PARTS CATALOG

PC-3024

LYCOMING

O-235-P2A

AIRCRAFT ENGINES

AUGUST 1995

652 Oliver Street

Williamsport PA 17701 U.S.A.
7171323.6181
 INTRODUCTION

This illustrated parts catalog contains a complete parts listing for the Avco Lycoming O-235-P2A model air-
craft engines.

Major assembly and sub-assembly parts of the engines are listed in the Group Assembly sections in the
general sequence of engine build up.

A Service Kits section and Oversize and Undersize Parts List are included to aid in ordering parts as necessary
during overhaul.

The Numerical Index is provided for convenience in finding parts when only the part number is known.

Parts coverage of Vendor Accessories used on Avco Lycoming engines may be found in the appropriate Ven-
dor's Parts Catalog. A list of these publications appear in the latest edition of Service Letter No. L114.

NOTE

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

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

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

SERVICE BULLETINS, INSTRUCTIONS AND LETTERS

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

HOW TO ORDER PARTS

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

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

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

i
 LYCOMING 0-235-P2APARTSCATALOG

TABLE OF CONTENTS

SECTION PAGE

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

1. CRANKCASE, CRANKSHAFT AND CAMSHAFT GROUP

Crankcase A ssem bly ..................................................... ............... 1-1
Oil Level Gage Assem bly ................................................................. 1-3
Crankshaft, Camshaft and Related Parts ................................................... 1-5
Crankcase Related Parts .................................................................. 1-7
Crankshaft Idler Gears and Tachometer Shaft ................................................ 1-9
Crankcase Attaching Parts ................................................... ......... 1-11

2. ACCESSORY HOUSING AND RELATED PARTS

Accessory Housing Assembly ....................... ................................ ..... 2-1
Oil Pump Assembly and Accessory Housing Attaching Parts .................................... 2-3
Propeller Governor Oil Line ............................................................ 2-5
Propeller Governor Drive and Cover ................. .................................. 2-7
Fuel Pump Assembly and Attaching Parts ................................................... 2-9
Vacuum Pump Drive and Cover ......................................................... 2-10
Oil Filter Assembly and Oil Cooler Bypass Valve ............................................. 2-11

3. CYLINDER, PISTON AND VALVE TRAIN

Connecting Rods, Pistons and Ring Assemblies ............................................... 3-1
Cylinder Assembly ................................................................. 3-3
Cylinder R elated Parts .................................................................. 3-5
Valve Assembly ................................................................. 3-7
Cylinder Head Drain Tubes and Intercylinder Cooling Baffles ................... ............ 3-9

4. IGNITION SYSTEM
Magnetos, Drives, Harnesses and Spark Plugs ............................ ................... 4-1

5. ELECTRICAL COMPONENTS
Starter Motor and Attaching Parts ......................................................... 5-1

6. OIL SUMP AND INDUCTION SYSTEM

Oil Sump Assembly and Oil Suction Screen ................................................... 6-1
Intake Pipe Assembly ................................................................ 6-3
Carburetor Assembly ................................................................... 6-5
Prim ing System ......................................................................... 6-7

7. SERVICE KIT SECTION

Seal and G asket Set ...................................................................... 7-1
Cylinder, Piston and Ring Assembly ........................................................ 7-2

8. NUMERICAL INDEX ......... . ................................................... 8-1

ii
 LYCOMING 0-235-P2APARTSCATALOG

Oversize
and Unclersize
PartsListing

PARTNO. DESCRIPTION OVERSIZE UNDERSIZE

P02 P05 P10 P15 P20 P30 P40 P50 M03 M06 M10
.002 .005 .010 .015 .020 .030 .040 .050 .003 .006 .010
60814 BUSHING X X X X
61681 GUIDE X X X X X
66796 INSERT X
68763 BEARING X X X
69373 BEARING X X X X
69796 DOWEL X
73757 BUSHING X X X X
LW-11626 GUIDE X X X X X
LW-11900 SEAT X X X
LW-13792 SEAL X
LW-13884 BEARING X X X X
LW-16699 SEAT X X X
STD-1065 DOWEL X X X X

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

NOTE

Whenorderingoversizeand undersizeparts, besure to specifythe requiredoversizeand undersizedimensionalongwiththe proper

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

iii
 O-235-P2A PARTSCATALOG
CRANKCASE,
CRANKSHAFT
ANDCAMSHAFT
GROUP
CRANKCASE
ASSEMBLY

FIG. QUANTITY
REF. PART PER
I NUUMBER DESCRIPTION ASSEMBLY

1 LW-16354* CRANKCASEASSEMBLY 1
2 STD-557 DOWEL,1/2 dia.x 19/32 long,hollow 2
3 LW-11623 STUD,7/16-20x 10-7/16long 2
4 LW-11622 STUD,7/16-14x 9-25/32long 4
5 44-13 STUD,7/16-14x 1-5/8 long 8
6 38-13 STUD,3/8-16x 1-5/8 long 16
7 1102 PLUG,
1/8-27 NPT,Allen 3
8 STD-514 DOWEL,5/16 dia.x 1/2 long 2
9 69796 DOWEL,Crankshaftbearing 2
10 STD-111 ELBOW,3/4 pipe & hose(90° ) 1
11 31C-12 STUD,5/16-18x 1-1/2 long 4

* Usedwithvariablepitchprop.

1-1
LYCOMING 0-235-P2APARTSCATALOG

10

6
5

Figure 1. CRANKCASEASSEMBLY
1-2
 CRANKCASE,
CRANKSHAFT ANDCAMSHAFT
GROUP
OIL LEVELGAGEASSEMBLY

FIG. QUANTITY
REF. PART PER
2 NUMBER DESCRIPTION ASSEMBLY

1 75767 TUBE,Oillevelgage 1
2 72059 GASKET, Oil levelgage 1
3 74065 RING,Oillevelgageseal 1
4 LW-14781 GAGE
ASSY.,Oil level 1
5 72844 PLUG, Oillevelgage 1

1-3
LYCOMING 0-235-P2APARTSCATALOG

-2

Figure 2. OIL LEVELGAGE ASSEMBLY

1-4
 LYCOMING O-235-P2APARTSCATALOG
CRANKCASE,
CRANKSHAFT
ANDCAMSHAFTGROUP
CRANKSHAFT,
CAMSHAFT
ANDRELATED
PARTS

FIG. QUANTITY
REF. PART PER
3 NUMBER DESCRIPTION ASSEMBLY

1 LW-12695* CRANKSHAFT ASSEMBLY 1

2 STD-1211 PLUG,2.00dia. expansion 1
3 STD-1065 DOWEL, Stepped, 19/64x 1/4 dia.x 35/64 long 1
4 61510 PLUG,1-3/4 O.D. 1
5 73757 BUSHING,Propeller flange(index) 1
6 60814 BUSHING,Propeller 5
7 75706 CAMSHAFT 1
8 61155 GEAR,
Crankshaft 1
9 LW-18639 LOCKPLATE,
Crankshaft gear 1
10 STD-2213 SCREW,5/16-24x 1.00long 1
11 LW-13675 SUPPORTASSY.,Starterring gear,10/12 pitch3.25:1drive 1
12 60882 GEAR,Starterring, 10/12 pitch 1

* Usedwithvariable
pitchprop.

1-5
 LYCOMING 0-235-P2APARTSCATALOG

12-

11-

Figure 3. CRANKSHAFT, CAMSHAFT AND RELATED PARTS

1-6
 35-P2APARTSCATALOG
CRANKCASE,
CRANKSHAFT
ANDCAMSHAFT
GROUP
CRANKCASE
RELATED
PARTS

FIG. QUANTITY
REF. PART PER
4 NUMB
ER DESCRIPTION ASSEMBLY

1 1028B BALL,11/16dia. 1
2 61084 SPRING,Oilpressurereliefvalve 1
3 STD-425 WASHER, No. 10 plain (max.9) AR
4 STD-1045 GASKET, 1-1/4 I.D. x 1-1/2O.D.x 3/32 annular 1
5 76529 PLUG,Oilreliefvalve 1
6 68763* BEARING,Crankshaft (usein pairs) 4
7 LW-13884* BEARING,Crankshaft, front 2
8 LW-13792 SEAL,Crankshaft oil 1
9 72091 RING,Oilseal23/64 I.D. x 7/64 dia.section 8
10 71105 BODY,Tappet 8

*Used withvariable
pitchprop.

1-7
 LYCOMING 0-235-P2APARTSCATALOG

10

Figure 4. CRANKCASERELATEDPARTS
1-8
 LYCOMING 0-23
35-P2A PARTSCATALOG
CRANKCASE,
CRANKSHAFT
ANDCAMSHAFT
GROUP
CRANKSHAFT
IDLERGEARS
ANDTACHOMETER
SHAFT

FIG. QUANTITY
REF. PART PER
5 NUMBER DESCRIPTION ASSEMBLY

1 61544 PLUNGER, Fuelpump,long 1

2 74996 GEARASSY.,Crankshaft idler 1
3 77309 BUSHING, 'Crankshaftidlergear 1
4 75072 GEARASSY.,Crankshaft idler 1
5 77309 BUSHING, Crankshaftidlergear 1
6 75708 SHAFTASSY.,Tachometer 1
7 LW-18667 PIN,3/16 x 2-5/16 long 1
8 45530 RING,Oilpumpshaftretaining 1
9 61151 SHAFT,Crankshaftidlergear 2
10 73817 LOCKPLATE, 1/4 bolt,1-3/4 spacing 2
11 STD-705 BOLT,1/4-20x 11/16 long 4

1-9
LYCOMING 0-235-P2APARTSCATALOG

Figure 5. CRANKSHAFT IDLER GEARSAND TACHOMETER SHAFT

1-10
 0-235-P2APARTSCATALOG
CRANKCASE,
CRANKSHAFT
ANDCAMSHAFTGROUP
CRANKCASE
ATTACHING
PARTS

FIG. QUANTITY
REF. PART PER
6 NUMBER DESCRIPTION ASSEMBLY

1 LW-25-1.50 BOLT,1/4-20 x 1-1/2 long,hex.head 8

2 STD-8 WASHER, 1/4 plain 16
3 60803 STRAP,Lifting 1
4 LW-25-1.75 BOLT,1/4-20 x 1-3/4 long,hex.head 1
5 AN6-21 BOLT,3/8-24 x 13/64 long,hex.headdrive 1
6 STD-160 WASHER, 1/4 lock,internallock 9
7 STD-1411 NUT,1/4-20 plain 9
8 LW-25S1.50 BOLT,1/4-20x 1-1/2 long,dr. end 3
9 STD-8 WASHER, 1/4 plain(Max.9) AR
10 STD-1409 NUT,1/4-20 slottedshear 3
11 STD-33 WASHER, 3/8 plain 2
12 STD-872 NUT,3/8-24, slotted 1
13 AN6-34A BOLT,3/8-24 x 37/64 long,hex.hd. 2
14 STD-33 WASHER, 3/8 plain 4
15 STD-678 WASHER, 3/8 lock, internalteeth 2
16 STD-596 NUT,3/8-24 plain 2

1-11
 LYCOMING 0-235-P2APARTSCATALOG

1 -5,11,12

13,1

13,14 15,16

6,7,8,9

1,6,7,9

1,2,6,7

Figure 6. CRANKCASEATTACHING PARTS

1-12
 LYCOMING 0-235-P2APARTSCATALOG
ACCESSORY
HOUSING
ANDRELATED
PARTS
ACCESSORY
HOUSING
ASSEMBLY

FIG. QUANITITY
REF. PART PER
7 NUMBER DESCRIPTION ASSEMBLY

1 73818 GASKET,
Accessoryhousing 1
2 LW-12044 HOUSINGASSEMBLY, Accessory 1
3 31C-12 STUD,5/16-18x 1-1/2 long 6
4 31C-19 STUD,5/16-18x 2-3/8 long 2
5 31CD-17 STUD,5/16-18x 2-1/8 long,drilled 3
6 1102 PLUG,
1/8-27 NPT 2
7 61175 ADAPTER,Tachometer 1
8 STD-783 PLUG,
1/4-28 NPT,Allen 1
9 61400 STUD,1/4-20x 1-3/16 long 2
10 25C-22 STUD,1/4-20x 2-3/4 long 4
11 STD-784 PLUG,
3/8-18 NPT,Allen 1

2-1
Figure 7. ACCESSORYHOUSING ASSEMBLY
2-2
 PARTSCATALOG
O-235-P2A
ACCESSORYHOUSING
ANDRELATED
PARTS
OIL PUMPASSEMBLYANDACCESSORY
HOUSING
ATTACHING
PARTS

FIG. QUANTITY
REF. PART PER
8 NUMBER DESCRIPTION ASSEMBLY

1 78531 BODYASSY.,Oilpump 1
2 LW-18110 IMPELLERASSY.,Oil pumpdriven 1
3 61174 SHAFT,Oilpumpdriven 1
4 LW-18109 IMPELLER,Oilpumpdriving 1
5 STD-35 WASHER, 5/16 plain 1
6 STD-1420 NUT,5/16-18slotted 3
7 LW-14260 SEAL,Tachometerdrive,oil 1
8 STD-8 WASHER, 1/4 plain 13
9 STD-160 WASHER, 1/4 lock,internalteeth 12
10 LW-25-2.00 BOLT,1/4-20x 2.00long,hex.head 2
11 LW-25-0.94 BOLT,1/4-20x 15/16 long,hex.head 10
12 STD-1411 NUT,1/4-20 plain 2

2-3
 LYCOMING 0-235-P2APARTSCATALOG

8,9,11

8,9,10

2-

8,9,11
8,9-

1
12

12

Figure 8. OIL PUMP ASSEMBLYAND ACCESSORYHOUSING ATTACHING PARTS

2-4
 ACCESSORY
HOUSINGANDRELATED PARTS
PROPELLER
GOVERNOR
OIL LINE

FIG. QUANTITY
REF. PART PER
9 NUMBER DESCRIPTION ASSEMBLY

1 75167 TUBEASSY.,Prop.governor oil line 1

2 STD-1930 HOSE,3/8 I.D. x 1.00long 1
3 75165 CLIP,Prop.governor oil linesupport 1
4 STD-35 WASHER, 5/16 plain 3
5 STD-475 WASHER, 5/16 lock,internalteeth 1
6 STD-1838 BOLT,5/16-18x 15/16long,hex.hd. 1
7 LW-16266-25-38 CLAMP 1
8 MS20822-6* ELBOW, 3/8 flaredtube& 1/4 NPT,90° 1
9 74070** ELBOW, 3/8 flaredtube& 9/16-18str. thd., adj.45° 1
10 MS29512-06 "O" RING 1

* Assemble
in rightcrankcase,
front.
** Assemblein prop. governoradapter.

2-5
LYCOMING 0-235-P2A PARTS CATALOG

-1

Figure 9. PROPELLERGOVERNOR OIL LINE

2-6
 LYCOMING 0-235-P2APARTSCATALOG
ACCESSORY
HOUSING
ANDRELATED PARTS
PROPELLER
GOVERNORDRIVEANDCOVER

FIG. QUANTITY
REF. PART PER
10 NUMBER DESCRIPTION ASSEMBLY

1 68317 SHAFTGEAR, Prop.governor drive 1

2 71596 WASHER, Accessory drivengear 1
3 STD-1221 RING,13/16dia.x 3/64 thick, internalretaining 1
4 68315 GASKET,Accessory driveadapter 1
5 75153 ADAPTERASSY.,Prop.governor drive 1
6 1102 PLUG, 1/8-27 NPT,Allen 1
7 31C-16 STUD,5/16-18x 2.00 long 4
8 STD-1774 PIN,1/8 x 1/4 long 1
9 STD-35 WASHER, 5/16 plain 4
10 STD-475 WASHER, 5/16 internallock 4
11 STD-1410 NUT,5/16-18plain 4
12 72053 GASKET,Governor 1
13 72378 COVER,Governor drive 1
14 STD-35* WASHER, 5/16 plain AR
15 STD-475 WASHER, 5/16 internallock 4
16 STD-1410 NUT,5/16 plain 4

* 32 requiredfor Woodward
governor;
4 requiredfor ANgovernor.

2-7
Figure 10. PROPELLERGOVERNOR DRIVE AND COVER
2-8
 LYCOMING 0-235-P2APARTSCATALOG
ACCESSORY
HOUSINGANDRELATED
PARTS
FUELPUMPASSEMBLYANDATTACHING
PARTS

FIG. QUANTITY
REF. PART PER
11 NUMBER DESCRIPTION ASSEMBLY

1 60096 GASKET,Fuelpump 1
2 LW-15472 FUELPUMP,Low pressure,dual diaphragm(6441271) 1
3 STD-33 WASHER,3/8 plain 2
4 STD-1882 SCREW,3/8-16 x 1-9/32 long, sockethead, dr. hd. 2

Figure 11. FUEL PUMP ASSEMBLYAND ATTACHING PARTS

2-9
 LYCOMING 0-235-P2APARTSCATALOG
ACCESSORY
HOUSING
ANDRELATEDPARTS
VACUUMPUMPDRIVEANDCOVER

FIG. QUANTITY
REF. PART PER
12 NUMBER DESCRIPTION ASSEMBLY

1 61183 GASKET, Accessoryadapter 1

2 61098 ADAPTER ASSY.,Vacuumpump 1
3 STD-1774 PIN, 1/8 dia. x 1/4 long 1
4 STD-2217 SEAL,Oil, 7/8 I.D. x 1-1/2 O.D. x 5/16 wide 1
5 72970 GEARASSY.,Vacuumpump driven 1
6 71596 WASHER,Accessorydriven gear 1
7 8313 GASKET, Vacuumpump 1
8 60430 COVER,Vacuumpump 1
9 STD-8 WASHER,1/4 plain 4
10 STD-160 WASHER,1/4 lock 4
11 STD-1411 NUT,1/4-20 plain 4

7-

8
9
10-
11 - \

Figure 12. VACUUM PUMP DRIVE AND COVER

2-10
 ACCESSORY
HOUSING
ANDRELATED PARTS
OIL FILTERASSEMBLY
ANDOIL COOLER
BYPASSVALVE

FIG. QUANTITY
REF. PART PER
13 NUMBER DESCRIPTIONI ASSEMBLY

1 LW-12795 GASKET,Oil filter adapter 2

2 LW-12999 PLATE,Oilfilter adapter 1
3 77852 BASEASSY. , Oil filter 1
4 LW-13215 OIL FILTER,Short, spin-on 1
5 STD-8 WASHER,1/4 plain 4
6 STD-160 WASHER,1/4 lock 1
7 STD-1411 NUT,1/4-20 plain 1
8 STD-1856 SCREW,1/4-20 x 1.00 hex. hd., self-locking 3
9 75944 VALVEASSY.,Temp.control, oil coolerbypass 1
10 76510 GASKET, Valveassembly 1
11 25C-10 STUD,1/4-20 x 1-1/4 long 1
12 STD-294 GASKET, 7/8 x 5/8 I.D. x 3/32 annular 1
13 62417 PLUG,Oil coolerbypass 1
14 STD-784 PLUG,3/8 NPT 2

2-11
 LYCOMING O-235-P2APARTSCATALOG

12

2-
1
3

6
7

4 i

5
-8

10

Figure 13. OIL FILTERASSEMBLYAND OIL COOLER BYPASSVALVE

2-12
 CYLINDER,
PISTONANDVALVETRAIN
CONNECTING
RODS,PISTONS
ANDRINGASSEMBLIES

FIG. QUANTITY
REF. PART PER
14 NUMBER DESCRIPTION ASSEMBLY

1 78030 ROD ASSY.,Connecting 4

2 LW-13923 BUSHING, Connecting rod, upper 4
3 78027 BOLT,Connecting rod 8
4 LW-12186 NUT,Connecting rod 8
5 69373 BEARING,Connecting rod 8
6 LW-13623 PISTON,Compression ratio8.5:1 4
7 LW-13445 PIN,Piston 4
8 LW-11625 PLUG,Pistonpin 8
9 78862 RING,Piston,compression 8
10 78864 RING,Piston,oil regulating,
expandertype 4

3-1
LYCOMING 0-235-P2APARTSCATALOG

4
1

-1

-9

Figure 14. CONNECTING RODS, PISTONSAND RING ASSEMBLIES

3-2
 LYCOMING 0-235-P2APARTSCATALOG
PISTONANDVALVETRAIN
CYLINDER,
CYLINDER
ASSEMBLY

FIG. QUANTITY
REF. PART PER
15 NUMBER DESCRIPTION ASSEMBLY

1 LW-18290* CYLINDER& HEAD ASSY.,Nitrided 4

2 LW-11900 SEAT,Intakevalve 4
3 LW-16699 SEAT,Exhaust valve(Allisonvalveseat) 4
4 61681 GUIDE,Valve,intake(flanged) 4
5 LW-11626 GUIDE,Valve,exhaust(flanged) 4
6 66796 INSERT,Sparkplug,18-1.5MM 8
7 31C-12 STUD,5/16-18x 1-1/2 long 8
8 STD-700 ELBOW,90° , 3/8 flared tube 4

* Incorporates
Allisonexhaust
valveseats.

3-3
LYCOMING O-235-P2A
PARTSCATALOG

3-

Figure 15. CYLINDER ASSEMBLY

3-4
 LYCOMING O-235-P2A PARTSCATALOG
CYLINDER,
PISTONANDVALVETRAIN
CYLINDERRELATED
PARTS

FIG. QUAIITITY
REF. PART PER
16 NUMBER DESCRIPTION ASSEMBLY

1 383-B NUT,3/8-24 plain 16

2 STD-2106 NUT, 7/16-20 plain 16
3 73806 RODASSY.,Push 8
4 60831 ROCKER ASSY.,Valve 8
5 60398 BUSHING, Valverocker 8
6 73807 SCREW,Valveadjusting 8
7 STD-587 NUT,9/16-18 x 5/32 thick 8
8 LW-13790 SHAFT,Valve rocker 4
9 LW-12892 THRUSTBUTTON,Rockershaft 8
10 75906 GASKET,Rockerbox 4
11 61247 COVER,Rockerbox 4
12 STD-1925 SCREW,1/4-20 x 5/8, self-locking 24
13 STD-35 WASHER,5/16 plain 8
14 STD-475 WASHER,5/16 lock, internalteeth 8
15 STD-1410 NUT,5/16-18 plain 8
16 62869 RING,Oil seal,3/32 dia. x 4-3/8 4
17 LW-19296 GASKET,Exhaustflange 4
18 61260 FLANGE,Exhaust,stainless 4

3-5
 LYCOIVIING 0-235-P2APARTSCATALOG

16

17
11
12-
13
14
15

Figure 16. CYLINDER RELATED PARTS

3-6
 LYCOMING O-235-P2APARTSCATALOG
CYLINDER,
PISTONANDVALVETRAIN
VALVEASSEMBLY

FIG. QUANTITY
REF. PART PER
17 NUMBER DESCRIPTION ASSEMBLY

1 LW-11901 VALVE,Intake 4
2 LW-19034 VALVE,Exhaust 4
3 61252 SEAT,Valve.spring,
outer 8
4 LW-13320 SEAT,Valvespring,inner 8
5 LW-11795 SPRING,Valve,auxiliary 8
6 LW-11800 SPRING,Valve,outer 8
7 LW-10077 SEAT,Valvespring 8
8 60009 KEY,Valve 16
9 LW-18661 SEAL,Shroudtube 16
10 60903 TUBE,Pushrodshroud 16

3-7
 O-235-P2APARTSCATALOG

Figure 17. VALVE ASSEMBLY

3-8
 LYCOMING 0-235-P2APARTSCATALOG
CYLINDER,
PISTONANDVALVETRAIN
COOLING
HEADDRAINTUBESANDINTERCYLINDER
CYLINDER BAFFLES

FIG. QUANTITY
REF. PART PER
18 NUMBER DESCRIPTION ASSEMBLY

1 STD-684 NIPPLE,Straight,3/8 I.D. hose 4

2 STD-2180 HOSE,3/8 I.D.x 1-13/16long 4
3 LW-15592-5-05 CLAMP, Hose 8
4 60890 TUBEASSY.,Oildrain,cyl. no. 1 1
5 60821 TUBEASSY.,Oildrain,cyl. no.2 1
6 60928 TUBEASSY.,Oildrain,cyls.no.3 & 4 2
7 LW-13304 BAFFLEASSY.,Intercylinder 2
8 71611 RETAINER,Intercylinderbaffle 2
9 LW-13303 HOOK,Intercylinderbaffleretainer 2
10 65614 PLUG,
Baffleattaching 4
11 STD-251 WASHER, No. 10lock 4
12 STD-665 SCREW, No.10-32x 3/4 long,fill. hd.dr. 4

3-9
 LYCOMING 0-235-P2APARTSCATALOG

8-

-12
1

4,5,6

Figure 18. CYLINDER HEAD DRAIN TUBESAND INTERCYLINDER COOLING BAFFLES

3-10
 IGNITIONSYSTEM
MAGNETOS,
DRIVES,HARNESSES
ANDSPARKPLUGS

FIG. QUANTITY
REF. r
PART PER
19 ER DESCRIPTION ASSEMBLY

1 61665 GEAR, Magneto, impulsecoupling 1

2 61163 GEAR, Magneto 1
3 62224 GASKET, Magneto adapterandmagneto 3
4 LW-12706 ADAPTER, Magneto, impulsecoupling 1
5 LW-163045-6 MAGNETO, S4LN-204 (withelectrictach.pickup) 1
LW-51360-54 MAGNETO, Impulse coupling,S4LN-21 1
6 STD-1727 WASHER, Plain,3/4 O.D.x 21/64 I.D. x 1/8 thick 4
7 STD-475 WASHER, 5/16 lock, internalteeth 4
8 STD-1410 NUT,5/16-18plain 4
9 LW-157209 KIT,Magnetogroundterminal(w/S4LN-204) 1
LW-52305-1 KITASSY.,Magneto groundterminal(w/S4LN-21) 1
10 LW-M-2403 HARNESS ASSY.,Leftmagneto (Slick) 1
LW-M-2404 HARNESS ASSY.,Rightmagneto (Slick) 1
11 LW-M-2375 PLATE,Sparkplugcable 2
12 LW-14060 CLIP,Twowirefor 1/4 screw 3
13 STD-8 WASHER, 1/4 plain 1
14 STD-160 WASHER, 1/4 lock, internalteeth 2
15 AN500-416-12 SCREW, 1/4-20x 3/4 long,fill. head 1
16 STD-1411 NUT,1/4-20plain 1
17 AN500A-416-10 SCREW, 1/4-20x 5/8 long 1
18 LW-18959-150-25 CLAMP, 1-1/2 I.D., offset 4
19 STD-553 SCREW, 6/32 x 1/2 long,rd. hd. 4
20 AN365-632A NUT,6/32 self-locking 4
21 LW-16266-25-50 CLAMP 1
22 76734 ZIPSTRAP 2
23 1182-B7 SPARK PLUG,(Champion REM-37BY) shielded 8
* M-1985-48 LEADASSY.,Replacement top& bottomleads AR

* Replacementleadassemblieshavesparkplugterminal
endassembled
andareshipped
withnecessary
partsto complete
magneto
endassembly
afterbeingcutto properlength.
NOTE
Theabovesparkplugsarethoseusedincurrentproductiononly;thislist doesnotincludeadditional
sparkplugsthat
areapproved
for usein theseengines.
SeelatesteditionofServiceInstructionNo.1042for completelistingofallap-
provedsparkplugs.

4-1
 LYCOMING 0-235-P2APARTSCATALOG

10

10 18

22
1
21 12

LEADASSY.
M-1985-48

Figure 19. MAGNETOS, DRIVES, HARNESSESAND SPARKPLUGS

4-2
 LYCOMING 0-235-P2APARTSCATALOG
ELECTRICAL
COMPONENTS
STARTERMOTORANDATTACHING
PARTS

FIG. QUANTITY
REF. PART PER
20 NUMBER DESCRIPTION ASSEMBLY

1 76210 STARTER,12volt, 10/12 pitchpinion(MZ-4204) 1

2 STD-35 WASHER, 5/16 plain 4
3 STD-475 WASHER, 5/16 lock, internalteeth 4
4 STD-1410 NUT,5/16-18plain 4

5-1
LYCOMING 0-235-P2APARTSCATALOG

Figure 20. STARTERMOTOR AND ATTACHING PARTS

5-2
 235-P2APARTSCATALOG
OIL SUMPASSEMBLYANDOIL SUCTION
SCREEN

FIG. QUANTITY
REF. PART PER
21 NUMBER DESCRIPTION ASSEMBLY

1 LW-13353 GASKET, Oilsump 1

2 LW-15688 SUMPASSY.,Oil 1
3 61376 CONNECTION, Intakepipe,front 2
4 61377 CONNECTION, Intakepipe,rear 2
5 25C-12 STUD,1/4-20x 1-1/2 long
6 STD-551 PLUG,1/2-14 NPT,sq. hd. 1
7 STD-8 WASHER, 1/4 plain 32
8 STD-160 WASHER, 1/4 lock, internalteeth 20
9 LW-25-0.94 BOLT,1/4-20 x 15/16 long,hex.head 18
10 STD-1411 NUT,1/4-20 plain 14
11 60820 GASKET, Oilsuctiontubeflange 1
12 61381 TUBEASSY.,Oilsuction 1
13 STD-1227 WASHER, 1/4 plain,copper 2
14 STD-1433 BOLT,1/4-20 x 1-1/2 long,hex.hd., drilledend 2
15 STD-8 WASHER, 1/4 plain(max.4) AR
16 STD-1409 NUT,1/4-20slottedshear 2
17 STD-68 PIN,Cotter,1/16 x 1/2 long 2
18 61378 SCREEN, Oilsuction 1
19 STD-1045 GASKET, 1-1/4 I.D.x 1-1/2 O.D.x 3/32 annular 1
20 61358 PLUG,1-1/2x 1-1/4-12,hex.hd. 1

6-1
 LYCOMING 0-235-P2APARTSCATALOG

14

20

Figure 21. OIL SUMP ASSEMBLYAND OIL SUCTION SCREEN

6-2
 LYCOMING 0-235-P2A PARTSCATALOG
OILSUMPANDINDUCTIONSYSTEM
INTAKEPIPEASSEMBLY

FIG. QUANTITY
REF. PART PER
22 NUMBER DESCRIPTION ASSEMBLY

1 LW-16728 PIPE,Intakecyls.nos.1 & 2 2

2 LW-16730 PIPE,Intakecyl. no.3 1
3 LW-16729 PIPE,Intakecyl. no.4 1
4 STD-1196 HOSE, 1-1/2 I.D. x 1-7/8 O.D.x 1-1/2 long 4
5 LW-15592-8-28 CLAMP, Hose 8
6 71973 GASKET, 2 boltflange,1-3/4 I.D. 4
7 74360 FLANGE, Intakepipe,upper 4
8 STD-8 WASHER, 1/4 plain 8
9 STD-160 WASHER, 1/4 lock,internallock 8
10 LW-25-1.25 BOLT,1/4-20x 1-1/4 long,hex.hd. 8

6-3
 LYCOIVIING 0-235-P2APARTSCATALOG

8
9
10

Figure 22. INTAKE PIPE ASSEMBLY

6-4
 O-235-P2APARTSCATALOG
OILSUMPANDINDUCTION
SYSTEM
CARBURETOR
ASSEMBLY

FIG. QUANTITY
REF. PART PER
23 NUMBER DESCRIPTION ASSEMBLY

1 60592 GASKET,Carburetor 1
2 LW-16073 CARBURETOR, Marvel-Schebler,MA-3PA
(10-5220) 1
3 STD-8 WASHER, 1/4 plain 4
4 STD-160 WASHER, 1/4 lock,internalteeth 4
5 STD-1411 NUT,1/4-20 plain 4

6-5
LYCOMING O-235-P2APARTSCATALOG

Figure 23. CARBURETORASSEMBLY

6-6
 LYCOMING 0-235-P2APARTSCATALOG
OIL SUMPANDINDUCTIONSYSTEM
PRIMINGSYSTEM

FIG. QUANTITY
REF. PART PER
24 NUMBER DESCRIPTION ASSEMBLY

1 LW-12098-1-170 TUBEASSY.,Primercylinderno.2 1
2 LW-12098-1-116 TUBEASSY.,Primercylinderno.4 1
3 LW-12098-1-284 TUBEASSY.,Primercylinderno. 1 1
4 LW-12098-0-100 TUBEASSY.,Primer,intermediate 1
5 LW-16266-25-13 CLAMP 3
6 LW-18959-150-25 CLAMP,1-1/2 I.D. with1/4 dia.offset 3
7 STD-553 SCREW, No.6-32x 1/2 long,rd. hd. 3
8 AN365-632A NUT,No.6-32self-locking 3
9 STD-853 TEE,Union,1/8 tube 1
10 LW-18071 TEE,Union,1/8 tube 1
11 74225 NIPPLEASSY.,Primer 3
12 1102* PLUG,1/8 NPT,Allenhead 1

* Assemblein cylinderhead.

6-7
Figure 24. PRIMING SYSTEM
6-8
 SERVICE KIT SECTION

SEAL AND GASKET SET

WIDE CYLINDER FLANGE MODELS
Part No. Part Name Qty.

61499-1 SEAL AND GASKET SET 1

STD-111 GASKET 1
STD-2217 SEAL, Oil 1
STD-294 GASKET, Annular 2
STD-1045 GASKET, Annular 2
8313 GASKET, Vac. pump 2
60096 GASKET, Fuel pump 1
60592 GASKET, Carb. 1
60820 GASKET, Oil suction tube flange 1
LW-18639 LOCKPLATE, Crankshaft gear 1
LW-14260 SEAL, Tach. shaft 1
61173 GASKET, Oil press. hsg. 1
61183 GASKET, Accy. adapter 1
61523 CONTAINER 1
61531 GASKET, Hydraulic valve 1
62224 GASKET, Mag. adapter 3
LW-18661 SEAL, Shroud tube 16
LW-19296 GASKET, Exhaust flange 4
68315 GASKET, Accy. dr. adapter 1
LW-13353 GASKET, Oil sump 1
71973 GASKET, Intake flange 4
72053 GASKET, Gov. drive 1
72059 GASKET 1
72078 LOCKPLATE, Cam gear 2
72091 RING, Oil seal 8
73383 LOCKPLATE 1
73817 LOCKPLATE, Camshaft idler gear shaft 2
73818 GASKET, Accy. hsg. 1
74065 RING, Oil level gage seal 1
74068 RING, Oil level gage seal 1
75906 GASKET, Rocker box cover 4
76940 SEAL, Crankshaft oil 1
LW-13792 SEAL, Crankshaft oil 1
LW-12681 GASKET, Mag. 2
LW-12795 GASKET 1
LW-11632 RING, Oil seal 6
62869 RING, Cyl. base 4

LW-12040 TOP OVERHAUL GASKET SET 1

62869 SEAL, Cylinder base 4
LW-18661 SEAL, Shroud tube 16
71973 GASKET, Intake, 2 bolt flange 4
75906 GASKET, Rocker box cover 4

7-1
 LYCOMING 0-235-P2APARTSCATALOG

SERVICE KIT SECTION

CYLINDER, PISTON AND RING KIT

WIDE CYLINDER FLANGE MODELS
Part No. Part Name Qty.

LW-18660 CYLINDER, PISTON AND RING ASSEMBLY 1

STD-587 NUT, 9/16-18 x 5/32 thick 2
STD-1215 BOLT 2
STD-1925 SCREW, 1/4-20 x 5/8 long, fill. hd. 6
1102 PLUG, 1/8 pipe x 3/8 long, socket 1
60009 KEY, Valve 4
60831 ROCKER ASSY., Valve 2
61247 COVER, Rocker box 1
LW-13320 SEAT, Valve spring, inner 2
61252 SEAT, Valve spring, outer 2
LW-13790 SHAFT, Valve rocker 1
62869 RING, Oil seal (cylinder base) 1
LW-18661 SEAL, Shroud tube 4
71195 BOX, Set-up 1
73807 SCREW, Valve adjusting 2
75906 GASKET, Rocker box cover 1
LW-13445 PIN, Piston 1
78862 RING, Piston compression 2
78864 RING, Piston, oil regulator 1
LW-10077 SEAT, Valve spring 2
LW-13623 PISTON 1
LW-11625 PLUG, Piston pin 2
LW-18290 CYLINDER ASSY., Nitrided 1
LW-19034 VALVE, Exhaust 1
LW-11795 SPRING, Valve, auxiliary 2
LW-11800 SPRING, Valve, outer 2
LW-11901 VALVE, Intake 1
LW-12892 THRUST BUTTON 2

7-2
 LYCOMING O-235-P2APARTSCATALOG

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

AN365-632A Nut 4-1 LW-1 63045-6 Magneto 4-1

AN365-632A Nut 6-7 LW-16354 Crankcase Assy. 1-1
AN500-416-12 Screw 4-1 LW-1 6699 Seat 3-3
AN 500A-41 6-10 Screw 4-1 LW-16728 Pipe 6-3
AN6-21 Bolt 1-11 LW-16729 Pipe 6-3
AN6-34A Bolt 1-11 LW-1 6730 Pipe 6-3
LW-10077 Seat 3-7 LW-1 8071 Tee 6-7
LW-11622 Stud 1-1 LW-18109 Impeller 2-3
LW-11623 Stud 1-1 LW-18110 Impeller Assy. 2-3
LW-11625 Plug 3-1 LW-18290 Cylinder Assy. 3-3
LW-11626 Guide 3-3 LW-18639 Lockplate 1-5
LW-11795 Spring 3-7 LW-18661 Seal 3-7
LW-11800 Spring 3-7 LW-1 8667 Pin 1-9
LW-11900 Seat 3-3 LW-1 8959-150-25 Clamp 4-1
LW-11901 Valve 3-7 LW-1 8959-1 50-25 Clamp 6-7
LW-1 2044 Housing Assy. 2-1 LW-19034 Valve 3-7
LW-1 2098-0-1 00 Tube Assy. 6-7 LW-1 9296 Gasket 3-5
LW-1 2098-1-116 Tube Assy. 6-7 LW-25-0.94 Bolt 2-3
LW-1 2098-1-170 Tube Assy. 6-7 LW-25-0.94 Bolt 6-1
LW-1 2098-1-284 Tube Assy. 6-7 LW-25-1.25 Bolt 6-3
LW-12186 Nut 3-1 LW-25-1.50 Bolt 1-11
LW-1 2695 Crankshaft Assy. 1-5 LW-25S1.50 Bolt 1-11
LW-12706 Adapter 4-1 LW-25-1.75 Bolt 1-11
LW-12795 Gasket 2-11 LW-25-2.00 Bolt 2-3
LW-1 2892 Thrust Button 3-5 LW-51360-54 Magneto 4-1
LW-1 2999 Plate 2-11 LW-52305-1 Kit 4-1
LW-13215 Oil Filter 2-11 LW-M-2375 Plate 4-1
LW-1 3303 Hook 3-9 LW-M-2403 Harness Assy. 4-1
LW-13304 Baffle Assy. 3-9 LW-M-2404 Harness Assy. 4-1
LW-1 3320 Seat 3-7 M-1985-48 Lead Assy. 4-1
LW-1 3353 Gasket 6-1 MS20822-6 Elbow 2-5
LW-1 3445 Pin 3-1 STD-8 Washer 1-11
LW-1 3623 Piston 3-1 STD-8 Washer 2-3
LW-13675 Support Assy. 1-5 STD-8 Washer 2-10
LW-1 3790 Shaft 3-5 STD-8 Washer 2-11
LW-13792 Seal 1-7 STD-8 Washer 4-1
LW-1 3884 Bearing 1-7 STD-8 Washer 6-1
LW-1 3923 Bushing 3-1 STD-8 Washer 6-3
LW- 14060 Clip 4-1 STD-8 Washer 6-5
LW-14260 Seal 2-3 STD-33 Washer 1-11
LW-14781 Gage Assy. 1-3 STD-33 Washer 2-9
LW-1 5472 Fuel Pump 2-9 STD-35 Washer 2-3
LW-15592-5-05 Clamp 3-9 STD-35 Washer 2-5
LW-15592-8-28 Clamp 6-3 STD-35 Washer 2-7
LW-1 5688 Sump Assy. 6-1 STD-35 Washer 3-5
LW-157209 Kit 4-1 STD-35 Washer 5-1
LW-1 6073 Carburetor 6-5 STD-68 Pin 6-1
LW-1 6266-25-1 3 Clamp 6-7 STD-160 Washer 1-11
LW-1 6266-25-38 Clamp 2-5 STD-160 Washer 2-3
LW-1 6266-25-50 Clamp 4-1 STD-160 Washer 2-10

8-1
 LYCOMING 0-235-P2APARTSCATALOG

NUMERICAL INDEX (Cont.)

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

STD-160 Washer 2-11 STD-1411 Nut 6-5

STD-160 Washer 4-1 STD-1420 Nut 2-3
STD-160 Washer 6-1 STD-1433 Bolt 6-1
STD-160 Washer 6-3 STD-1727 Washer 4-1
STD-160 Washer 6-5 STD-1774 Pin 2-7
STD-251 Washer 3-9 STD-1774 Pin 2-10
STD-294 Gasket 2-11 STD-1838 Bolt 2-5
STD-425 Washer 1-7 STD-1856 Screw 2-11
STD-475 Washer 2-5 STD-1882 Screw 2-9
STD-475 Washer 2-7 STD-1925 Screw 3-5
STD-475 Washer 3-5 STD-1930 Hose 2-5
STD-475 Washer 4-1 STD-2106 Nut 3-5
STD-475 Washer 5-1 STD-2180 Hose 3-9
STD-514 Dowel 1-1 STD-2213 Screw 1-5
STD-551 Plug 6-1 STD-2217 Seal 2-10
STD-553 Screw 4-1 25C-10 Stud 2-11
STD-553 Screw 6-7 25C-12 Stud 6-1
STD-557 Dowel 1-1 25C-22 Stud 2-1
STD-587 Nut 3-5 31C-12 Stud 1-1
STD-596 Nut 1-11 31C-12 Stud 2-1
STD-665 Screw 3-9 31C-12 Stud 3-3
STD-678 Washer 1-11 31C-16 Stud 2-7
STD-684 Nipple 3-9 31C-19 Stud 2-1
STD-700 Elbow 3-3 31 CD-17 Stud 2-1
STD-705 Bolt 1-9 38-13 Stud 1-1
STD-783 Plug 2-1 44-13 Stud 1-1
STD-784 Plug 2-1 383B Nut 3-5
STD-784 Plug 2-11 1028B Ball 1-7
STD-853 Tee 6-7 1102 Plug 1-1
STD-872 Nut 1-11 1102 Plug 2-1
STD-1045 Gasket 1-7 1102 Plug 2-7
STD-1045 Gasket 6-1 1102 Plug 6-7
STD-1065 Dowel 1-5 1182-B7 Spark Plug 4-1
STD-1111 Elbow 1-1 8313 Gasket 2-10
STD-1196 Hose 6-3 45530 Ring 1-9
STD-1211 Plug 1-5 60009 Key 3-7
STD-1221 Ring 2-7 60096 Gasket 2-9
STD-1227 Washer 6-1 60398 Bushing 3-5
STD-1409 Nut 1-11 60430 Cover 2-10
STD-1409 Nut 6-1 60592 Gasket 6-5
STD-1410 Nut 2-7 60803 Strap 1-11
STD-1410 Nut 3-5 60814 Bushing 1-5
STD-1410 Nut 4-1 60820 Gasket 6-1
STD-1410 Nut 5-1 60821 Tube Assy. 3-9
STD-1411 Nut 1-11 60831 Rocker Assy. 3-5
STD-1411 Nut 2-3 60882 Gear 1-5
STD-1411 Nut 2-10 60890 Tube Assy. 3-9
STD-1411 Nut 2-11 60903 Tube 3-7
STD-1411 Nut 4-1 60928 Tube Assy. 3-9
STD-1411 Nut 6-1 61084 Spring 1-7

8-2
 LYCOMING O-235-P2A
PARTSCATALOG

NUMERICAL INDEX (Cont.)

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

61098 Adapter Assy. 2-10 72059 Gasket 1-3

61151 Shaft 1-9 72091 Ring 1-7
61155 Gear 1-5 72378 Cover 2-7
61163 Gear 4-1 72844 Plug 1-3
61174 Shaft 2-3 72970 Gear Assy. 2-10
61175 Adapter 2-1 73757 Bushing 1-5
61183 Gasket 2-10 73806 Rod Assy. 3-5
61247 Cover 3-5 73807 Screw 3-5
61252 Seat 3-7 73817 Lockplate 1-9
61260 Flange 3-5 73818 Gasket 2-1
61358 Plug 6-1 74065 Ring 1-3
61376 Connection 6-1 74070 Elbow 2-5
61377 Connection 6-1 74225 Nipple Assy. 6-7
61378 Screen 6-1 74360 Flange 6-3
61381 Tube Assy. 6-1 74996 Gear Assy. 1-9
61400 Stud 2-1 75072 Gear Assy. 1-9
61510 Plug 1-5 75153 Adapter Assy. 2-7
61544 Plunger 1-9 76165 Clip 2-5
61665 Gear 4-1 75167 Tube Assy. 2-5
61681 Guide 3-3 75706 Camshaft 1-5
62224 Gasket 4-1 75708 Shaft Assy. 1-9
62417 Plug 2-11 75767 Tube 1-3
62869 Ring 3-5 75906 Gasket 3-5
65614 Plug 3-9 75944 Valve Assy. 2-11
66796 Insert 3-3 76210 Starter 5-1
68315 Gasket 2-7 76510 Gasket 2-11
68317 Shaftgear 2-7 76529 Plug 1-7
68763 Bearing 1-7 76734 Zip Strap 4-1
69373 Bearing 3-1 77309 Bushing 1-9
69796 Dowel 1-1 77852 Base Assy. 2-11
71105 Body 1-7 78027 Bolt 3-1
71596 Washer 2-7 78030 Rod Assy. 3-1
71596 Washer 2-10 78531 Body Assy. 2-3
71611 Retainer 3-9 78862 Ring 3-1
71973 Gasket 6-3 78864 Ring 3-1
72053 Gasket 2-7

8-3