Suffolk SS100 - Exhaust System Assembly

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SS100 Build Manual (Export Edition) Rev 10 November 2013

Page 79

Figure 3 – Exhaust system assembly

Table of Contents

Table of Contents3
Index3
Tools, Equipment & Ordering of Parts6
Tools Required6
Fasteners6
Introduction6
Ordering of Parts7
Parts Delivery Disclaimer7
Build Sequence & Parts List8
3.2 Parts List12
Chassis, Suspension, Steering & Final Drive18
Rear Suspension and Final Drive18
- Fitting Bushes19
- Differential Mounting Plate19
- Rear Axle Set up19
- Installing Axle19
- Handbrake Return Springs20
Front Suspension20
- Rear Tie Bars20
- Coil over Damper Mounting with Spacer20
- Upper Wishbone Pivot Shaft21
- Upper Wishbone Bushes21
- Upper Ball Joint21
- Lower Wishbone Pivot Shaft21
- Lower Wishbone Bushes22
- Hub and Brake Disc22
- Fitting the Hub22
- Coil over Dampers22
Steering23
- Fitting Brake Caliper, Steering Arm and Disc Protector23
- Pre-Drill Brake Line Hose Clips23
- Steering Rack23
- Clutch Master Cylinder24
- Pedals24
- Brake Master Cylinder and Servo24
Braking System & Clutch Hydraulics24
- Rear Brake Line25
- Rear Brake Link Pipes25
- Front Brake Lines25
- Brake Lamp Switch25
Fuel Tank, Fuel Pump and Fuel Line26
- Setting Tank Fuel Sender26
- Fitting Tank Fuel Sender26
- Fuel Tank and Straps26
Engine, Gearbox, Exhaust System, Cooling System & Initial Wiring27
Engine, Gearbox & Prop-Shaft27
- Engine Brackets and Timing Pointer27
- Gearbox Mount Plate, Rubber Mount and Adaptor27
Exhaust System28
- Servo Vacuum Hose28
- Connect and Bleed Clutch28
- Clutch Slave Cylinder28
- Fitting Engine28
Cooling System29
- Down Pipes or Stainless Manifold Extension Pipes29
- Silencers29
- Rear Tie Bracket29
Initial Wiring30
- Radiator Lower Mounts30
- Bottom Hose30
- Radiator Top Mounts30
- Front End Wiring Loom31
- Rear and Gearbox Loom31
- Coil31
- Electric Oil Gauge Sender31
- Overdrive Inhibit Switch32
- Fuel Pump32
- Overdrive Solenoid32
- Cooling Fan and Switch32
- Fog Lamp33
- Reverse Lamp33
- Brake Fluid Reservoir Wires33
- Starter Moto33
Wheels & Tyres34
Splined Hubs34
Fitting Wheels34
Body, Doors and Bonnet Fitting34
7.1 Body34
Preparing Wheels34
- Lifting on the Body35
- Bolting on the Bod35
- Body Tightening Sequence35
- Dashboard Stays36
Bonnet36
- Final Body Mount Bolts and Spacers36
- Windscreen Wiper/Scuttle Bracket36
- Door Fitting36
- Bonnet Details37
- Bonnet Fitting/Cutting Advice37
- Preparing Centre Hinge37
- Preparing Outer Hinges38
- Positioning Top Hinge38
- Radiator Hoop and Long Stays38
- Radiator Shell38
- Securing Top Bonnet Panel39
- Marking the Bonnet Panels39
- Cutting the Top Bonnet Panels39
- Fitting Side Hinges39
7.3 Painting40
- Fitting Bonnet Studs40
- Cutting Bottom Panels40
- Bottom Bonnet Beaded Edge40
- Refitting Body41
- Refitting Doors41
- Refitting Painted Bonnet41
Body Fittings42
Safe Storage42
Floorboards, Handbrake and Seat Runners42
- Handbrake Cable42
- Rear Floorboard Upright Mount43
- Rear Floorboard43
- Rear Brake Access Panel and Tool Tray43
- Handbrake Lever43
Windscreen and Wipers44
- Gearbox Cover44
- Sealing Floorboards44
- Wiper Spindle Holes45
- Mirror and Aero Screen Brackets45
- Fixing Windscreen45
- Windscreen Positioning45
Remaining Body Fittings46
- Tenax and Lift the Dot Studs46
- Aero Screens46
- Wiper Arms and Blades46
- Front Valance and Dummy Starting Handle Eye47
- Fitting the Lamp Bar47
- Lamp Bar Stays47
- Wing Stays47
- Upper Steering Column48
- Lower Steering Column and Escutcheon48
- Throttle Pedal48
- Choke Cable48
- Fuel Cap, Adaptor and Link Pipe49
- Rear Reflectors49
- Spare Wheel Bracket49
- Rear Lamp Brackets49
- Running Board Strakes50
Dashboard Fittings51
- Grab Handle51
- Fuel Switch (Dummy)51
Wiring and Electrical Fittings51
- Main Earth52
- Main Power Feed52
- Stalk Switch52
- Relay Earths52
- Steering Column Ignition Key53
- Hazard Warning Lamps53
- Heater53
- Electrical Instruments and Automatic Gearbox Illumination54
- Low Charge Warning54
- Main Wiring Earth54
- Wiper Motor54
- Instrument Illumination55
- Ammeter55
- Headlamp Switch55
- Fuel Gauge56
- Windscreen Wiper Switch56
- Starter Push Button56
- Dashboard Ignition Key56
- Overdrive Switch57
- Tachometer57
- Spot Lamp Feed57
- Oil Pressure Gauge57
Front Lamps, Horns and Alternator58
- Speedometer58
- Headlamps Type 40 and Horns58
- Headlamps QK596 and Horns59
- Flasher Lamps60
- Spot Lamps60
- Rear Lamps61
- Side Lamps Combined with Flasher Lamps61
- Alternator61
- Right Hand Lamp62
- Left Hand Rear Lamp62
- Fuel Gauge Sender62
- Earth Feed62
- Testing63
- Wiper Blade Fitting63
Interior Trimming64
Trimming65
Final Body Fittings66
Steering Wheel and Boss66
Front Number Plate66
Rear Number Plate and GB Plate66
Luggage Rack66
- Ignition Settings67
- Ignition Setting, Carburetion, Testing Running and Tuning67
- Chassis Plate67
- Seat Belts67
- Carburetion68
- Carburettor Base Settings68
- Warm up68
- Dwell Angle68
- Setting Mixtures69
- Engine Checks69
- Test Running and Tuning69
- Driving and Service69
- Road Preparation70
- Wheel Alignment70
- Suspension Setting70
- Headlamp Alignment70
- Servicing71
- Tyre Pressures & Greasing Points71
- Speedometer Calibration71
- Electrical Systems72
- Wiring Loom Positions Key72
- Fuses74
- Line Fuses74
- Relay Fuses74
- Relays74
- Wiring Diagram75
- Key to Circuit Diagram75
- Wire Colour Coding75
- Optional Items75
- Figures77
- Puller for Differential Mounting Bushes78
- Setting Rear Wheel Camber78
- Exhaust System Assembly79
- Early XJ6 Upper Wishbones80
- Early XJ6 Lower Wishbones80
- Late XJ6 Lower Wishbones80
- Front Wishbone Identification80
- Peering of the Bonnet Panel Edges81
- Carburettor Pipe Location81
- Seat Runner Positions82
- Jig Tool for Marking out Lower Body Fixing Holes83
- Location of Throttle Pedal83
- Location of Door Latches84
- Location of Rear Reflectors84
- Strake Fitting85
- Cutting and Gluing Rubber Insert85
- Dashboard Layout and Grab Handle Location86
- Windscreen Fitting86
- Floorboard Fitting Kit87
- Picture to Left87
- Body to Chassis Fixing Locations88
- Heater Fitting Instructions89
- Heater Kit Contents89
- Loom Placement Diagram90
- Drilling Hole of Bonnet Hinges for Rivets91
- Headlamp Bar Fixings Positions91
- Steering Column Locating Jig91
- Cut out Holes in Gearbox Cover for Maintenance92
- Shock Absorber Height Adjustment92
- Wiring of Rear Lamps93
- Photographs94
- Rear Axle Components94
- Assembled Engine, Gearbox and Rear Axle94
- Rear Axle Fitted95
- Early Build Stages96
- Rolling Chassis96
- Stainless Steel Manifolds Fitted97
- Lucas Qk596 Headlamps98
- Different Headlamp Options98
- Type 40 Headlamps98
- Fluids, Lubricants and Maintenance Data99
- Tyre Pressures99
- Wire Wheels99
- Adjustable Shock Absorbers99
- Running in and Service Instructions100
- 500 Miles100
- 500 - 1000 Miles100
- 1500 Miles100
- Suffolk Sportscars ANNUAL SERVICE101
- Speedo Calibration103
- RHD Brake Pipe Locations104
- Suffolk SS100 Dimensions105
- Suffolk SS100 Chassis Details106