Lister Petter TR1, Workshop Manual

Page: 52 / 121

page 52
02.39 THE CYLINDER BARREL
Before removing any cylinder barrel it should be
marked to ensure it is replace to its original orientation.
Cylinder Barrel Removal
1. Remove the cylinder head and sump.
2. Place a retaining tube, secured by a hand tight
cylinder head nut, over one stud of each cylinder
from which the head was removed.
This will prevent the cylinder rising as the
crankshaft is turned.
3. With the engine turned over and standing on the
flywheel, rotate the crankcase until one connecting
rod big end is at BDC.
4. Remove the big end bearing cap.
5. To protect the crankshaft journal from possible
damage, fit a suitable tube over each connecting
rod bolt and secure it with a hand tight nut.
6. Rotate the crankcase until the same piston is at
TDC.
7. Mark the cylinder for position and number.
8. Remove the tube securing the barrel.
9. Lift off the barrel, piston and connecting rod as a
complete assembly.
10.Remove the tubes from the big end.
11. Replace the big end bearing cap.
12.Remove the piston from the cylinder barrel.
13.Thoroughly clean the cylinder barrel and check for
scoring and wear.
Cylinder Barrel Replacement
1. Fit the piston to the connecting rod.
On TS/TR engines ensure the wording 'CAMSHAFT
SIDE' on the piston crown is the same side as the
identification marks on the connecting rod big end.
2. Insert the gudgeon pin and two circlips; ensure the
circlips are correctly located in the grooves.
3. Fit the piston rings in the order as shown in 'Figure
2.40.1'
4. Ensure the piston ring gaps are staggered and fit
the piston into the cylinder barrel while compressing
the rings.
5. If necessary, fit new big end bearing shells ensuring
they are correctly located in both the connecting
rod and cap.
6. On TS/TR engines:
Coat the bottom jointing face surface of the cylinder
barrel with Hylomar PL32M.
Fit a new joint and coat it with Hylomar PL32M.
7. On TX engines:
Clean and dry the cylinder head clearance shims,
the cylinder barrel and crankcase mating surfaces.
Place the shims, dry, onto the bottom of the
cylinder barrel.
8. Turn the crankshaft crankpin to TDC.
9. To protect the crankshaft journal from possible
damage, fit a suitable tube over each connecting
rod bolt and secure it with a hand tight nut.
10.On TS/TR engines:
Ensure the deeper cylinder barrel fins will be facing
towards the manifold side and 'CAMSHAFT SIDE'
on the piston crown will face towards the camshaft.
10a.On TX engines:
Ensure the connecting rod identification marks will
face towards the camshaft.
11. Lower the cylinder and piston assembly into
position.
12.Push down on the top of the piston as the
crankcase is rotated until the crankshaft crankpin
is at BDC.
13.Remove the protective tubes.
14.Ensure the connecting rod cap bolt head is
correctly located against the shoulder on the
connecting rod as shown below.
15.Fit the big end bearing cap ensuring the
identification numbers are on the same side and
identical.
Figure 2.39.1 Bearing Cap Bolt Head Location
16. Replace the connecting rod nuts and torque them
to 43.5Nm (32.0lbf ft).
It is recommended that connecting rod bolts and
nuts are replaced at every major overhaul.
Section 02
Engine Servicing and Adjustments
- cylinder barrel