Well So It Was a plesant sunday and Pal Mechanic Was With Me From Kharar Town .We Arrived To My Native Place Mohali Before Noon .As Soon as he Dropped his tools he started the engine and then stopped the same .Well He Took Off to dismantle The engine .

 

 

Here Pal Took the Top cover Off and He Is Now Removing The Head of the engine By Unscrewing the Four Large Nuts [ See How Confidence He Has In the entire Process ] .See the Itsy Bitsy Intake Air section [ what No filter Haa Haa We Will sort it laterz ]

 

 

The Rocker And Tappet Support Section On the Head is Now Removed .Have a Look On the right where the fuel injector is ,The top reverse line for fuel is bend and we would do something on that .The Plate On the Engine is Painted Green [ What a Jerk That Malwa Generator Guys Were ] .

 

 

Side View Of this Section

 

 

The Shitty fuel Filter Is Now Removed .Also The fuel Pump Is Removed and The governer Section Thats Externally visible .The governer was now worn out bad .The fuel filter was always leaking at the lower side come what may i try .I hated the leaks in this engine .

 

 

The Tappet Rods And Rocker On The Ground .Also I Have a Small dish with Kerosene To Remove rust And Clean The Nuts .Also You Can See the Fuel Filter And the Metal Pipe That runs From Fuel Pump to Injector Section .Also You Can See the External Governer on the Ground .Visible is The Fuel Pump Also .The Top Head Cover Is also There On the Ground .

 

 

Have a Look At the fuel filter ,Even After Doing everything I Could Not Solve the Leakage At the Bottom .It Use to Stop But Later On again Start .The Nuts Has Washers also  [ Poor Me  ] .Later i will Add Picture of Its Internals Also .

 

The Head Of the Engine Is Out Near Pals Feet .Some tools and Also the fuel Pump Is visible .We did not Do Much In the Head Part Later On As According to Pal It Was Fine and Needed No More Working .This is the top side of the same where we have the injector and other few items .

The Bottom View Of the Head Where the Piston Goes .A Gasket Has To Be Used To Seal the Same To the Other Piston Cylinder Block  .More on This Later .

 

 

Well You Can See the Gasket Of the Product Along with the Head .The Gasket is Nothing But a Heavy Duty Seal As this Section Of The engine Is Critical  .

 

 

Have a Look At the Fuel Pump .This Is The Bottom Side .The Part That Controls the Fuel And Is the End Part Of the Governer Section Is Also Shown In this display .

 

 

 Well You Can See a Small Screw In the Back side Of the Pump .This Is for The Removal Of Air From this Fuel If You Ran Your engine Dry Or There was a Leakage Etc .

 

 

 

Well Lol Have a Look At the World Best Exhaust system, Haa Haa .Anyways You Can See That i Have a Used a Large Flex Pipe and Then Mounted This to The Smallest Muffler/Cylincer That Malwa Generator Man Could Lay Its Hands On [Shame On you Amrik Singh ] .I Would Be Changing This Soon In The Later stage of This Project .

 

 

 

This Is The Water system That Keeps the engine Cool .According To Pal This Is Not enough for The engine And We Need 200 Liters Of The Same .This will Also Undergo Improvement  In the Later stages .Keep Tuned and Glued To The Project Progress .

 

 

 

Very Rare Shots of The cylinder and the Piston Of the Lister Type Engine .Have a Look At the Inside .When I got the engine this Section Was Changed .Malwa Generators  [ cheaters ] Has Only changed the Cylinder ,The Piston And The rings Last time When they Gave Me the Engine .All Other Stuff they Had Left Out ,Cheaterssssssssssssssss .....

 

 

 

You Will See that Instead of Taking Out the cylinder Section Pal Is Now Removing One Of The side Doors of The Lister engine .Have a Look Carefully Why He Is Doing the Same .

 

 

 

According To Pal This Is done So That We Could Remove The Piston And the Connecting rod From The Crankshaft ASAP we remove the top cylinder Head So that there is always Minimum Damage to The Piston And The Rings And The Connecting Rods .

 

 

 

Well Here Pal Is Just About To Remove The Nut Connecting the Connecting Rod To the Crankshaft .This Portion Also Has CR Bearings .Now We Will Open Up the Other Side Of the engine Compartment To Remove the Second Screw .In this Picture the Screw Is Still There And Was Removed Once i Was Not there  [ Suu Suu Time Lol ] For My English Friends [ Pissing Time -  Su su time In India Lol ] .

 

 

Here Pal Has Removed the Door And You Can See the Governer Spring Hanging Still ,Old Guy Was Exhausted It was 45.6 Degree Celcius .

 

 

The CR Nuts Being Removed From The Other side So That We Could Remove The Piston Assembly Very Easily .You Will Just see the Same In a Little While .

 

 

Have a Look At the Piston Cylinder Block Out Of the Engine .This cylinder According To Malwa Generators Is New [ I Do not Think So ] .I think They Just Cleaned The Same .I Could Still See the Marks of Cleaning In the Cylinder  .

 

 

These Are Two Great Shots Of The Piston ,You Can See that the Piston And The Rings Were done By Malwa Generators [ This Was The Only thing they Had Done Other Then The Oil In This engine ] .

 

 

Here you Can See The Nuts From The Lower Portion Of The Rod Assembly Being Removed and Finally Being Removed .

 

 

The Lower CR Bearing Lying On the Floor Along With The fuel Pump Parts and the Top Head .

 

 

 

Pal Finaly Removed the Piston From the engine and Proceeds To Place the Same On The Floor .You Can Also See the Governer Assembly Lying On the Floor .

 

 

The Upper CR Bearing Of the Piston Rod Connecting To The Crank Rod Assembly .The Top And Lower CR Bearing Can Be Removed Effectively From The Same Now .

 

Here This is a Beautiful Shot Of the Crank From the Top When The Top Head and Piston Block Assembly is Removed.You Can See the Portion where the Piston Rod With CR Bearings Gets installed .

 

 

 

Here Have a Look At the Condition of The Oil [ engine Oil ] Its Not Bad Yet .Also Have a Look at the door seal .When i Got This engine None Of The Seals Were there that Were not Leaking .This Was Not Good and We Have to Reseal all the Leaking Seals .This Does Not Mean that Lister engines in Generally Bleed Like a Pig .This Show That Some Mechanics Just do Work To Get Rid of a Problem And Still Make Money .

 

 

The Right Flywheel Being Removed .Please Note That the Flywheel Key Head Was Missing this side .It Took Is 2.30 Hours To Get the Flywheel Key Off This Drive ,Pal Was Banging The Crank Rod Like Mad .I Wonder Whay It Whould Not Bend Or Get Partially Damaged .Malwa Generators Who Intially supplied Me The Generator Should Have Taken Care of the same .They Even did not bother For a Rs :25 /- Product ,Shame On those Scum Bags .

 

 

Well is was a tough job for Pal to remove the flywheel ,Due to the broken head of the flywheel key .Poor chap spend 2.30 hours under the sun when it was 45.5 degree celcius .Damn its very hot in india mostly .If someone has a good idea of how to remove the flywheel key when the head is broken please email us and tell us how it could be done .

 

Update :

John Emailed Me From Outside India With a Beautiful Idea ,the Same Is In this Section - > Lister Websites And Forums

 

 

Guys the Flywheel is Finally Off .Also You will See That There is Leakage At Mutiple Points In These Photos .We Will Work On them In the End when We Assemble The engine Back .

 

 

ASAP Mr Pal Proceeds to Remove The Left Flywheel Of the Engine ,What Stamina this 60 Year Old Indian Mechanic Had .Pooooffffff

 

 

The Pulley Was At this side ,First Pal Removes the Pulley  ,We again Faced a Problem That the Kay Had no Head for the Pulley Damn These Malwa Generators Scum Bags .This Wasted a Lot of Our time .Any Bright Ideas for Removal Guys ? .

 

Update :

 As Explained John Send Us a Bright Idea for The Same .

 

 

The Left Lywheel Key Had Blades Stuffed Under the Key By Old engine Owner I am sure As According To Me Malwa Generators Do Not Have This Much Brain Lol .

 

 

The Main Crank Had to Be filed so That the Flywheel Could Come Out Neatly ,This Was Also a Very time consuming thing  .

 

 

Mr Pal After Removing Most Parts Of The Engine ,Also In The Center Is Bhagwania My Wifes Tailor and Jeet Who to Is My Wifes Tailor .I am the Photographer there Hence No Pictures of Me .Now Lets Proceed to - > The Middle Stage

 

On Popular Demand I Am Adding My PICS Haa Haa