Textron Lycoming O-235-C User manual

OPERATOR’SMANUAL
REVISION
REVISIONNO. PUBLICATION PUBLICATIONNO. PUBLICATIONDATE
6029791 O235,O290SERIES 602979 January2007
Thepage(s)inthisrevisionreplace,addto,ordeletecurrentpagesintheoperator’smanual.
PREVIOUSREVISION CURRENTREVISION
NoneSeptember 2008
35,36,Addspage36A/B
©2008byLycoming“AllRightsReserved”
LycomingEngines,adivisionofAVCOCorporation,awhollyownedsubsidiaryofTextronInc.

NOTE
In order to accommodate clearer type, larger charts and graphs, and more
detailed illustrations, this edition of the O-235 and O-290 Series
Operator’s Manual, Lycoming Part Number 60297-9 is presented in an 8-
1/2 x 11 inch format. This edition is a complete manual, current as of the
date of issue. The manual incorporates all previously issued revisions.
This manual will be kept current by revisions available from Lycoming
distributors or from the factory. All revisions will be accompanied by an
Operator’s Manual Revision page which will identify the revision level, the
date of the revision, and the pages revised, added or deleted. All revisions
will be supplied in the 8-1/2 x 11 inch format.

Operator’s Manual
Lycoming
O-235 and O-290 Series
Approved by FAA
5th Edition Part No. 60297-9
652 Oliver Street January 2007
Williamsport, PA. 17701 U.S.A.
570/323-6181

O-235 and O-290 Series Operator’s Manual
Lycoming Part Number: 60297-9
©2007 by Lycoming. All rights reserved.
Lycoming and “Powered by Lycoming” are trademarks or registered trademarks of
Lycoming.
All brand and product names referenced in this publication are trademarks or registered
trademarks of their respective companies.
For additional information:
Mailing address:
Lycoming Engines
652 Oliver Street
Williamsport, PA 17701 U.S.A.
Phone:
Factory: 570-323-6181
Sales Department: 570-327-7268
Fax: [phone]
Lycoming’s regular business hours are Monday through Friday from 8:00 AM
through 5:00 PM Eastern Time (-5 GMT)
Visit us on the World Wide Web at:
http://www.lycoming.textron.com

LYCOMING OPERATOR’S MANUAL
ATTENTION
OWNERS, OPERATORS, AND MAINTENANCE PERSONNEL
This operator’s manual contains a description of the engine, its specifications, and detailed information on
how to operate and maintain it. Such maintenance procedures that may be required in conjunction with
periodic inspections arealso included. This manual is intended for use by owners, pilots and maintenance
personnel responsible for care of Lycoming powered aircraft. Modifications and repair procedures are
contained in Lycoming overhaul manuals; maintenance personnel should refer to these for such procedures.
SAFETY WARNING
NEGLECTING TO FOLLOW THE OPERATING INSTRUCTIONS AND TO CARRY OUT PERIODIC
MAINTENANCE PROCEDURES CAN RESULT IN POOR ENGINE PERFORMANCE AND POWER
LOSS. ALSO, IF POWER AND SPEED LIMITATIONS SPECIFIED IN THIS MANUAL ARE EXCEEDED,
FOR ANY REASON; DAMAGE TO THE ENGINE AND PERSONAL INJURY CAN HAPPEN. CONSULT
YOUR LOCAL FAA APPROVED MAINTENANCE FACILITY.
SERVICE BULLETINS, INSTRUCTIONS AND LETTERS
Although the information contained in this manual is up-to-date at time of publication, users are urged to
keep abreast of later information through Lycoming Service Bulletins, Instructions and Service Letters
which are available from all Lycoming distributors or from the factory by subscription. Consult the latest
revision of Service Letter No. L114 for subscription information.
SPECIAL NOTE
The illustrations, pictures and drawings shown in this publication are typical of the subject matter they
portray; in no instance are they to be interpreted as examples of any specific engine, equipment or part
thereof.
iii

LYCOMING OPERATOR’S MANUAL
IMPORTANT SAFETY NOTICE
Proper service and repair is essential to increase the safe, reliable operation of all aircraft engines. The
service procedures recommended by Lycoming are effective methods for performing service operations.
Some of these service operations require the use of tools specially designed to the task. These special tools
must be used when and as recommended.
It is important to note that most Lycoming publications contain various Warnings and Cautions which
must be carefully read in order to minimize the risk of personal injury or the use of improper service
methods that may damage the engine or render it unsafe.
It is also important to understand that these Warnings and Cautions are not all inclusive. Lycoming could
not possibly know, evaluate or advise the service trade of all conceivable ways in which service might be
done or of the possible hazardous consequences that may be involved. Accordingly, anyone who uses a
service procedure must first satisfy themselves thoroughly that neither their safety nor aircraft safety will be
jeopardized by the service procedure they select.
iv

WARRANTY
NEW AND REBUILT ENGINES
(1) WARRANTY AND REMEDY: Lycoming Engines, a division of Avco Corporation (hereinafter “Lycoming”)
warrants each new Lycoming reciprocating engine to be free from defect in material or workmanship under normal
use and service. Lycoming’s sole obligation under this warranty is limited to replacement or repair of parts which
are determined by Lycoming to have been defective within a period of twenty-four (24) months after new aircraft
delivery to the original retail purchaser or first user, or twenty-four (24) months from the date of first operation. The
warranty period of twenty-four (24) months commences on the earlier of the date of first operation after new aircraft
delivery to the original retail purchaser or first user, or twenty-four (24) months from the date of shipment from
Lycoming. Lycoming will, in connection with the foregoing warranty, cover reimbursement of reasonable freight
charges with respect to any such warranty replacement or repair.
(2) Within the warranty period, Lycoming will reimburse the Purchaser for labor charges associated with warranty
related issues. Lycoming will only reimburse the cost of such labor charges in connection with repair or
replacement of parts as provided in Lycoming’s then current Removal and Installation Labor and Allowance
Guidebook. Spare parts installed as warranty replacement on engines which are covered by this New Engine
Warranty will be warranted for the balance of the original warranty period or for the spare part warranty, whichever
is the greater. Replacement of parts may be with either new or reconditioned parts, at Lycoming’s election. A claim
for warranty on any part claimed to be defective must be reported in writing to Lycoming’s Warranty
Administration within 60 days of being found to require repair or replacement by the purchaser or service facility.
Warranty adjustment is contingent upon the Purchaser complying with the Lycoming’s Warranty Administration
disposition instructions for defective parts. Failure to comply with all of the terms of this paragraph may, at
Lycoming’s sole option, void this warranty.
(3) THIS WARRANTY IS GIVEN AND ACCEPTED IN PLACE OF (i) ALL OTHER WARRANTIES OR
CONDITIONS, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES
OR CONDITION OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND (ii) ANY
OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR IN TORT (DELICT),
INCLUDING PRODUCT LIABILITIES BASED UPON STRICT LIABILITY, NEGLIGENCE, OR IMPLIED
WARRANTY IN LAW AND PURCHASER HEREBY WAIVES SUCH RIGHTS AND CLAIMS.
(4) THIS WARRANTY IS THE ONLY WARRANTY MADE BY LYCOMING. THE PURCHASER’S SOLE
REMEDY FOR A BREACH OF THIS WARRANTY OR ANY DEFECT IN A PART IS THE REPAIR OR
REPLACEMENT OF ENGINE PARTS AND REIMBURSEMENT OF REASONABLE FREIGHT CHARGES AS
PROVIDED HEREIN. LYCOMING EXCLUDES LIABILITY, WHETHER AS A RESULT OF A BREACH OF
CONSEQUENTIAL DAMAGES, INCLUDING, BUT NOT LIMITED TO, DAMAGE TO THE ENGINE OR
OTHER PROPERTY (INCLUDING THE AIRCRAFT IN WHICH THE ENGINE IS INSTALLED), COSTS AND
EXPENSES RESULTING FROM REQUIRED CHANGES OR MODIFICATIONS TO ENGINE COMPONENTS
AND ASSEMBLIES, CHANGES IN RETIREMENT LIVES AND OVERHAUL PERIODS, LOCAL CUSTOMS
FEES AND TAXES, AND COSTS OR EXPENSES FOR COMMERCIAL LOSSES OR LOST PROFITS DUE TO
LOSS OF USE OR GROUNDING OF THE AIRCRAFT IN WHICH THE ENGINE IS INSTALLED OR
OTHERWISE. LYCOMING’S TOTAL LIABILITY FOR ANY AND ALL CLAIMS RELATED TO ANY
ENGINE SHALL IN NO CASE EXCEED THE ORIGINAL SALES PRICE OF THE ENGINE. SELLER MAKES
NO WARRANTY AND DISCLAIMS ALL LIABILITY WITH RESPECT TO COMPONENTS OR PARTS
DAMAGED BY, OR WORN DUE TO, CORROSION.

(5) This warranty shall not apply to any engine or part thereof which has been repaired or altered outside
Lycoming’s factory in any way so as, in Lycoming’s sole judgment, to affect its durability, safety or reliability, or
which has been subject to misuse, negligence or accident. Repairs and alterations which use or incorporate parts and
components other than genuine Lycoming parts or parts approved by Lycoming for direct acquisition from sources
other than Lycoming itself are not warranted by Lycoming, and this warranty shall be void to the extent that such
repairs and alterations, in Lycoming’s sole judgment, affect the durability, safety or reliability of the engine or any
part thereof, or damage genuine Lycoming or Lycoming-approved parts. No person, corporation or organization,
including Distributors of Lycoming engines, is authorized by Lycoming to assume for it any other liability in
connection with the sale of its engines or parts, nor to make any warranties beyond the foregoing warranty nor to
change any of the terms hereof. NO STATEMENT, WHETHER WRITTEN OR ORAL, MADE BY ANY
PERSON, CORPORATION OR ORGANIZATION, INCLUDING DISTRIBUTORS OF LYCOMING ENGINES
MAY BE TAKEN AS A WARRANTY NOR WILL IT BIND LYCOMING. NO AGREEMENT VARYING THE
TERMS OF THIS WARRANTY OR LYCOMING’S OBLIGATIONS UNDER IT IS BINDING UPON
LYCOMING UNLESS IN WRITING AND SIGNED BY A DULY AUTHORIZED REPRESENTATIVE OF
LYCOMING.
(6) All legal actions based upon claims or disputes pertaining to or involving this warranty including, but not limited
to, Lycoming’s denial of any claim or portion thereof under this warranty, must be filed in the courts of general
jurisdiction of Lycoming County, Commonwealth of Pennsylvania or in the United States District Court for the
Middle District of Pennsylvania located in Williamsport, Pennsylvania. In the event that Purchaser files such an
action in either of the court systems identified above, and a final judgment in Lycoming’s favor is rendered by such
court, then Purchaser shall indemnify Lycoming for all costs, expenses and attorneys’ fee incurred by Lycoming in
defense of such claims. In the event Purchaser files such a legal action in a court other than those specified, and
Lycoming successfully obtains dismissal of that action or transfer thereof to the above described court systems, then
Purchaser shall indemnify Lycoming for all costs, expenses and attorneys’ fees incurred by Lycoming in obtaining
such dismissal or transfer.
(7) Any invalidity of a provision of this Warranty shall not affect any other provision, and in the event of a judicial
finding of such invalidity, this Agreement shall remain in force in all other respects.
Effective September 2006 Revision “M”
Lycoming Engines
652 Oliver Street
Williamsport, Pennsylvania
17701
[phone]
www.lycoming.textron.com

LYCOMING OPERATOR’S MANUAL
TABLE OF CONTENTS
Page
SECTION1 DESCRIPTION 1-1
SECTION2 SPECIFICATIONS 2-1
SECTION 3 OPERATING INSTRUCTIONS 3-1
SECTION 4 PERIODIC INSPECTIONS 4-1
SECTION 5 MAINTENANCE PROCEDURES 5-1
SECTION6 TROUBLE-SHOOTING 6-1
SECTION 7 INSTALLATION AND STORAGE 7-1
SECTION8 TABLES 8-1
v

LYCOMING OPERATOR’S MANUAL
¾ Right Front View – O-235-C, O-290-D
Rear View – O-290-D2
vi

LYCOMING OPERATOR’S MANUAL
SECTION 1
DESCRIPTION
Page
General..........................................................................................................................................................1-1
Cylinders.......................................................................................................................................................1-1
Valve Operating Mechanism ......................................................................................................................1-1
Crankshaft....................................................................................................................................................1-1
Crankcase.....................................................................................................................................................1-1
Oil Sump.......................................................................................................................................................1-1
Connecting Rods ..........................................................................................................................................1-2
Pistons...........................................................................................................................................................1-2
Accessory Housing.......................................................................................................................................1-2
Gears.............................................................................................................................................................1-2
Cooling System.............................................................................................................................................1-2
Lubrication System......................................................................................................................................1-2
Induction System..........................................................................................................................................1-2
Ignition System.............................................................................................................................................1-2
Table of Models............................................................................................................................................1-3

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LYCOMING OPERATOR’S MANUAL SECTION 1
O-235 AND O-290 SERIES DESCRIPTION
SECTION 1
DESCRIPTION
The Lycoming O-235 series, O-290-D series and O-290-D2 series engines are four cylinder, direct drive,
horizontally opposed, wet sump, air-cooled models.
In referring to the location of the various engine components, the parts are described in their relationship
to the engine as installed in conventional airframes. Thus the power take-off end is considered the front and
the accessory drive section the rear. The sump section is considered the bottom and the opposite side of the
engine where the shroud tubes are located is the top. References to the left and right side of the engine are
made with the observer facing the rear of the engine. Thus the front cylinder on the left bank is number 2
and the rear cylinder is number 4. The front cylinder on the right bank is number 1 and the rear cylinder is
number 3. The direction of rotation for accessory drives is determined by the observer facing the drive pad.
The direction of rotation of the crankshaft, viewed from the accessory end of the engine is clockwise.
Cylinders – The cylinders are of conventional air-cooled construction with the two major parts, head and
barrel, screwed and shrunk together. The heads are made from an aluminum alloy casting with a fully
machined combustion chamber. The barrels, which are machined from chrome nickel molybdenum steel
forgings with deep integral cooling fins, are ground and honed to a specified finish.
The valve rocker shaft bearing supports and the rocker box housing are cast integrally with the head. The
valves are cooled by means of fins which completely surround the area of the exhaust valve and portions of
the intake valves. Valve guides and valve seats are shrunk into machined recesses in the head.
Valve Operating Mechanism – The valve operating mechanism is located on the topside. The camshaft is
located parallel to and above the crankshaft and operates in aluminum bearings. The camshaft in turn
actuates the valves by means of tappets. The valve rockers are supported on full floating steel shafts. The
valve springs bear against hardened steel seats.
NOTE
Hydraulic tappets which automatically keep the valve clearance at zero are employed on the
O-290-D2 series engines while solid tappets are employed on the O-235 and O-290-D series.
Proper valve clearance on the latter models is maintained by means of an adjusting screw
located in the valve rocker.
Crankshaft – Made from a chrome nickel molybdenum steel forging. All bearing surfaces are nitride
hardened. The expansion plug in the crankshaft must be removed on those models employing a two position
hydro control or variable pitch propeller.
Crankcase – Crankcase assembly consists of two reinforced aluminum alloy castings divided at the center
line of the engine and fastened together by bolts and nuts. The mating surfaces of the crankcase are joined
without the use of a gasket, and main bearing bores are machined for use of precision type main bearing
inserts.
Oil Sump – Incorporates an oil suction screen, carburetor mounting pad, the intake riser and intake pipe
connections. The fuel-air mixture, as it passes through the riser, is vaporized by the heated oil that surrounds
the riser.
1-1

SECTION 1 LYCOMING OPERATOR’S MANUAL
DESCRIPTION O-235 AND O-290 SERIES
Connecting Rods – Made in the form of “H” sections from alloy steel forgings. They have replaceable
bearing inserts in the crankshaft ends and split type bronze bushings in the piston ends. The bearing caps on
the crankshaft ends are retained by means of two bolts and nuts through each cap.
Pistons – Machined from an aluminum alloy. Two compression rings and an oil regulating ring are
employed on all pistons. In addition, the O-235 series employs an oil scraper ring below the piston pin. The
piston pin is of the full floating type with a plug located at each end to prevent the pin from touching the
cylinder wall.
Accessory Housing – Made from an aluminum casting and is fastened to the rear of the crankcase and the
top rear of the oil sump. It forms a housing for the oil pump and the various accessory drives.
Gears – Are of the conventional type and precision machined, hardened to insure long life and satisfactory
operating qualities.
Cooling System – These engines are designed to be cooled by air pressure actuated by the forward speed of
the aircraft. Close fitting baffles build up a pressure and force the air through the cylinder fins. The air is
then exhausted through gills or augmentor tubes usually located at the rear of the cowling.
Lubrication System – The full pressure wet sump lubrication system is actuated by an impeller type oil
pump contained within the accessory housing.
Induction System – These engines are equipped with either of two Marvel-Schebler carburetors, MA-3A or
MA-3SPA. See Table 1 for model application. Both carburetors are of the single barrel float type and are
equipped with manual mixture control and “idle cut-off”. Particularly good distribution of the fuel-air
mixture to each cylinder is obtained from the center zone induction system, which is integral with the sump
and is submerged in oil, insuring a more uniform vaporization of fuel and aiding in cooling the oil in the
sump. From the riser the fuel-air mixture is distributed to each cylinder by individual intake pipes.
Ignition System – Dual ignition is furnished by two magnetos. Consult Table 1 for proper model application.
Depending on installation, the ignition wiring is so arranged as shown in either Figure 5-1, 5-2 or 5-3.
1-2

LYCOMING OPERATOR’S MANUAL SECTION 1
O-235 AND O290 SERIES DESCRIPTION
TABLE 1
MODEL APPLICATION
Magneto
Model
Left Right
Carburetor
Propeller Flange
Specification
(Modified)
O-235-C S4LN-21 S4LN-20 MA-3A or –3PA AS-127-2
O-235-C1,-E1,-F1,-G1 S4LN-21 S4LN-20 MA-3A or –3PA AS-127-2
O-235-C1B,-E1B,-F1B,-G1B S4LN-200 S4LN-204 MA-3A or –3PA AS-127-2
O-235-C2A,-E2A,-F2A,-G2A,
-K2A,-J2A S4LN-21 S4LN-20 MA-3A or –3PA AS-127-1
O-235-L2A*,-N2A*,-P2A* S4LN-21 S4LN-20 or
S4LN-204 MA-3A or –3PA AS-127-1
O-235-M1* S4LN-21 S4LN-20 or
S4LN-204 MA-3A or –3PA AS-127-2
O-235-C2B,-E2B,-F2B,-G2B,
-K2B,-J2B S4LN-1227 S4LN-1209 MA-3A or –3PA AS-127-1
O-235-C2C,-H2C 4251 4250 MA-3A or –3PA AS-127-1
O-235-K2C 4252 4250 or
4252 MA-3A or –3PA AS-127-1
O-235-L2C,-N2C** 4252 or
4281 4250 or 4281 MA-3A or –3PA AS-127-1
O-290-D S4LN-21 S4LN-20 MA-3SPA AS-127-2
O-290-D2 S4LN-21 S4LN-20 MA-3SPA AS-127-2
O-290-D2A S4LN-21 S4LN-20 MA-3SPA AS-127-2
O-290-D2B S4LN-21 S4LN-20 MA-3SPA AS-127-2
O-290-D2C S4LN-200 S4LN-204 MA-3SPA AS-127-2
* - O-235-L2A, -M1, -N2A, -P2A may have two (2) S4LN-21 magnetos as optional equipment.
** - O-235-L2C, -N2C may have two (2) 4252 magnetos as optional equipment.
1-3

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LYCOMING OPERATOR’S MANUAL
SECTION 2
SPECIFICATIONS
Page
Specifications – O-235-C, -E Series; O-235-C1C......................................................................................2-1
Specifications – O-235-F, -G, -J, -N, -P, -K, -L, -M Series.......................................................................2-2
Specifications – O-235-H Series; O-235-K2C............................................................................................2-3
Specifications – O-290-D; O-290-D2, -D2A, -D2B, -D2C.........................................................................2-4
Accessory Drives ..........................................................................................................................................2-5
Alternate Power Settings.............................................................................................................................2-5
Detail Weights ..............................................................................................................................................2-6

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LYCOMING OPERATOR’S MANUAL SECTION 2
O-235 AND O-290 SERIES SPECIFICATIONS
SECTION 2
SPECIFICATIONS
O-235-C*, -E SERIES
FAA Type Certificate ....................................................................................................................................223
Take-off horsepower......................................................................................................................................115
Take-off RPM..............................................................................................................................................2800
Rated horsepower...........................................................................................................................................115
Rated RPM...................................................................................................................................................2800
Bore, inches.................................................................................................................................................4.375
Stroke, inches..............................................................................................................................................3.875
Displacement, cubic inches.........................................................................................................................233.3
Compression ratio..................................................................................................................................... 6.50:1
Prop. drive ratio ............................................................................................................................................. 1:1
Prop. driven rotation (viewed from rear)............................................................................................Clockwise
Firing orders............................................................................................................................................ 1-3-2-4
Spark occurs, BTC.........................................................................................................................................25°
Rocker clearance, cold......................................................................................................................... .007/.009
* - O-235-C1 has provision for two position prop. control valve.
O-235-C1C
FAA Type Certificate ....................................................................................................................................223
Take-off horsepower......................................................................................................................................115
Take-off RPM..............................................................................................................................................2800
Rated horsepower...........................................................................................................................................108
Rated RPM...................................................................................................................................................2600
Bore, inches.................................................................................................................................................4.375
Stroke, inches..............................................................................................................................................3.875
Displacement, cubic inches.........................................................................................................................233.3
Compression ratio..................................................................................................................................... 6.75:1
Prop. drive ratio ............................................................................................................................................. 1:1
Prop. driven rotation (viewed from rear)............................................................................................Clockwise
Firing orders............................................................................................................................................ 1-3-2-4
Spark occurs, BTC.........................................................................................................................................25°
Rocker clearance, cold......................................................................................................................... .007/.009
2-1

SECTION 2 LYCOMING OPERATOR’S MANUAL
SPECIFICATIONS O-235 AND O-290 SERIES
SPECIFICATIONS (CONT.)
O-235-F, -G, -J
FAA Type Certificate ....................................................................................................................................223
Take-off horsepower......................................................................................................................................125
Take-off RPM..............................................................................................................................................2800
Rated horsepower...........................................................................................................................................125
Rated RPM...................................................................................................................................................2800
Bore, inches.................................................................................................................................................4.375
Stroke, inches..............................................................................................................................................3.875
Displacement, cubic inches.........................................................................................................................233.3
Compression ratio....................................................................................................................................... 9.7:1
Prop. drive ratio ............................................................................................................................................. 1:1
Prop. driven rotation (viewed from rear)............................................................................................Clockwise
Firing orders............................................................................................................................................ 1-3-2-4
Spark occurs, BTC.........................................................................................................................................25°
Rocker clearance, cold......................................................................................................................... .007/.009
O-235-N, -P
FAA Type Certificate ....................................................................................................................................223
Take-off horsepower......................................................................................................................................116
Take-off RPM..............................................................................................................................................2800
Rated horsepower...........................................................................................................................................116
Rated RPM...................................................................................................................................................2550
Bore, inches.................................................................................................................................................4.375
Stroke, inches..............................................................................................................................................3.875
Displacement cubic inches..........................................................................................................................233.3
Compression ratio....................................................................................................................................... 8.1:1
Prop. drive ratio ............................................................................................................................................. 1:1
Prop. driven rotation (viewed from rear)............................................................................................Clockwise
Firing orders............................................................................................................................................ 1-3-2-4
Spark occurs, BTC.........................................................................................................................................20°
Rocker clearance, cold......................................................................................................................... .007/.009
O-235-K, -L, -M
FAA Type Certificate ....................................................................................................................................223
Take-off horsepower......................................................................................................................................118
Take-off RPM..............................................................................................................................................2800
Rated horsepower...........................................................................................................................................118
Rated RPM...................................................................................................................................................2800
Bore, inches.................................................................................................................................................4.375
Stroke, inches..............................................................................................................................................3.875
Displacement, cubic inches.........................................................................................................................233.3
Compression ratio....................................................................................................................................... 8.5:1
Prop. drive ratio ............................................................................................................................................. 1:1
Prop. driven rotation (viewed from rear)............................................................................................Clockwise
Firing orders............................................................................................................................................ 1-3-2-4
Spark occurs, BTC.........................................................................................................................................20°
Rocker clearance, cold......................................................................................................................... .007/.009
2-2