 STRUT, Alternator support BOLT, 5/6-8 x 3/4 long, hex. hd., drilled SHIM, 7/8 0.D. x 5/32 I.D. x.005 thick BOLT, 7/6-20 UNF-3A x -9/32 long, drilled end WASHER, 7/6 plain NUT, 7/6-20 plain, slotted PIN, Cotter, 3/32 dia. x.00 long BOLT, 7/6-20 UNF-3A x -/32 long, drilled end WASHER, 7/6 plain NUT, 7/6-20 plain, slotted PIN, Cotter 3/32 dia. x.00 long QUANTITY PER ASSEMBLY * Shim as required for belt alignment between crankcase idler adjusting bracket, alternator and alternator bracket. 5-3

52 Figure AMP ALTERNATOR MOUNTING AND ATTACHING PARTS 5-4

53 FIG. REF. 23 PART NUMBER STD STD LW-4637* 7 LW-4649* 8 STD MS STD STD STD LW-4637* 20 STD LW STD AN STD STD AN STD STD STD-73 ELECTRICAL COMPONENTS ALTERNATOR MOUNTING AND ATTACHING PARTS (70 AMP-WITH IDLER PULLEY BELT ADJUSTMENT) DESCRIPTION BRACKET, Alternator LOCKPLATE, 5/6 bolt x.00 spacing BOLT, 5/6-8 x 5/6 long, hex. hd. BRACKET, Alternator belt adjusting WASHER, Plain, 3/4 O.D. x /32 I.D. x /8 thick SHIM, 3/6 O.D. x /32 I.D. x.005 SHIM, 3/6 O.D. x /32 I.D. x.00 BOLT, 5/6-8 x -7/32 long, hex. hd., drilled PULLEY & SHAFT ASSY., Alternator belt adjusting PULLEY, Alternator belt adjusting BALL BEARING, Alternator idler pulley RING, Internal retaining, -/8 dia. SHAFT, Idler, alternator belt adjusting LOCK WASHER, Alternator idler pulley bearing LOCKNUT, Alternator idler pulley bearing WASHER, 33/64 I.D. x.00 O.D. x /8 thick NUT, /2-20 self-locking, 39/64 thick WASHER, Plain, 3/4 O.D. x /32 I.D. x /8 thick SHIM, 3/6 O.D. x /32 I.D. x.005 thick BOLT, 5/6-8 x -7/32 long, hex. hd., drilled SHIM, 3/6 O.D. x 3/32 I.D. x.005 WASHER, 3/6 O.D. x 25/64 I.D. x /6 thick BOLT, 3/8-24 x -2/64 long, hex. hd., drilled end NUT, 3/8-24, slotted PIN, Cotter, 3/32 dia. x 3/4 long SHIM, -/8 O.D. x 3/32 I.D. x.005 thick BOLT, 3/8-24 x -53/64 long, hex. hd., drilled end WASHER, 3/60.D. x 25/64 I.D. x /6 thick NUT, 3/8-24, slotted PIN, Cotter, 3/32 dia. x 3/4 long QUANTITY PER ASSEMBLY * Shim as required for belt alignment between crankcase idler adlusting bracket, alternator and alternator bracket. 5-5

54 Lycomlng Figure 23. ALTERNATOR MOUNTING AND ATTACHING PARTS (70 AMP-WITH IDLER PULLEY BELT ADJUSTMENT) 5-6

55 FIG. REF. 24 LW STD STD-35 6 LW-3H.75 7 STD LW-3H LW-3H.75 STD AN6-4 3 STD STD STD-73 6 AN STD STD STD-73 ELECTRICAL COMPONENTS ALTERNATOR MOUNTING AND ATTACHING PARTS (70 AMP-WITHOUT IDLER PULLEY BELT ADJUSTMENT) DESCRIPTION BRACKET, Alternator LOCKPLATE, 5/6 bolt x.00 spacing BOLT, 5/6-8 x 5/6 long, hex. hd. LINK, Alternator adjusting WASHER, 5/6 plain BOLT, 5/6-8 x 3/4 long, hex. hd. drive WASHER, Plain, 3/4 0.D. x /32 I.D. x /8 thick BOLT, 5/6-8 x 3/4 long, hex. hd. drive STRUT, Alternator support BOLT, 5/6-8 x 3/4 long, hex. hd. drive WASHER, 3/6 O.D. x 25/64 I.D. x /6 thick BOLT, 3/8-24 x -37/64 long, hex. hd., drilled end WASHER, 3/6 O.D. x 25/64 I.D. x /6 thick NUT, 3/8-24, slotted PIN, Cotter, 3/32 dia. x 3/4 long BOLT, 3/8-24 x -53/64 long, hex. hd., drilled end SHIM, -/8 O.D. x 3/32 I.D. x.005 thick WASHER, 3/6 O.D. x 25/64 I.D. x /6 thick NUT, 3/8-24, slotted PIN, Cotter, 3/32 dia. x 3/4 long QUANTITY PER ASSEMBLY 5-7

56 Figure 24. ALTERNATOR MOUNTING AND ATTACHING PARTS (70 AMP-WITHOUT IDLER PULLEY BELT ADJUSTMENT) 5-8

57 Lycomlng ELECTRICAL COMPONENTS COMPRESSOR MOUNTING, ATTACHMENTS AND LINKAGE FIG. REF PART NUMBER LW-6503 STD-33 STD B LW-6347 STD-8 LW-2232 STD-2025 LW STD-685 STD-290 STD-669 STD-676 LW-8809 LW MS LW LW-4278 STD-35 STD-837 STD-85 STD-33 AN6-4 AN6-22 LW-0952 STD-872 STD AN3-4 LW-8627 STD-22 STD-303 STD-68 LW-3429 STD-63 AN3-7 LW DESCRIPTION BRACKET, Freon compressor WASHER, 3/8 plain WASHER, 3/8 internal lock NUT, 3/8-24 plain SPACER, 33/64 I.D. x 7/8 O.D. x /8 thick BRACKET, Idler pulley WASHER, /4 plain SHIM, 9/6 O.D. x /4 I.D. x.005 thick BOLT, /4-20 x 2-7/6 long, hex. hd. BOLT, /4-20 UNC-3A x 3.00 long, hex. hd. NUT, /4-20 self-locking WASHER, /4 plain WASHER, 33/64 I.D. x.00 O.D. x /8 thick NUT, /2-20 self-locking PULLEY AND SHAFT ASSY., Idler PULLEY, Idler BALL BEARING, Idler pulley RING, Internal retaining IDLER SHAFT, Adlusting SHIELD, Idler bearing LOCKWASHER, Idler pulley bearing LOCKNUT, Idler pulley bearing BELT, Freon compressor drive WASHER, 5/6 plain BOLT, 5/6-8 x 2-9/32 long, hex. hd., drive end NUT, 5/6 self-locking WASHER, 3/8 plain BOLT, 3/8-24 x -37/64 long, hex. hd. BOLT, 3/8-24 x 2-2/64 long, hex. hd. SHIM, 3/6 O.D. x 3/32 I.D. x.005 thick NUT, 3/8-24 slotted PIN, Cotter, 3/32 dia. x.00 long SPACER, Controller connecting linkage BOLT, 0-32 x -7/32 long, hex. hd. HOSE, Linkage damper WASHER, 3/64,.D. x 5/6 O.D. x /32 thick NUT, 0-32 slotted shear PIN, Cotter, /6 x /2 long ROD END, 0-32, female NUT, 0-32 plain BOLT, 0-32 x 29/32 long, hex. hd. ROD, Connecting, inlector linkage QUANTITY PER ASSEMBLY 5-9

58 TIO/.TIO-540-V2AD PARTS CATALOG Figure 25. COMPRESSOR MOUNTING, ATTACHMENTS AND LINKAGE 5-0 Revised July, 986

59 OIL SUMP AND INDUCTION SYSTEM OIL SUMP AND INDUCTION HOUSING ASSEMBLY T0/LTIO-540-V2AD PARTS CATALOG FIG. REF. 26 PART NUMBER DESCRIPTION QUANTITY PER ASSEMBLY LW LW C- 5 STD-73 6 STD-55 7 STD-8 8 STD-60 9 STD-49 0 STD-688 STD-4 2 LW STD STD-8 7 STD-60 8 LW STD LW STD STD-8 23 STD STD STD-272 GASKET, Oil sump SUMP ASSY., Oil STUD, 3/8-6 x -7/8 long STUD, /4-20 x -3/8 long INSERT, /4-20 Heli-Coil x 3/4 long PLUG, /2-4 NPT, sq. hd., drilled WASHER, /4 plain WASHER, /4 internal lock BOLT, /4-20 x -/8 long, hex. hd. BOLT, /4-20 x.00 long, hex. hd. NUT, /4-20 plain HOUSING ASSY., Induction PLUG, /8 NPT x 3/8 long INSERT, /4-20 Heli-Coil x 3/4 long PLUG, -/2-8, hex hd. WASHER, /4 plain WASHER, /4 internal lock SHIM, /4 I.D. x.005 thick BOLT, /4-20 x 4-3/32 long, hex. hd. STRAP, Support, induction housing WASHER, 9/32 I.D. x 5/8 O.D. x /6 thick WASHER, /4 plain WASHER, /4 internal lock BOLT, /4-20 x 3/6 long, hex. hd. SCREEN, Oil suction GASKET, Oil suction screen 6-

60 Figure 26. OIL SUMP AND INDUCTION HOUSING ASSEMBLY 6-2

61 OIL SUMP AND INDUCTION SYSTEM INTAKE PIPES AND AIR INLET HOUSING FIG. REF. 27 PART NUMBER DESCRIPTION QUANTITY PER ASSEMBLY LW LW LW STD-64 5 STD-73 6 STD-8 7 STD-60 8 STD LW LW-9325 LW STD-8 3 STD-60 4 STD STD STD STD LW LW LW LW STD-8 25 STD STD-25 GASKET, Air inlet housing HOUSING ASSY., Air inlet BAFFLE, Air inlet housing INSERT, 5/6-8 Heli-Coil, 5/8 long INSERT, /4-20 Hell-Coil, /2 long WASHER, /4 plain WASHER, /4 internal lock BOLT, /4-20 x 5/6 long, hex. hd. SPACER, Air inlet housing, support BRACKET, Support, left BRACKET, Support, right WASHER, /4 plain WASHER, /4 internal lock BOLT, /4-20 x -3/6 long, hex. hd. WASHER, Plain, 3/4 O.D. x 2/64 I.D. x /8 thick WASHER, 5/6 internal lock BOLT, 5/6-8 x -5/6 long, hex. hd. (air inlet end) BOLT, 5/6-8 x -3/32 long, hex. hd. (inner cooler end) RING, Seal, intake pipe PIPE, Intake, cylinder no. & 6 PIPE, Intake, cylinder no. 2 & 5 PIPE, Intake, cylinder no. 3 & 4 GASKET, 2 bolt flange, -7/8 I.D. WASHER, /4 plain WASHER, /4 internal lock BOLT, /4-20 x -/4 long, hex. hd. Revised July,

62 I I Figure 27. INTAKE PIPES AND AIR INLET HOUSING 6-4 Revised July, 986

63 OIL SUMP AND INDUCTION SYSTEM FUEL INJECTOR, FUEL MANIFOLD AND AIR BLEED NOZZLES FIG. REF. 28 PART NUMBER DESCRIPTION QUANTITY PER ASSEMBLY LW AN LW S STD-8 7 STD-60 8 STD-49 9 LW STD-425 STD STD LW LW LW STD AN STD-48 9 MS STD STD LW LW LW LW LW LW LW LW STD STD LW STD LW LW STD STD LW-8675 LW LW LW STD STD STD STD-2042 GASKET, Air inlet adapter FUEL INJECTOR REDUCER, Flared tube (3/8 O.D. to /4 O.D.) HOSE ASSY., Inlector to fuel manifold BRACKET, Extension WASHER, /4 plain WASHER, /4 internal lock BOLT, /4-20 x -/8 long, hex. hd. CLAMP, Cushion type WASHER, No. 0 plain SCREW, 0-32 x /2 long, fillister head NUT, 0-32, self-locking NOZZLE ASSY., Injection BRACKET, Fuel manifold MANIFOLD ASSY., Fuel ELBOW, Union (90 ) /8 tube ELBOW, Union (45 ) /8 tube NIPPLE, Union, /8 tube ELBOW, /4 tube, 45 PLUG, /8 NPT WASHER, No. 0 plain SCREW, 0-24 x /2 long, fillister hd., dr. hd. TUBE ASSY., Fuel injection line, cylinder no. TUBE ASSY., Fuel injection line, cylinder no. 2 TUBE ASSY., Fuel injection line, cylinder no. 3 TUBE ASSY., Fuel inlection line, cylinder no. 4 TUBE ASSY., Fuel inlection line, cylinder no. 5 TUBE ASSY., Fuel injection line, cylinder no. 6 CLAMP, /8 dia. x no. 0 screw CLAMP, 3/4 dia. x no. 0 screw SCREW, 0-32 x 5/8 long, fillister hd. NUT, 0-32, self-locking MANIFOLD, Inlector nozzle vent PLUG, /6-27 NPT, Allen head HOSE, 3/6 I.D. x 7/6 O.D. x 2.00 long CLAMP, 7/6 I.D. CLAMP, /4 dia. tube for /4 dia. screw BOLT, /4-20 x -/8 long, hex. hd. HOSE, Nozzle vent (39.50 long) HOSE, Nozzle vent (45.50 long) CLAMP, 7/6 I.D. BRACKET, Support clamp CLAMP WASHER, No. 0 plain SCREW, 0-32 x 29/64 long NUT, No. 0, self-locking ZIP STRAP BOLT, /4-20 x -3/6 long 6-5

64 / 4 5 Figure 28. FUEL INJECTOR, FUEL MANIFOLD AND AIR BLEED NOZZLES 6-6

65 OIL SUMP AND INDUCTION SYSTEM CYLINDER HEAD AND MANIFOLD FUEL DRAINS FIG. REF. 29 PART NUMBER DESCRIPTION QUANTITY PER ASSEMBLY LW-8535 LW-6866 STD LW-3807 STD-969 STD-8 STD-60 STD-460 STD-670 LW LW LW LW LW STD-853 LW LW MANIFOLD ASSY., Fuel drain MANIFOLD, Fuel NIPPLE, Union, /8 tube PLUG, /8 NPT, Allen head ADAPTER ASSY., Fuel drain valve SCREW, 0-32 x /2 long, fillister head WASHER, /4 plain WASHER, /4 internal lock BOLT, /4-20 x 3/4 long, hex. hd. NUT, 0-32, self-locking TUBE ASSY., Fuel drain, cylinder no. TUBE ASSY., Fuel drain, cylinder no. 2 TUBE ASSY., Fuel drain, cylinder no. 3, 4 & 6 TUBE ASSY., Fuel drain, cylinder no. 5 TUBE ASSY., Fuel drain, intermediate TEE, Union, /8 tube CLAMP, 3/8 dia., no. 0 screw CLAMP, /8 dia., no. 0 screw 6-7

66 Figure 29. CYLINDER HEAD AND MANIFOLD FUEL DRAINS 6-8

67 FIG. REF. 30 PART NUMBER LW LW LW LW LW LW STD LW LW LW-8446 LW LW LW LW LW LW LW STD STD STD LW LW LW LW STD-8 27 STD-4 28 LW STD STD STD STD STD LW LW LW S LW S LW S TURBOCHARGER AND EXHAUST SYSTEMS EXHAUST MANIFOLD AND TRANSITION ASSEMBLY DESCRIPTION GASKET, Exhaust flange MANIFOLD ASSY., Exhaust, right PIPE, Exhaust, cylinder no. PIPE, Exhaust, cylinder no. 3 PIPE, Exhaust, cylinder no. 5 ADAPTER, Exhaust pipe BUSHING, Reducer, /4 to /8 NPT (No. 5 pipe) PIPE, Exhaust, intermediate (right) MANIFOLD ASSY., Exhaust, left PIPE, Exhaust, cylinder no. 6 ADAPTER, Exhaust pipe, cylinder no. 4 PIPE, Exhaust, cylinder no. 4 PIPE, Exhaust, cylinder no. 2 PIPE, Transition exhaust GASKET, V-Band coupling, 2-/2 tube COUPLING, V-Band, 2-/2 tube TRANSITION ASSY., Exhaust BUSHING, Reducer, /4 to /8 NPT PLUG, /8 NPT, square head drive NUT, /4-20, self-locking VALVE, Exhaust bypass GASKET, V-Band coupling, 2-/4 tube COUPLING, V-Band, 2-/4 tube BRACKET, Wastegate WASHER, /4 I.D. x 3/4 O.D. x 3/32 thick WASHER, /4 plain BOLT, /4-20 x -/2 long, hex. hd. (in wastegate) SUPPORT, Wastegate WASHER, 5/6 internal lock BOLT, 5/6-8 x 3/6 long, hex. hd. WASHER, 2/64 I.D. x 3/4 0.D. x /8 thick BOLT, 5/6-8 x 5/6 long, hex. hd. NUT, 5/6-8, self-locking SHIELD, Heat CLAMP, Hose HOSE ASSY., Accessory housing to wastegate inlet ELBOW, 3/8 tube, 90 adj. (wastegate outlet) HOSE ASSY., Wastegate to variable controller inlet ELBOW, 3/8 tube to 9/6 thread, 90 (variable controller inlet) ELBOW, 3/8 tube to 9/6 thread, 90 (variable controller outlet) HOSE ASSY., Variable controller to accessory housing ELBOW, /4 tube, 90 (wastegate inlet) QUANTITY PER ASSEMBLY 7-

68 Figure 30. EXHAUST MANIFOLD AND TRANSITION ASSEMBLY 7-2

69 TURBOCHARGER AND EXHAUST SYSTEMS TURBOCHARGER, SUPPORT AND ATTACHING PARTS FIG. REF PART NUMBER LW-845 STD-2205 STD-297 LW-3S-4.94 LW-3S-4.72 STD-420 STD-68 LW-8452 LW STD-33 STD-342 LW-8456 STD-42 STD-2045 LW-8470 AN960C-66 AN6C-3A MS2Q LW-8520 AN960C-66 MS AN6C-26A DESCRIPTION SUPPORT ASSY., Turbocharger WASHER, 2/64 I.D. x 9/6 O.D. x.032 thick WASHER, 2/64 I.D. x 3/6 O.D. x.064 thick BOLT, 5/6-8 x 4-5/6 long, hex. hd. drive BOLT, 5/6-8 x 4-23/32 long, hex. hd. drive NUT, 5/6-8 slotted PIN, Cotter, /6 diameter x /2 long SPACER, Turbocharger BRACKET, Turbocharger and compressor DAMPER, 3/8 square x 6-/32 to 6-3/32 long WASHER, 3/8 plain WASHER, 25/64 I.D. x 7/8 0.D. x /8 thick BRACKET, Sonic nozzle BOLT, 3/8-24 x 7/8 long, hex. hd. NUT, 2/64-24, self-locking TURBOCHARGER WASHER, 3/8 plain BOLT, 3/8-24 x -7/6 long, hex. hd. NUT, 3/8-24, self-locking SPACER, Turbocharger WASHER, 3/8 plain NUT, 3/8-24, self-locking BOLT, 3/8-24 x 2-3/6 long, hex. hd. QUAlTITY PER 7-3

70 N Figure 3. TURBOCHARGER, SUPPORT AND ATTACHING PARTS 7-4

71 FIG. REF. 32 PART NUMBER LW LW-999* * 5 LW LW AN90-8A 8 LW MS STD-33 4 STD STD STD LW LW S-50 9 LW LW AN MS STD STD STD MS LW LW S LW-376-8S LW STD STD STD STD-63 TURBOCHARGER AND EXHAUST SYSTEMS TURBOCHARGER TANK ASSY., HOSES AND RELATED PARTS DESCRIPTION REDUCER, 7/8-4 to 9/6-8 (ACC. Housina to Controller Drain) ELBOW, 3/8 tube, 45 (Acc. Housing to Controller Drain) REDUCER, 7/8-4 to 9/6-8 (Tank to Accessory Housing) ELBOW, /4 tube (90 ) (Tank to Accessory Housing) SPACER, Oil pressure fitting BOLT, Oil pressure fitting GASKET, 3/4 I.D. x.00 O.D. TEE, /4 and 3/6 tube x /8 NPT on run (restricted) PLUG, /8 NPT x 3/8 long (in spacer) ELBOW, /4 tube x /8 NPT (in accessory housing) GASKET, Turbo oil inlet adapter ADAPTER, Turbo oil inlet WASHER, 3/8 plain WASHER, 3/8 internal lock BOLT, 3/8-6 x 7/8 long, hex. hd. BUSHING, /4 NPT to /8 NPT ELBOW, /4 tube to /8 NPT - long (in adapter) HOSE ASSY., (Accessory housing to turbo inlet) GASKET, Turbo oil drain adapter TANK ASSY., Turbo oil drain NIPPLE, /4 tube x /8 NPT ELBOW, /2 tube x 3/8 NPT (45 ) WASHER, 3/8 plain WASHER, 3/8 internal lock BOLT, 3/8-6 x 7/8 long, hex. hd. "O" RING, 4/64 I.D. x 7/8 wall ELBOW, /2 tube x 3/4-6 thread (90 ) (in scavenge pump) HOSE ASSY., (Tank to accessory housing) (vent) HOSE ASSY., (Tank to scavenge pump) ZIP STRAP SHIELD, Heat SCREW, 0-32 x 29/64 long WASHER, No. 0 plain WASHER, No. 0 internal lock NUT, No plain QUANTITY PER ASSEMBLY * Used in accessory housing for scavenge tank vent. 7-5

72 o N Figure 32. TURBOCHARGER TANK ASSY., HOSES AND RELATED PARTS 7-6

73 FIG. REF. 33 PART NUMBER TURBOCHARGER AND EXHAUST SYSTEMS INTERCOOLER ASSEMBLY AND RELATED PARTS DESCRIPTION LW-2434 HOSE, 3.00 I.D. x 2-5/6 long 2 LW CLAMP, Hose 3 LW-8869 GASKET, Intercooler air inlet duct 4 LW-8868 DUCT, Intercooler air inlet 5 STD-8 WASHER, /4 plain 6 STD-60 WASHER, /4 internal lock 7 STD-875 BOLT, /4 O.D. x 3/6 long, hex. head 8 STD-688 BOLT, /4-20 x.00 long, hex. head 9 STD-4 NUT, /4-20 plain 0 LW-8822 INTERCOOLER ASSEMBLY, AirResearch ( ) GASKET 2 LW-8457 BRACKET, Intercooler support 3 LW-8458 SPACER, Intercooler 4 STD-727 WASHER, Plain, 3/4 O.D. x 2/64 I.D. x /8 thick 5 STD-252 BOLT, 5/6-8 x 3/6 long, hex. head 6 STD-2043 NUT, 5/6-8 self-locking 7 STD-35 WASHER, 5/6 plain 8 STD-475 WASHER, 5/6 internal lock 9 LW-8738 ELBOW, /4 tube and nozzle vent 20 STD-252* BOLT, 5/6-8 x 3/6 long, hex. head 2 STD-825* BOLT, 5/6-8 x -/6 long, hex. head 22 LW-2745 VALVE, Check, vent line 23 MS "0" RING, 5/32 I.D. x 5/64 section 24 LW-3807 ADAPTER ASSY., Fuel drain valve 25 LW-2975 ADAPTER, Reducer, 3/8 to /4 26 AN88-6 NUT, Coupling GASKET, Controller 28 LW-859 CONTROLLER ASSY., Absolute pressure, adjusting 29 LW-2773 LEVER, Controller 30 STD-2099 PIN, Roll /8 diameter x 3/4 long 3 STD-28 WASHER, No. 0 plain 32 STD-566 SCREW, 0-24 x 3/4 long, fillister drive head GASKET, Absolute pressure relief valve 34 LW-8955 ADAPTER, Absolute pressure relief valve 35 STD-28 WASHER, No. 0 plain 36 STD-25 WASHER, No. 0 internal lock 37 STD-375 SCREW, 0-24 x 5/8 long, fillister head 38 LW-8956 GASKET, Absolute pressure relief valve 39 LW VALVE ASSY., Absolute pressure relief 40 STD-28 WASHER, No. 0 plain 4 STD-25 WASHER, No. 0 internal lock 42 STD-375 SCREW, 0-24 x 5/8 long, fillister head 43 MS ELBOW, 3/6 tube, STD-0* SCREW, 0-24 x /2 long, fillister head 45 STD-25**' WASHER, No. 0 internal lock 46 STD-33 WASHER, 3/8 plain 47 STD-678 WASHER, 3/8 internal lock 48 AN6C5A BOLT, 3/8-24 x 45/64 long, hex. head 49 MS SEAL, Oil, 5/64 dia. sect. x 5/32 I.D. 50 AN84-6L PLUG, 9/6-8, hex. head * Intercooler to intercooler support bracket. ** Assemble in baffle attaching holes. QUANTITY PER ASSEMBLY

74 Figure 33. INTERCOOLER ASSEMBLY AND RELATED PARTS 7-8

75 Part No. LW-8786 MS AN90-8A MS MS MS MS MS MS STD-227 STD-23 STD-045 STD-272 STD LW-022 LW-0332 LW-2272 LW-268 LW-3306 LW-492 LW-4260 LW-5628 LW-8234 LW-8329 LW-848 LW-8526 LW SERVICE KIT SECTION SEAL AND GASKET SET WIDE CYLINDER FLANGE MODELS Part Name SEAL AND GASKET SET "O" RING GASKET RING, Oil seal RING, Internal retaining RING, Internal retaining SEAL, Oil "O" RING SEAL SEAL, Oil SEAL GASKET GASKET, Oil suction screen RING, Exhaust retaining GASKET, Vacuum pump GASKET, Valve rocker shaft cover GASKET, Fuel pump adapter SEAL, Shroud tube GASKET RING, Oil seal GASKET, Intake flange GASKET, Governor "O" RING, Oil filler extension RING, Oil seal GASKET, Oil filler adapter GASKET, Air inlet adapter GASKET, Controller LOCKPLATE GASKET, Accessory housing RING, Oil seal GASKET GASKET, Turbo oil inlet adapter GASKET, V Band coupling GASKET, Rocker box cover RING, Seal, intake pipe GASKET, Turbo oil drain adapter LOCKPLATE, Crankshaft gear LOCKPLATE, Shroud tube GASKET, Magneto GASKET, Oil sump GASKET, Sonic nozzle SEAL, Tachometer SEAL, Crankshaft oil GASKET, Exhaust flange GASKET, Air inlet housing GASKET, Oil filler adapter GASKET, V Band coupling SEAL, Shroud tube GASKET, Oil level gauge Qty

76 Part No. SERVICE KIT SECTION CYLINDER, PISTON AND RING KIT WIDE CYLINDER FLANGE MODELS Part Name Qty. LW LW-0545-S LW-775 LW-796 LW-797 LW-3262 LW-332 LW-3322 LW-3446 or LW-4077 LW-4433 LW-5732 LW-6475 LW-866 LW-8739 LW-8852* MS MS SSP-2272 STD-60 STD-25 STD-4 STD-2059 CYLINDER, PISTON AND RING KIT PLUG, Piston pin CAP GASKET, Rocker shaft cover SEAT, Valve spring SEAL BOX, Set up RING, Oil seal WASHER KEY, Valve SHAFT, Valve rocker SCREW COVER, Valve rocker shaft RING, Oil regulator RING, Piston PLATE, Spark plug reach caution GASKET, Rocker box cover PISTON PLUG, Piston pin SPRING, Valve, outer SPRING, Valve, auxiliary VALVE, Intake SEAT, Valve spring, lower intake SEAT, Valve spring, lower exhaust PIN, Piston COVER ASSY., Rocker box VALVE, Exhaust SEAT, Valve spring SEAL, Shroud tube ROCKER ASSY., Intake and exhaust CYLINDER AND HEAD ASSEMBLY KEY, Valve (rotator type) CAP, Valve stem TAG WASHER, Internal lock BOLT NUT, Plain SCREW * Nitrided cylinder, long reach plug. 8-2

77 NUMERICAL INDEX PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO. AN3-7 AN3-4 AN30-7 AN AN565B032H5 AN6-2 AN6-4 AN6-4 AN6-6 AN6-6 AN6-22 AN6-34A AN6C-5A AN6C-3A AN6C-26A AN7-2 AN7-4 AN79-2 AN8-4A AN84-6L AN86-4 AN86-4 AN86-6 AN8 8-6 AN90-8A AN99-6 AN99-5 AN960C-66 LW-022 LW-0284 LW-0292 LW-0297 LW-0299 LW-0307 LW-038 LW-0320 LW-032 LW-0324 LW-0325 LW-0329 LW-0332 LW-034 LW LW LW-054 LW-0545 LW-055 LW-0576 LW-0578 Nut Screw Screw Elbow Plug Nipple Nipple Nipple Nut Gasket Reducer Nipple Gasket Gear Gear Assy. Gear Assy. Shaft Gear Assy. Gear Assy. Sleeve Spring Gear Assy. Spacer Shaftgear Assy. Lockplate Insert Body Assy. Gear Gear Assy. Piston Gear Shaft Pulley & Shaft Assy LW-0637 LW-0799 LW LW-098 LW-0952 LW-0952 LW-0966 LW-0967 LW-0970 LW-097 LW-47 LW-253 LW-635 LW-665 LW-73 LW-796 LW- 797 LW- 999 LW-2056 LW LW LW LW LW LW LW LW LW LW LW LW LW LW-286 LW-220 LW-2232 LW-2232 LW-2272 LW-2434 LW-2589 LW-2596 LW-268 LW-2688 LW-2745 LW-2773 LW LW LW S-30 LW S- 50 LW S- 90 LW S- 30 Elbow Spacer Housing Assy. Housing Assy. Shim Shim Alternator Alternator Assy. Strut Bracket Body Assy. Shield Thrust Button Spring Spring Spring Reducer Spacer Coupling Coupling Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Nut Camshaft Shim Shim Lockplate Hose Insert Gasket Seat Valve Lever Hose Assy. Hose Assy. Hose Assy. Hose Assy. Hose Assy. Hose Assy Revised July,

78 NUMERICAL INDEX (Cont.) PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO. LW S-222 LW S-373 LW S-300 LW-2975 LW-3039 LW-328 LW-334 LW-376-8S-80 LW-3209 LW-322 LW-3226 LW-3227 LW-3262 LW-3306 LW-332 LW-3322 LW-3422 LW-3429 LW-364 LW-3642 LW-3807 LW-3807 LW-3885 LW-3896 LW-3904 LW-3905 LW-3920 LW-3923 LW-402 LW-4078 LW-44 LW-442 LW-424 LW-4260 LW-4278 LW-4324 LW-4325 LW-4433 LW LW-4637 LW-4637 LW-4649 LW-4649 LW-4650 LW LW-4820 LW-4830 LW-4995 LW-5550 LW-5568 Hose Assy. Hose Assy. Hose Assy. Adapter Bracket Elbow Valve Assy. Hose Assy. Bearing Bearing Nut Adapter Valve Gasket Seat Seat Rod Rod End Cushion Gear Adapter Assy. Adapter Assy. Bearing Plug Kit Filter Pump Bushing Shaft Pin Bracket Bracket Starter Seal Belt Alternator Alternator Cover Assy. Valve Assy. Shim Shim Shim Shim Shim Bracket Ring Bearing Spring Pump Adapter LW-5572 LW-5579 LW-5580 LW LW LW LW-5628 LW-572 LW-5732 LW-5740 LW LW-5996 LW-643 LW LW LW LW LW-6347 LW LW-6475 LW-6503 LW-6866 LW-7765 LW-7766 LW-7790 LW-779 LW-87 LW-882 LW-8234 LW-8325 LW-8326 LW-8327 LW-8329 LW-8330 LW-8378 LW LW-8440 LW-844 LW-8444 LW-8445 LW-8446 LW-845 LW-8452 LW-8453 LW-8456 LW-8457 LW-8458 LW-8466 LW-8467 Starter Adapter Assy. Drive Assy. Clamp Clamp Clamp Seal Support Assy. Valve Pump Clamp Bearing Clamp Clamp Clamp Clamp Bracket Gear Assy. Seat Bracket Manifold Crankshaft Crankshaft Crankshaft Crankshaft Elbow Nozzle Assy. Gasket Pipe Pipe Pipe Gasket Housing Assy. Clamp Shield Adapter Pipe Pipe Pipe Pipe Support Assy. Spacer Bracket Braclet Bracket Spacer Housing Assy. Strap Revised July, 986

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