AIRCRAFT ENGINES IO-540-ACA5 Wide Series Flange Crankcase Model Engine PARTS CATALOG PC-5- November 008 Lycoming 5 Oliver Street Williamsport, PA 770 U.S.A. 570/33-8
IO-540-ACA5 PARTS CATALOG This illustrated parts catalog contains a complete parts listing for the Textron Lycoming IO-540-ACA5 wide cylinder flange crankcase model aircraft engines. Major assembly and sub-assembly parts of the engine are listed in the Group Assembly sections in the general sequence of engine build up. 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 Textron Lycoming engines may be found in the appropriate Vendor's Parts Catalog. A list of addresses of where to obtain these publications appears in the latest edition of Service Letter No. L4. NOTE The illustrations, pictures and drawings shown in the 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 manufacturer's product, by name, trademark, part number or other description is solely for the purposes of identification and does not indicate or infer that Textron Lycoming accepts responsibility for quality control and/or airworthiness of parts which do not pass through the Textron Lycoming quality control system. 999 by Textron Lycoming, "All Rights Reserved." All Textron Lycoming publications are to be considered copyrighted and may not be reproduced without permission of the company. SERVICE BULLETINS, INSTRUCTIONS AND LETTERS Although the information contained in this parts catalog is up-to-date at time of publication, users are advised to procure current information through all Textron Lycoming distributors or from the factory by subscription. Consult the latest edition of Service Letter No. L 4 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
SECTION Lycoming IO-540-ACA5 PARTS CATALOG TABLE OF CONTENTS PAG: E Introduction... i Table of C ontents... ii Oversize and Undersize Parts Listing...... iii. CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP Crankcase Assembly... - Oil Level Gage Assembly and Engine Mounting Brackets... -3 Crankcase Related Parts... -5 Camshaft, Crankshaft, Counterweight and Related Parts...... -7 Propeller Governor Drive Assembly... -9 Crankshaft and Fuel Pump Idler Gears...... - Crankcase Attaching Parts...... -3. ACCESSORY HOUSING AND RELATED PARTS Accessory Housing Assembly... - Oil Pump Assembly and Accessory Housing Attaching Parts... -3 Fuel Pump Assembly and Attaching Parts... -5 Vacuum and Hydraulic Pump Drives and Covers...... -7 Oil Filter Assembly, Oil Cooler Bypass Valve and Breather Fitting... -9 3. CYLINDER, PISTON AND VALVE TRAIN Connecting Rods, Pistons and Ring Assemblies...... 3- Cylinder A ssem bly... 3-3 Valve Assembly and Related Parts...... 3-5 Cylinder R elated Parts... 3-7 4. IGNITION SYSTEM Magnetos (SLICK), Magneto Drives, Harnesses and Spark Plugs... 4-5. ELECTRICAL SYSTEM Sky-Tec Starter and Attaching Parts... 5- Alternator Mounting and Attaching Parts... 5-3. OIL SUMP AND INDUCTION SYSTEM Oil Sump Assembly, Induction Housing and Oil Suction Screen... - Intake Pipes and Attaching Parts...... -3 Fuel Injector, Fuel Manifold and Injection Nozzles...... -5 Fuel Lines and Attaching Parts......... -7 Fuel Drain Manifold and Tube Assemblies...... -9 7. SERVICE KIT SECTION... 7-8. NUMERICAL INDEX... 8- ii
IO-540-ACA5 PARTS CATALOG Oversize and Undersize Parts Listing PART No. 70 90 979 7903-A 755-S 7557-S 78443 LW-383 LW-3885 LW-4830 LW-58 LW-904 T948 P709 R70 8A9399 Description BUSHING INSERT DOWEL BUSHING BUSHING BUSHING SEAL BEARING BEARING BEARING SEAL SEAT SEAT GUIDE GUIDE BEARING P0 P05 P0.00.005.00 Oversize P5 P0.05.00 P30 P40 P50.030.040.050 X X X X X See Latest Edition of Service Instruction No. 43. X X X X See Latest Edition of Service Instruction No. 34. See Latest Edition of Service Instruction No. 34. X X X X X X See Latest Edition of Service Instruction No. 5. See Latest Edition of Service Instruction No. 5. I I Undersize M03 M0 M0.003.00.00 X X* X* X X* X* X X* X* X* * Also available in P5 oversize. In addition to the above, studs are available in P03, P07 & P. 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-M03. Oversize code letter is "P" while undersize code letter is "M". These letters are then followed by the number designating the size in thousandths of an inch. iii
IO-540-ACA5 PARTS CATALOG CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP CRANKCASE ASSEMBLY FIG REF. PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 4 5 7 8 9 0 F404-S7 38-38- 38-3 3C-3 38-3 50-5 38-38D-7 0-8 0D-8 LW-3794 979 STD-54 STD-557 758 3C-7 7377 MS95-0 AN84-L CRANKCASE ASSEMBLY (See Note) STUD. 3/8- x -5/8 long STUD, 3/8- x 3-/4 long STUD, 3/8- x -7/8 long STUD. 5/-8 x -5/8 long STUD. 3/8- x -5/8 long STUD. /-3 x -7/8 long STUD. 3/8- x -3/4 long STUD, 3/8- x -/8 long, drilled STUD, No. 0-3 x.00 long STUD, No. 0-3 x.00 long, drilled STUD, 5/-8 x.00 long, drilled DOWEL, Crankshaft bearing DOWEL, 5/ dia. x / long DOWEL, / dia. x / long, hollow BUSHING, Governor drive idler shaft STUD, 5/-8 x -/8 long NOZZLE ASSY., Piston cooling "O" RING, 5/3 I.D. x 5/4 section PLUG, 9/-8 hex. head NOTE This crankcase assembly is not available as a service item. Refer to Service Kits, Section 7, for applicable Crankcase Assembly and Governor Stud Kit Part Number. -
IO-540-ACA5 PARTS CATALOG 8-9- 8 Figure. CRANKCASE ASSEMBLY -
IO-540-ACA5 PARTS CATALOG CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP OIL LEVEL GAGE ASSEMBLY AND ENGINE MOUNTING BRACKETS FIG REF. PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 4 5 7 8 9 0 3 4 5 LW-848 D3 STD-8 STD-5 STD-3 7059* 5C33* 07C33 * 739* 07A39* STD-8* STD-0* LW-5-.50* STD-45* STD-80* STD-70* 7408* LW-783-* A0 A0 A33 A34 STD-33 STD-78 STD-59 GASKET, Oil filler adapter ADAPTER. Oil filler tube WASHER, No. 0 plain WASHER. No. 0 internal lock NUT, No. 0-3 plain GASKET, Oil level gage TUBE, Oil level gage (long) CLAMP. Oil filler tube SPACER BRACKET, Twist, 55 WASHER, /4 plain WASHER, /4 lock, internal teeth BOLT, /4-0 x -/ long, hex. hd. WASHER, No. 0 plain SCREW, No. 0-3 x 5/8 long, fill. hd. LOCKNUT, No. 0-3 RING, Oil level gage plug GAGE ASSY., Oil level BRACKET, Engine mount, left rear BRACKET, Engine mount, right rear BRACKET, Engine mount, left front BRACKET, Engine mount, right front WASHER, 3/8 plain WASHER, 3/8 lock, internal teeth NUT, 3/8-4 plain * These parts are shipped loose. -3
IO-540-ACA5 PARTS CATALOG Figure. OIL LEVEL GAGE ASSEMBLY AND ENGINE MOUNTING BRACKETS -4
IO-540-ACA5 PARTS CATALOG CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP CRANKCASE RELATED PARTS FIG REF. 3 PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 08-B 084* 88* 7747* LW-73* LW-8085* 0E979-.5 77808 LW-383 LW-4830 LW-3885 8A9399 LW-58** 78443** 709 7877 BALL, / diameter SPRING, Oil pressure relief valve SPRING, Oil pressure relief valve SPRING, Oil pressure relief valve SPRING, Oil pressure relief valve SPRING, Oil pressure relief valve GASKET, -/4 I.D. x -/ O.D. x 3/3 annular VALVE ASSY., Oil pressure relief valve, adj. BEARING, Crankshaft BEARING, Crankshaft (alternate) BEARING, Crankshaft, front BEARING, Crankshaft, front (alternate) SEAL, Crankshaft oil, solid SEAL, Crankshaft oil, split RING, Oil seal, 3/4 I.D. x 7/4 dia. BODY, Hydraulic tappet * Select spring to give a minimum of three threads exposed on adjusting screw to allow field adjustment. Reference latest revision of Textron Lycoming Table of Limits SSP-77, Part I for spring identification. ** See latest edition of Textron Lycoming Service Instruction No. 34 for installation. -5
IO-540-ACA5 PARTS CATALOG Figure 3. CRANKCASE RELATED PARTS -
IO-540-ACA5 PARTS CATALOG CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP CAMSHAFT, CRANKSHAFT, COUNTERWEIGHT AND RELATED PARTS FIG REF. 4 PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 4 5 7 8 9 0 3 3F7743 7380* STD-05 0945 755-S 7557-S STD- LW-90** 7903-A+ 7348** 7788** 7907 LW-480 3S948++ LW-838++ STD-09++ LW-9340 78 755 LW-87 STD-3 3M4 75 CRANKSHAFT AND BUSHING ASSEMBLY BUSHING, Crankshaft, dynamic DOWEL. Stepped. 5/ & /4 dia. x 35/4 long PLUG, -/4 O.D. BUSHING, Propeller flange, long BUSHING. Propeller flange, indexing PLUG..00 dia. expansion COUNTERWEIGHT ASSEMBLY BUSHING, Dynamic counterweight ROLLER. Dynamic counterweight, 5. order ROLLER. Dynamic counterweight..3 order WASHER, Dynamic counterweight RING, Internal retaining GEAR. Crankshaft LOCKPLATE. Crankshaft gear BOLT, 5/-4 x -3/4 long CAMSHAFT ASSEMBLY SPACER, Tachometer shaft centering SHAFT ASSY.. Tachometer PIN, 3/ dia. x -/4 long RING, Internal retaining SUPPORT ASSY., Starter ring gear. /4 pitch GEAR, Starter ring * See latest edition of Textron Lycoming Service Instruction No. 4 for application. ** See latest edition of Textron Lycoming Service Instruction No. 0 for application. + See latest edition of Textron Lycoming Service Instruction No. 43 for application. ++ See latest edition of Textron Lycoming Service Bulletin No. 475 for application. CRANKSHAFT & COUNTERWEIGHT ASSEMBLY, Kit P/N 05K7793 available. -7
0-540-ACA5 PARTS CATALOG -3 9 9 3 9 3 5 Figure 4. CAMSHAFT, CRANKSHAFT, COUNTERWEIGHT AND RELATED PARTS -8
IO-540-ACA5 PARTS CATALOG CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP PROPELLER GOVERNOR DRIVE ASSEMBLY FIG REF. 5 PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 4 5 LW- 044 LW-40 LW-054 7787 STD-9 STD-798 7349 7350 735 735 0L48 AN55B 03H5 70455 LW-389 7053 7378 STD-35 STD-475 STD-40 GEAR, Propeller governor driven SHAFT, Propeller governor idler gear GEAR ASSY., Propeller governor idler BUSHING, Propeller governor idler gear DOWEL, 3/3 dia. x 7/3 long DOWEL, 3/3 dia. x 9/3 long WASHER, Thrust (.0585 -.0595 thick) WASHER, Thrust (.0 -.03 thick) WASHER, Thrust (.055 -.05 thick) WASHER, Thrust (.09 -.070 thick) WASHER, Thrust (.055 -.05 thick) SET SCREW, No. 0-3 x 5/ long GASKET, 5/3 I.D. x -/8 O.D. x /3 thick PLUG, 3/4- hex. hd. GASKET, Governor COVER, Governor drive WASHER, 5/ plain WASHER, 5/ lock, internal teeth NUT, 5/-8 plain -9
0-540-ACA5 PARTS CATALOG 5-9 -7 Figure 5. PROPELLER GOVERNOR DRIVE ASSEMBLY -0
, Lycoming 0-540-AClA5 PARTS CATALOG CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP CRANKSHAFT AND FUEL PUMP IDLER GEARS FIG REF. PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 544 75 7530 78 7530 LW-3795 LW-3H0.88 STD-8 PLUNGER. Fuel pump, long GEAR ASSY.. Crankshaft idler BUSHING. Crankshaft idler gear GEAR ASSY.. Crankshaft idler, plain BUSHING. Crankshaft idler gear SHAFT, Crankshaft idler gear BOLT. 5/-8 x 7/8 long, hex. hd. dr. NUT, 5/-8 NC-3 slotted shear -
IO-540-ACA5 PARTS CATALOG Figure. CRANKSHAFT AND FUEL PUMP IDLER GEARS -
O-540-ACA5 PARTS CATALOG CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP CRANKCASE ATTACHING PARTS FIG REF. 7 PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 4 5 7 8 9 0 3 4 5 07E59 LW-5-.75 LW-5-.75 LW-5-.50 LW-5-.3 STD-8 STD-0 STD-4 LW-5S.50 STD-8 STD-409 STD-33 STD-87 AN-34A STD-33 STD-78 STD-59 70 B87 STD-78 LW-38-.3 LW-3-.75 LW-3-. STD-35 STD-475 SUPPORT. Induction housing BOLT. /4-0 x -3/4 long, hex. hd. BOLT. /4-0 x -3/4 long, hex. hd. BOLT, /4-0 x -/ long, hex. hd. BOLT. /4-0 x -/8 long. hex. hd. WASHER. /4 plain WASHER. /4 lock, internal teeth NUT, /4-0 plain BOLT. /4-0 x -/ long, hex. hd., dr. end WASHER, /4 plain NUT, /4-0 slotted shear WASHER, 3/8 plain NUT, 3/8-4 slotted BOLT, 3/8-4 x 3-37/4 long, hex. hd. WASHER, 3/8 plain WASHER. 3/8 lock, internal teeth NUT, 3/8-4 plain STUD, /-0 x 0-45/4 long EYE, Lifting, rear WASHER, 3/8 lock, internal teeth BOLT, 3/8- x -/8 long, hex. hd. BOLT, 5/-8 x -3/4 long BOLT, 5/-8 x -5/3 long WASHER, 5/ plain WASHER, 5/ lock, internal teeth -3
LycomIng IO-540-ACA5 PARTS CATALOG Note: See Fig. Figure 7. CRANKCASE ATTACHING PARTS -4
, Lycoming 0-540-ACA5 PARTS CATALOG ACCESSORY HOUSING AND RELATED PARTS ACCESSORY HOUSING ASSEMBLY FIG REF. 8 QTY. PART PER NUMBER DESCRIPTION ASSY. 3 4 5 7 8 7388 C539-04 3C- 3C- 5C- 3CD-0 0 STD-784 GASKET. Accessory housing HOUSING ASSY.. Accessory STUD. 5/-8 x -/ long STUD. 5/-8 x -5/8 long STUD. /4-0 x -5/8 long STUD. 5/-8 x -/ long. drilled PLUG. /8-7 NPT. Allen head PLUG, 3/8-8 NPT, Allen head -
0-540-ACA5 PARTS CATALOG Figure 8. ACCESSORY HOUSING ASSEMBLY -
0-540-ACA5 PARTS CATALOG ACCESSORY HOUSING AND RELATED PARTS OIL PUMP ASSEMBLY AND ACCESSORY HOUSING ATTACHING PARTS FIG REF. 9 PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 4 5 5A8 5D7 STD-74 STD-339 7784 97 98 STD-35 STD-40 LW-40 STD-8 STD-0 LW-5-0.94 LW-5-.3 LW-5-.50 BODY ASSY.. Oil pump SHAFT. Oil pump. idler COTTER PIN. /8 dia. x.00 long PLUG. /-7 NPT SHAFT. Oil pump drive IMPELLER. Oil pump. driving IMPELLER. Oil pump driven WASHER. 5/ plain NUT. 5/-8 slotted SEAL. Tachometer drive, oil WASHER. /4 plain WASHER, /4 lock. internal teeth BOLT. /4-0 x 5/ long. hex. hd. BOLT. /4-0 x -/8 long. hex. hd. BOLT, /4-0 x -/ long, hex. hd. -3
IO-540-ACA5 PARTS CATALOG Figure 9. OIL PUMP ASSEMBLY AND ACCESSORY HOUSING ATTACHING PARTS -4
IO-540-AClA5 PARTS CATALOG ACCESSORY HOUSING AND RELATED PARTS FUEL PUMP ASSEMBLY AND ATTACHING PARTS FIG REF. 0 PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 009 LW-5473 STD-33 STD-88 7377 MS95-0 GASKET. Fuel pump FUEL PUMP. Dual diaphragm (4434) WASHER. 3/8 plain SCREW. 3/8- x -9/3 socket head. dr. ELBOW. 3/8 flared tube. adjustable (outlet) "O" RING -5
IO-540-ACA5 PARTS CATALOG Figure 0. FUEL PUMP ASSEMBLY AND ATTACHING PARTS -
, Lycoming IO-540-ACA5 PARTS CATALOG ACCESSORY HOUSING AND RELATED PARTS VACUUM AND HYDRAULIC PUMP DRIVES AND COVERS FIG REF. PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 4 5 7 8 9 0 3 4 5 7 8 83 753 0A995 STD-774 7974 79 759 833 0430 STD-8 STD-0 STD-4 794 79 759 835 775 0A995 STD-774 5C- STD-35 STD-475 STD-40 833 0430 STD-8 STD-0 STD-4 GASKET, Accessory adapter ADAPTER ASSY., Vacuum pump OIL SEAL, 7/8 I.D. x -/ O.D. x 5/ wide PIN, /8 dia. x /4 long GEAR ASSY., Vacuum pump driven THRUST BUTTON WASHER, Accessory drive gear GASKET, Vacuum pump COVER, Vacuum pump WASHER, /4 plain WASHER, /4 lock, internal teeth NUT, /4-0 plain GEAR ASSY., Hydraulic pump driven THRUST BUTTON WASHER, Accessory drive gear GASKET, Accessory drive adapter ADAPTER ASSY.. Hydraulic pump OIL SEAL, 7/8 I.D. x -/ O.D. x 5/ wide PIN, /8 dia. x /4 long STUD, /4-0 x -/ long WASHER, 5/ plain WASHER, 5/ lock, internal teeth NUT, 5/-8 plain GASKET, Hydraulic pump COVER, Hydraulic pump WASHER, /4 plain WASHER. /4 lock, internal teeth NUT, /4-0 plain -7
IO-540-ACA5 PARTS CATALOG 4-0 8 5 Figure. VACUUM AND HYDRAULIC PUMP DRIVES AND COVERS -8
0-540-ACA5 PARTS CATALOG ACCESSORY HOUSING AND RELATED PARTS OIL FILTER ASSEMBLY, OIL COOLER BYPASS VALVE AND BREATHER FITTING FIG REF. PART NUMBER DESCRIPTION QTY. PER ASSY. I 3 4 5 7 8 9 0 3 4 LW-795* 7785 LW-35** STD-8 STD-0 STD-4 STD-85 53E44 750 5C-0 AN840-D STD-38 0E 979-0.3 47 GASKET. Oil filter adapter OIL FILTER BASE ASSEMBLY OIL FILTER WASHER, /4 plain WASHER. /4 lock, internal teeth NUT. /4-0 plain SCREW. /4-0 x.00 long. hex. hd. VALVE ASSY.. Temp. control oil cooler GASKET, Valve assembly STUD. /4-0 x -/4 long FITTING. Breather NIPPLE. -0 to - special GASKET. Annular. 5/8 I.D. PLUG, Oil cooler bypass * Extra gasket, shipped as loose part, with engine. ** See latest edition of Textron Lycoming SSP-885 for oil filter kits and replacement filters. -9
IO-540-ACA5 PARTS CATALOG 3 Figure. OIL FILTER ASSEMBLY, OIL COOLER BYPASS VALVE AND BREATHER FITTING -0
IO-540-ACA5 PARTS CATALOG CYLINDER, PISTON AND VALVE TRAIN CONNECTING RODS, PISTONS AND RING ASSEMBLIES FIG REF. 3 PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 LW-933-S LW-393 LW-59 LW-8 74309 LW-007-S LW-4077 088 744 4H950 CONNECTING ROD ASSEMBLY BUSHING, Connecting rod, upper BOLT, Connecting rod NUT, Connecting rod bolt BEARING, Connecting rod PISTON, Compression ratio, 8.7: PIN, Piston PLUG, Piston pin RING, Piston, compression RING, Piston, oil regulating, expander type 3-
0-540-ACA5 PARTS CATALOG -5-4 -7 8 Figure 3. CONNECTING RODS, PISTONS AND RING ASSEMBLIES 3-
IO-540-ACA5 PARTS CATALOG CYLINDER, PISTON AND VALVE TRAIN CYLINDER ASSEMBLY FIG REF. 4 PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 4 5 A54 LW-904 T948 P709* R70* 90 770 5C- 70 5C-8 AN8- STD-48 LW-834 AN90C4 STD-044 0** CYLINDER ASSY.. Up Intake.4: SEAT, Intake valve SEAT, Exhaust valve GUIDE, Intake valve, flanged GUIDE, Exhaust valve, flanged INSERT. Spark plug. 8 -.5 MM (long reach) INSERT. /4-0 UNC x 3/8 long STUD. /4-0 x -3/8 long BUSHING, Rocker shaft, inner STUD, /4-0 x.00 long NIPPLE, /4 NPT to 3/8 tube NIPPLE, Union, /8 NPT GASKET. Exhaust flange WASHER. /4 plain NUT, /4-0 self-locking PLUG, /8 pipe * See latest edition of Textron Lycoming Service Instruction No. 5. ** Assemble in cylinder head when no priming lines are installed. 3-3
IO-540-ACA5 PARTS CATALOG Figure 4. CYLINDER ASSEMBLY 3-4
IO-540-ACA5 PARTS CATALOG CYLINDER, PISTON AND VALVE TRAIN VALVE ASSEMBLY AND RELATED PARTS FIG REF. 5 PART NUMBER DESCRIPTION QTY. PER ASSY. I LW-3 LW-8497 3 LW-797 4 LW-79 5 LW-33 LW-33 7 953 8 LW-475 9 7050 0 7C9 7C938 388 3 7890 4 5B39 5 LW-8944 LW-4995 7 LW-7 8 STD-4 9 LW-8 0 7030 5F9957-3* 5F9957-4* 5F9957-5* 5F9957-* 5F9957-7* 5F9957-8* 7F4** 3 74389 4 7549 5 7 LW-5 VALVE, Intake, hollow stem 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 SEAT. Valve spring, upper exhaust KEY, Valve intake KEY, Valve exhaust CAP, Valve stem, exhaust (rotator type) CAP, Valve stem PLUNGER ASSY., Hydraulic tappet SOCKET. Hydraulic tappet TUBE, Push rod shroud SPRING, Shroud tube LOCKPLATE, Shroud tube NUT, /4-0 plain SEAL. Shroud tube SEAL, Shroud tube ROD ASSEMBLY, Push ROD ASSEMBLY, Push ROD ASSEMBLY, Push ROD ASSEMBLY, Push ROD ASSEMBLY, Push ROD ASSEMBLY. Push ROCKER ASSY., Intake & exhaust valve BUSHING, Valve rocker WASHER. Valve rocker SHAFT, Valve rocker THRUST BUTTON, Rocker shaft * See latest edition of Textron Lycoming Service Instruction No. 00 for complete push rod application. ** Due to the size of the area where the part number is stamped, the last five digits may be all that is shown (4) 3-5
IO-540-ACA5 PARTS CATALOG Figure 5. VALVE ASSEMBLY AND RELATED PARTS 3-
0-540-ACA5 PARTS CATALOG CYLINDER, PISTON AND VALVE TRAIN CYLINDER RELATED PARTS FIG REF. PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 4 5 7 8 9 0 3 73 770 7709 STD-0 STD-4 703 LW-4433 STD-95 74494 748 7790 74887 383-B STD-090 STD-84 STD-80 LW-559-5-05 LW-8555 7T9439 LW-8557 LW-883 70 7 GASKET. Valve rocker shaft cover COVER. Valve rocker shaft SCREW. /4-0 x 5/8 long WASHER. /4 lock. internal teeth NUT. /4-0 plain GASKET. Rocker box cover COVER ASSY.. Rocker box SCREW. /4-0 x 5/8 long. pan. head PLATE. Spark plug reach caution RING. Oil seal. 3/3 dia. x 4-7/3 I.D. SPACER. 33/4 I.D. x 7/8 O.D. x /8 thick SPACER, 33/4 I.D. x 7/8 O.D. x 3/8 thick NUT. 3/8-4 plain NUT. /-0 plain NIPPLE. Straight. 3/8 I.D. hose HOSE, 3/8 I.D. x -3/ long CLAMP, Hose TUBE ASSY.. Cyl. hd. oil drain. cyl. # TUBE ASSY.. Cyl. hd. oil drain. cyl. # TUBE ASSY.. Cyl. hd. oil drain. cyl. # 3.4.5. BAFFLE ASSY.. Intercylinder HOOK. Intercylinder baffle RETAINER, Intercylinder baffle 3-7
IO-540-ACA5 PARTS CATALOG Figure. CYLINDER RELATED PARTS 3-8
IO-540-ACA5 PARTS CATALOG IGNITION SYSTEM MAGNETOS (SLICK), MAGNETO DRIVES, HARNESSES AND SPARK PLUGS PART NUMBER LW-34 LW-909 754 4 LW-707 LW-8 LC35SDNN 7J009-P 7J008-P M95 STD-475 STD-40 STD-73 8-H7* 0P97-4-7 DESCRIPTION CUSHION, Magneto drive RETAINER GEAR ASSY. BALL BEARING GASKET, Magneto adapter ADAPTER, Magneto GASKET, Magneto MAGNETO, Impulse, Slick Model No. 35 HARNESS. Left. Slick Model No. M-95 HARNESS, Right, Slick Model No. M-9 CLAMP, Magneto WASHER. 5/ lock, internal teeth NUT, 5/-8 plain COTTER PIN, 3/3 dia. x 3/4 long SPARK PLUG, Champion (RHB37E) or Auburn (73) BAG, Magneto harness attaching QTY. PER ASSY. * Item No. 4 spark plugs are used in current production only. Additional spark plugs are available for this engine. See latest edition of Textron Lycoming Service Instruction No. 04 for complete listing of all approved spark plugs. ** See page 4- for a breakdown of individual parts contained in the magneto and harness attaching parts bag. These parts to be attached by customer per engine line drawing included in each bag. 4-
0-540-AClA5 PARTS CATALOG P/N 0P97-4-7 LW--5-5 LW-400 STD-8 STD-0 STD-874 7734 LW--0-75 LW--5-44 STD-9 STD-9 STD-95 785 STD-9 STD-45 STD-70 LW-M-37 CLIP, One wire CLIP, Two wire WASHER, /4 plain WASHER,/4 lock SCREW, /4-0 x 3/ long ZIP STRAP CLAMP CLAMP, 7/ I.D. x /4 dia. screw WASHER, /4 plain (thin) SCREW, /4-0 x -/8 long SCREW, /4-0 x 5/8 long BRACKET, Support clamp, 90 SCREW, No. 0-3 x / long WASHER, No. plain LOCKNUT, No. 0-3 PLATE, Spark plug cable 4 4 8 5 4 4 4 4 4 5 -- 4 7-8- Figure 7. MAGNETOS (SLICK), MAGNETO DRIVES, HARNESSES AND SPARK PLUGS 4-
IO-540-ACA5 PARTS CATALOG ELECTRICAL SYSTEM SKY-TEC STARTER AND ATTACHING PARTS FIG REF. 8 QTY. PART PER NUMBER DESCRIPTION ASSY. 3B0 STD-475 3 LW-3-. 4 STD-40 STARTER, Sky-Tec (49-4 PM) WASHER. 5/ lock, internal teeth BOLT, 5/-8 x -5/3 long, hex. hd. NUT, 5/-8 plain NOTE See latest edition of Textron Lycoming Service Instruction No. 54 for complete listing of FAA approved starters, generators, alternators, regulators and relays. 5-
IO-540-ACA5 PARTS CATALOG Figure 8. SKY-TEC STARTER AND ATTACHING PARTS 5-
0-540-ACA5 PARTS CATALOG ELECTRICAL SYSTEM ALTERNATOR MOUNTING AND ATTACHING PARTS FIG REF. 9 PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 4 5 7 8 9 0 3 4 5 07A4 STD-33 STD-78 STD-59 07F43 STD-35 LW-3 H0.75 STD-34 LW-38H.09 AN7-4 STD-09 AN30-7 LW-450 STD-73 7534 3A70 3B47 789 MS5-5 LW-938 LW-35 778 779 STD-9 STD- BRACKET, Alternator WASHER. 3/8 plain WASHER. 3/8 lock, internal teeth NUT, 3/8-4 plain LINK, Alternator WASHER. 5/ plain BOLT. 5/-8 x 3/4 long, hex. hd., dr. WASHER. 7/8 O.D. x 5/4 I.D. x /8 thick BOLT, 3/8-8 x -3/3 long, hex. hd., dr. BOLT. 7/-0 x 4-/4 long, hex. hd. WASHER. 9/4 I.D. x 7/8 O.D. x /8 thick NUT, 7/-0 plain, slotted SHIM, 7/8 O.D. x 5/3 I.D. x.005 thick COTTER PIN. 3/3 dia. x 3/4 long SHIM, -/8 O.D. x 3/3 I.D. x.005 thick PULLEY & SHAFT ASSY.. Alternator belt PULLEY. Idler BALL BEARING. Double row, alt. RING. Internal retaining, -/4 dia. SHAFT, Alternator dual belt idler SHIELD. Alternator idler bearing LOCKWASHER, Alternator idler pulley brg. LOCKNUT, Alternator idler pulley bearing WASHER, 33/4 I.D. x.00 O.D. x /8 thick NUT, /-0 self-locking 5-3
IO-540-ACA5 PARTS CATALOG 0 Figure 9. ALTERNATOR MOUNTING AND ATTACHING PARTS 5-4
IO-540-ACA5 PARTS CATALOG OIL SUMP AND INDUCTION SYSTEM OIL SUMP ASSEMBLY, INDUCTION HOUSING AND OIL SUCTION SCREEN FIG REF. 0 PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 4 5 7 8 9 0 3 4 5 7 8 0B3 5A39 38-0 38-8 5C- STD-55 STD-8 STD-0 7455 LW-5-.75 LW-5-.3 LW-5-.00 STD-4 7744 0E979-.50 7745 4A49 0 07A43 0L43 STD-8 STD-0 LW-5-3.3 STD-8 STD-0 LW-5-0.8 LW-5-.88 LW-5-.00 GASKET, Oil sump SUMP ASSY., Oil STUD. 3/8- x -/ long STUD. 3/8- x 3-/ long STUD. /4-0 x -3/8 long PLUG, /-4 NPT, Sq. hd.. drilled WASHER, /4 plain WASHER, /4 lock, internal teeth SPACER. Exhaust manifold BOLT, /4-0 x -3/4 long, hex. hd. BOLT, /4-0 x -/8 long, hex. hd. BOLT, /4-0 x.00 long, hex. hd. NUT, /4-0 plain SCREEN, Oil suction GASKET, Annular, -/ I.D. PLUG, -/ - 8 hex. hd. HOUSING, Induction PLUG, /8 pipe BRACKET, Support induction housing SPACER, 9/3 I.D. x 9/ O.D. x.00 WASHER, /4 plain WASHER, /4 lock, internal teeth BOLT, /4-0 x 3-5/8 long, hex. hd. WASHER, /4 plain WASHER, /4 lock, internal teeth BOLT, /4-0 x 3/ long, hex. hd. BOLT, /4-0 x -7/8 long, hex. hd. BOLT, /4-0 x.00 long, hex. hd. -
IO-540-ACA5 PARTS CATALOG 7 Figure 0. OIL SUMP ASSEMBLY, INDUCTION HOUSING AND OIL SUCTION SCREEN -
0-540-ACA5 PARTS CATALOG OIL SUMP AND INDUCTION SYSTEM INTAKE PIPES AND ATTACHING PARTS FIG REF. PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 77 4E47 4E48 4E49 4E40 4E4 4E4 7973 7430 STD-8 STD-0 LW-5-.5 RING. Seal, intake pipes PIPE. Intake, cyl. no. PIPE. Intake. cyl. no. PIPE. Intake. cyl. no. 3 PIPE. Intake. cyl. no. 4 PIPE. Intake, cyl. no. 5 PIPE. Intake. cyl. no. GASKET. bolt flange. -3/4 I.D. FLANGE. Intake pipe WASHER. /4 plain WASHER. /4 lock, internal teeth BOLT, /4-0 x -/4 long, hex. head -3
IO-540-ACA5 PARTS CATALOG - 8 Figure. INTAKE PIPES AND ATTACHING PARTS -4
IO-540-ACA5 PARTS CATALOG OIL SUMP AND INDUCTION SYSTEM FUEL INJECTOR, FUEL MANIFOLD AND INJECTION NOZZLES FIG REF. PART NUMBER DESCRIPTION QTY. PER ASSY. 7303 M0 3 STD-77 4 STD-475 5 LW-3-. 0G379 7 AN99-8 MS95-0 9 7830 0 3B494 STD- AN79-3 STD-48 4 MS08-4 5 0G38 07A398 7 07A397 8 0L35* 9 STD-05* 0 STD-8 STD-0 STD-4 3 LW-5-0.50 4 STD-0 5 STD-5 STD-8 7 LW-878-4S0 8 LW-877-S80 9 LW-85 30 9539 GASKET. Fuel injector FUEL INJECTOR. (5754-) WASHER. Plain. /4 I.D. x 3/4 O.D. x /8 thick WASHER, 5/ lock, internal teeth BOLT. 5/-8 x -5/3 long, hex. hd. NIPPLE, /8 NPT to /4 tube REDUCER. 3/8 flared tube to /4 "O" RING. 5/3 I.D. x 5/4 section ELBOW, /4 tube. 90. 7/-0 adj. MANIFOLD ASSY.. Fuel, vented ELBOW, Union, 90, /8 NPT ELBOW. Union, 45, /8 tube NIPPLE, Union, /8 NPT ELBOW. /8 NPT to /4 tube, 90 NIPPLE, Nozzle pressure gauge BRACKET. Fuel manifold BRACKET, Fuel manifold SPACER. /4 long BOLT. /4-0 x -7/ long, hex. hd. WASHER, /4 plain WASHER. /4 lock, internal teeth NUT, /4-0 plain BOLT, /4-0 x / long WASHER, /4 lock, internal teeth WASHER. No. 0. internal lock SCREW, No. 0-4 x / long, fill. hd. HOSE ASSY., /4 hose, 45 elbow HOSE ASSY., 3/8 hose, 90 elbow NOZZLE, Injection (5484) "0" RING * These bolts and spacers replace P/N manifold bracket is installed. LW-5-.50 bolts shown on Figure 7, Page -3 when the fuel -5
IO-540-ACA5 PARTS CATALOG Figure. FUEL INJECTOR, FUEL MANIFOLD AND INJECTION NOZZLES -
IO-540-ACA5 PARTS CATALOG OIL SUMP AND INDUCTION SYSTEM FUEL LINES AND ATTACHING PARTS FIG REF. 3 PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 LW-098-0-0 LW-098-0-4 LW-098-0-40 LW- 098-0-340 LW-098-0-70 LW-098-0-80 0M47 733 STD-8 LW--0-3 LW--0-75 STD-80 STD-70 TUBE ASSY., Fuel manifold to nozzle TUBE ASSY., Fuel manifold to nozzle TUBE ASSY., Fuel manifold to nozzle TUBE ASSY., Fuel manifold to nozzle TUBE ASSY., Fuel manifold to nozzle TUBE ASSY., Fuel manifold to nozzle HOSE, 3/ I.D. x 7/ O.D. x -7/8 long BRACKET, Extension WASHER, /4 plain CLAMP, /8 dia. for No. 0 screw CLAMP SCREW. No. 0-3 x 5/8 long, fill. hd. LOCKNUT, No. 0-3 -7
IO-540-ACA5 PARTS CATALOG 0,,,3 0,,,3-8,9,0,0,,3 \ 0,0,,3 0,0,,,3 0,,,3 Figure 3. FUEL LINES AND ATTACHING PARTS -8
IO-540-ACA5 PARTS CATALOG OIL SUMP AND INDUCTION SYSTEM FUEL DRAIN MANIFOLD AND TUBE ASSEMBLIES FIG REF. 4 PART NUMBER DESCRIPTION QTY. PER ASSY. 3 4 5 7 8 9 0 3 4 5 3M38 LW-3807 STD-48 0 LW-098-0-0 LW-098-0-00 LW-098-0-090 LW-098-0-30 LW-098-0-0 STD-48 STD-853 LW--0-38 LW--0-3 STD-80 STD-70 MANIFOLD ASSY., Fuel drain ADAPTER ASSY.. Fuel drain valve NIPPLE. Union. /8 NPT PLUG. /8 pipe TUBE ASSY.. Fuel drain. cyl. no. TUBE ASSY.. Fuel drain. cyl. no. TUBE ASSY.. Fuel drain, cyl. no. 3 & 4 TUBE ASSY.. Fuel drain, cyl. no. & 5 TUBE ASSY.. Fuel drain. int.. rt. & It. NIPPLE. Union. /8 NPT TEE. Union, /8 tube CLAMP. 3/8 dia. for No. 0 screw CLAMP. /8 dia. for No. 0 screw SCREW. No. 0-3 x 5/8 long, fill. hd. LOCKNUT, No. 0-3 -9
0-540-ACA5 PARTS CATALOG 0 0 4 8 0 0 5 3 8- Figure 4. FUEL DRAIN MANIFOLD AND TUBE ASSEMBLIES -0
IO-540-ACA5 PARTS CATALOG SERVICE KIT SECTION... SEAL AND GASKET SET Part No. Part Name Qty. 05K79 LW-7 LW-8 LW-795 LW-40 LW-4995 LW-58 LW-834 LW-848 LW-838 LW-8 MS95-0 STD-80 STD-3 0M47 0A995 0B3 0E 979-0.3 0E979-.5 0E979-.50 833 009 83 4 73 835 7030 70455 748 7973 7053 7059 709 77 7303 7388 7408 7454 74944 703 SEAL & GASKET SET LOCKPLATE, Shroud tube GASKET, Magneto GASKET, Oil filter adapter SEAL, Tachometer SPRING, Shroud tube SEAL, Crankshaft GASKET, Exhaust GASKET, Oil filler adapter LOCKPLATE, Crankshaft gear SEAL, Shroud tube O-RING HOSE, Cyl. drain tube RING, Internal retaining HOSE, Fuel manifold tube OIL SEAL GASKET, Oil sump GASKET, Annular GASKET, Annular GASKET, Annular GASKET, Vacuum pump GASKET, Fuel pump GASKET, Accessory adapter GASKET, Magneto GASKET, Valve rocker cover GASKET, Accessory drive adapter SEAL, Shroud tube GASKET RING, Cylinder base GASKET, Intake GASKET, Governor drive pad GASKET, Oil level gage RING, Oil seal GASKET, Oil seal intake pipe GASKET, Air inlet housing GASKET, Accessory housing GASKET, Oil level gage RING, Oil level gage bushing GASKET, Fuel injector GASKET, Rocker box 7-3 3
LycomIng IO-540-ACA5 PARTS CATALOG SERVICE KIT SECTION... CYLINDER, PISTON & RING ASSY. KIT Part No. Part Name Qty. 05K7 A54 748 LW-8497 LW-3 LW-79 LW-797 953 LW-475 LW-33 LW-33 7050 7C9 388 7C938 LW-007-S 744 4H950 LW-4077 088 LW-775 LW-8 7030 LW-7 73 703 LW-834 7973 SSP-7 KIT, CYLINDER, PISTON & RING ASSY. (Long Reach) CYLINDER & HEAD ASSEMBLY RING, Cylinder base seal VALVE, Exhaust VALVE, Intake SPRING, Valve, outer SPRING, Valve, inner SEAT, Valve spring, upper intake SEAT, Valve spring, upper exhaust SEAT, Valve spring, lower intake SEAT, Valve spring, lower ehaust KEY, Valve, intake KEY, Valve, exhaust CAP, Valve stem, intake CAP, Valve stem, exhaust PISTON RING, Piston, compression RING, Piston, oil regulating PIN, Piston PLUG, Piston pin PLUG, Piston pin SEAL, Shroud tube, lower SEAL, Shroud tube, upper LOCKPLATE, Shroud tube GASKET, Valve rocker shaft cover GASKET, Rocker box cover GASKET, Exhaust GASKET, Intake TAG SERVICE KIT SECTION... CRANKCASE ASSY. AND THRU STUD KIT F404-S7-S F404-S7 70 3C-7 STD-339 AN55B03H4 AN55B 03H5 SSP-7 SSP-57 0 CRANKCASE ASSY. AND THRU STUD KIT CRANKCASE ASSEMBLY THRU STUD STUD, Governor PLUG, /-7 NPT SET SCREW, No. 0-3 x /4 long SET SCREW, No. 0-3 x 5/ long TAG, Piston cooling nozzles TAG, Gov. drive idler shaft PLUG, /8 pipe, oil pressure 7-8 4 7 4
IO-540-ACA5 PARTS CATALOG WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE NUMERICAL INDEX PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO. AN30-7 AN55B 03H5 AN-34A AN7-4 AN79- AN84-L AN8- AN840-D AN99- AN90C4 LW-5-0.50 LW-5-0.8 LW-5-0.94 LW-5-.00 LW-5-.3 LW-5-.3 LW-5-.3 LW-5-.5 LW-5-.50 LW-5-.50 LW-5-.50 LW-5S.50 LW-5-.75 LW-5-.75 LW-5-.88 LW-5-3.3 LW-3-. LW-3-. LW-3-. LW-3-.75 LW-3H0.75 LW-3H0.88 LW-38-.3 LW-38H.09 LW-007-S LW-044 LW-054 LW-35 LW- 5 LW-73 LW- 79 LW-797 Nut Set Screw Bolt Bolt Elbow Plug Nipple Breather Fitting Reducer Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Piston Gear Gear Assy. Shield Thrust Button Spring Spring Spring 5-3 -9-3 5-3 -5-3-3-9 -5 3-3 -5 - -3 - -3-3 - -3-3 -3-3 -3-3 - - - -3 5- -5-3 5-3 - -3 5-3 3- -9-9 5-3 3-5 -5 3-5 3-5 LW-098-0-0 LW-098-0-090 LW-098-0-00 LW-098-0-30 LW-098-0-40 LW-098-0-0 LW-098-0-70 LW-098-0-0 LW-098-0-80 LW-098-0-340 LW-098-0-4 LW-8 LW-7 LW-59 LW-8 LW-707 LW-795 LW-877-S80 LW-878-4S0 LW-35 LW-3 LW-33 LW-33 LW-34 LW-383 LW-3794 LW-3795 LW-3807 LW-3885 LW-389 LW-393 LW-40 LW-4077 LW-40 LW-4433 LW-450 LW-480 LW-4830 LW-4995 LW-5473 LW-559-5-05 LW-58 Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Tube Assy. Nut Lockplate Bolt Gasket Adapter Gasket Hose Assy. Hose Assy. Oil Filter Intake Valve Seat Seat Cushion Bearing Stud Shaft Adapter Assy. Bearing Plug Bushing Shaft Piston Pin Seal Rocker Cover Assy. Shim Ring Bearing Shroud Tube Spring Fuel Pump Clamp Seal -9-9 -9-9 -7-9 -7-7 -7-7 -7 3-3-5 3-4- 4- -9-5 -5-9 3-5 3-5 3-5 4- -5 - - -9-5 -9 3- -9 3- -3 3-7 5-3 -7-5. 3-5 -5 3-7 -5 8-
IO-540-ACA5 PARTS CATALOG WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE NUMERICAL INDEX (Continued) PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO. LW--0-3 LW--0-3 LW--0-38 LW--0-75 LW-475 LW-783- LW-8085 LW-834 LW-85 LW-848 LW-8497 LW-8555 LW-8557 LW-838 LW-8 LW-87 LW-883 LW-8944 LW-904 LW-909 LW-90 LW-938 LW-933-S LW-9340 MS5-5 MS08-4 MS95-0 MS95-0 MS95-0 STD-8 STD-8 STD-8 STD-8 STD-8 STD-8 STD-8 STD-8 STD-8 STD-9 STD-8 STD-33 STD-33 Clamp Clamp Clamp Clamp Seat Gage Assy. Spring Exhaust Gasket Injection Nozzle Gasket Exhaust Valve Tube Assy. Tube Assy. Lockplate Seal Pin Baffle Assy. Shroud Tube Seat Retainer Gear Assy. Counterweight Assy. Shaft Connecting Rod Assy. Camshaft Assy. Ring Elbow "O" Ring "O" Ring "O`" Ring Dowel -7-9 -9-7 3-5 -3-5 3-3 -5-3 3-5 3-7 3-7 -7 3-5 -7 3-7 3-5 3-3 4- -7 5-3 3- -7 5-3 -5 - -5-5 -3-3 -7-9 - -3-5 -7-3 -9-3 -3-3 STD-33 STD-33 STD-35 STD-35 STD-35 STD-35 STD-35 STD-3 STD-8 STD-48 STD-48 STD-48 STD-48 STD-0 STD-0 STD-0 STD-0 STD-0 STD-0 STD-0 STD-0 STD-0 STD-5 STD-5 STD-45 STD-475 STD-475 STD-475 STD-475 STD-475 STD-475 STD-54 STD-55 STD-557 STD-59 STD-59 STD-59 STD-9 STD-70 STD-70 STD-70 STD-78 Nut Screw Nipple Nipple Nipple Dowel Plug Dowel Nut Nut Nut Locknut Locknut Locknut -5 5-3 -9-3 -3-7 5-3 -3-5 3-3 -5-7 -9-3 -3-3 -7-9 3-7 - -3-5 -3-5 -3-9 -3-7 4-5- -5 - - - -3-3 5-3 5-3 -3-7 -9-3 8-
0-540-ACA5 PARTS CATALOG WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE NUMERICAL INDEX (Continued) PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO. STD-78 STD-78 STD-84 STD-73 STD-73 STD-74 STD-784 STD-798 STD-853 STD-80 STD-80 STD-80 STD-87 STD- 05 STD- STD-339 STD-34 STD-409 STD-40 STD-40 STD-40 STD-40 STD-4 STD-4 STD-4 STD-4 STD-4 STD-4 STD-4 STD- 40 STD-77 STD- 774 STD-85 STD-88 STD-95 STD-05 STD-044 STD-090 STD-09 STD- STD-8 STD-80 Nipple Cotter Pin Cotter Pin Cotter Pin Plug Dowel Tee Screw Screw Screw Nut Dowel Plug Plug Nut Nut Nut Nut Nut Nut Nut Nut Nut Nut Nut Nut Nut Pin Screw Screw Screw Bolt Nut Nut Elbow Nut Hose -3 5-3 3-7 4-5-3-3 - -9-9 -7-9 -3-3 -7-7 -3 5-3 -3-9 -7 4-5- -3-7 -9 3-5 3-7 - -5-3 -5-7 -9-5 3-7 -5 3-3 3-7 5-3 -5-3-7 STD-80 STD-09 STD- STD-3 STD-38 0-8 OD-8 5C-8 5C-0 5C- 5C- 5C- 5C- 3C- 3C-3 3C-7 3C- 3CD-0 38-3 38-0 38-38- 38-3 38-38-8 38D-7 50-5 383-B 08-B 0 0 0 0 8-H7 833 009 0430 088 0945 084 83 97 Hose Bolt Nut Ring Nipple Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Stud Nut Ball Plug Plug Plug Plug Spark Plug Gasket Gasket Cover Piston Plug Plug Spring Gasket Impeller 3-7 -7 5-3 -7-9 - - 3-3 -9 3-3 - -7 - - - - - - - - - - - - - - - 3-7 -5-3-3 - -9 4- -7-5 -7 3- -7-5 -7-3 8-3
IO-540-ACA5 PARTS CATALOG WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE NUMERICAL INDEX (Continued) PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO. 98 544 4 388 47 70 73 7530 753 754 835 88 90 953 979 7030 70455 748 7549 759 70 7 75 78 775 7903-A 7907 7973 7050 7053 7059 709 758 7377 7378 75 7 770 7709 770 77 7877 Impeller Plunger Gasket Cap Plug Bushing Gasket Bushing Adapter Assy. Ball Bearing Gasket Spring Insert Seat Dowel Seal Gasket Ring Hook Retainer Gear Assy. Gear Assy. Adapter Assy. Bushing Gasket Key Gasket Gasket Ring Bushing Elbow Cover Gear Shaft Insert Screw Cover Ring Body -3-4- 3-5 -9 3-3 3-7 - -7 4- -7-5 3-3 3-5 - 3-5 -9 3-7 3-5 -7 3-7 3-7 - - -7-7 -7-3 3-5 -9-3 -5 - -5-9 -7 3-5 3-3 3-7 3-7 -3-5 79 794 7974 7303 733 7349 7350 735 735 7348 7377 7380 7388 739 7408 744 74309 7430 74389 74494 7455 74887 755-S 7557-S 703 78 755 70 750 7534 778 779 7784 7788 7744 7745 7747 77808 7785 7787 7790 7890 Thrust Button Gear Assy. Gear Assy. Gasket Bracket Roller Nozzle Assy. Bushing Gasket Spacer Ring Ring Bearing Flange Bushing Plate Spacer Spacer Bushing Bushing Gasket Spacer Shaft Assy. Stud Gasket Shim Lockwasher Locknut Shaft Roller Screen Plug Spring Valve Assy. Oil Filter Base Assy. Bushing Spacer Plunger Assy. -7-7 -7-5 -7-9 -9-9 -9-7 - -7 - -3-3 3-3- -3 3-5 3-7 - 3-7 -7-7 3-7 -7-7 -3-9 5-3 5-3 5-3 -3-7 - - -5-5 -9-9 3-7 3-5 8-4
IO-540-ACA5 PARTS CATALOG WIDE CYLINDER FLANGE CRANKCASE MODEL ENGINE NUMERICAL INDEX (Continued) PART NO. PART NAME PAGE NO. PART NO. PART NAME PAGE NO. 789 9539 0L48 0L35 0L43 0P97-4-7 0G379 0G38 0M47 0A995 0B3 0E 979-0.3 0E 979-.5 0E979-.50 07A4 07A39 07A397 07A398 07A43 07C33 07E59 07F43 F404-S7 A0 A0 A33 A34 B87 D3 3F7743 3S948 4H950 5B39 5F9957-3 5F9957-4 5F9957-5 5F9957-5F9957-7 5F9957-8 A54 P709 R70 Ball Bearing 5-3 "O" Ring -5-9 Spacer -5 Spacer - Bag Attaching 4- Nipple -5 Nipple -5 Hose -7 Oil Seal -7 Gasket - Gasket -9 Gasket -5 Gasket - Bracket 5-3 Bracket -3 Bracket -5 Bracket -5 Bracket - Clamp -3 Support -3 Alternator Link 5-3 Crankcase Assy. - Eng. Mtg. Bracket -3 Eng. Mtg. Bracket -3 Eng. Mtg. Bracket -3 Eng. Mtg. Bracket -3 Lifting Eye -3 Adapter -3 Crk'shft & Bush. Assy. -7 Gear -7 Ring 3- Socket 3-5 Push Rod Assy. 3-5 Push Rod Assy. 3-5 Push Rod Assy. 3-5 Push Rod Assy. 3-5 Push Rod Assy. 3-5 Push Rod Assy. 3-5 Cylinder Assy. 3-3 Intake Valve Guide 3-3 Exhaust Valve Guide 3-3 T948 7C938 7C9 7F4 7T9439 8A9399 C539-04 3B0 3M4 3A70 3B47 4A49 4E47 4E48 4E49 4E40 4E4 4E4 5A8 5D7 53E44 5A39 5C33 M0 3B494 3M38 LC35SDNN M95 7J008-P 7J009-P Exhaust Seat Cap Key Rocker Assy. Tube Assy. Bearing Accy. Hsg. Assy. Starter Support Assy. Pulley & Shaft Assy. Idler Pulley Induction Housing Intake Pipe Intake Pipe Intake Pipe Intake Pipe Intake Pipe Intake Pipe Body Assy. Shaft Valve Assy. Sump Assy. Tube Fuel Injector Manifold Assy. Manifold Assy. Slick Magneto Clamp Harness Assy. Harness Assy. 3-3 3-5 3-5 3-5 3-7 -5-5- -7 5-3 5-3 - -3-3 -3-3 -3-3 -3-3 -9 - -3-5 -5-9 4-4- 4-4- 8-5