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Suffolk SS100 User Manual
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SS100 B
uild Manual (Export Editi
on)
Rev 10 November 20
13
Page
91
Figure 2
0 – Drilling hole of bonnet hinges for rivets
Figure 2
1 – Steering column locating jig
a
c
b
d
f
e
a
b
Headla
mp bar
fixi
ngs
posit
ions
a
–
‘O’
rings, slide over bar before
fitting.
b
–
Rubber wash
ers Super
glue t
o
hold in place t
o protect body.
c
–
Spacer to fit
inside wing
aperture.
d
–
M8 x
30 mm
si
de fixing
bolt,
plain and lock washer
s
e
–
Locking nut.
Sits abo
ve chassis,
adjust height to touch chassis
before
tightening f b
elow chas
sis.
f
–
Plain nut and
lock washer
90
92
Table of Contents
Table of Contents
3
Index
3
Tools, Equipment & Ordering of Parts
6
Tools Required
6
Fasteners
6
Introduction
6
Ordering of Parts
7
Parts Delivery Disclaimer
7
Build Sequence & Parts List
8
3.2 Parts List
12
Chassis, Suspension, Steering & Final Drive
18
Rear Suspension and Final Drive
18
Fitting Bushes
19
Differential Mounting Plate
19
Rear Axle Set up
19
Installing Axle
19
Handbrake Return Springs
20
Front Suspension
20
Rear Tie Bars
20
Coil over Damper Mounting with Spacer
20
Upper Wishbone Pivot Shaft
21
Upper Wishbone Bushes
21
Upper Ball Joint
21
Lower Wishbone Pivot Shaft
21
Lower Wishbone Bushes
22
Hub and Brake Disc
22
Fitting the Hub
22
Coil over Dampers
22
Steering
23
Fitting Brake Caliper, Steering Arm and Disc Protector
23
Pre-Drill Brake Line Hose Clips
23
Steering Rack
23
Clutch Master Cylinder
24
Pedals
24
Brake Master Cylinder and Servo
24
Braking System & Clutch Hydraulics
24
Rear Brake Line
25
Rear Brake Link Pipes
25
Front Brake Lines
25
Brake Lamp Switch
25
Fuel Tank, Fuel Pump and Fuel Line
26
Setting Tank Fuel Sender
26
Fitting Tank Fuel Sender
26
Fuel Tank and Straps
26
Engine, Gearbox, Exhaust System, Cooling System & Initial Wiring
27
Engine, Gearbox & Prop-Shaft
27
Engine Brackets and Timing Pointer
27
Gearbox Mount Plate, Rubber Mount and Adaptor
27
Exhaust System
28
Servo Vacuum Hose
28
Connect and Bleed Clutch
28
Clutch Slave Cylinder
28
Fitting Engine
28
Cooling System
29
Down Pipes or Stainless Manifold Extension Pipes
29
Silencers
29
Rear Tie Bracket
29
Initial Wiring
30
Radiator Lower Mounts
30
Bottom Hose
30
Radiator Top Mounts
30
Front End Wiring Loom
31
Rear and Gearbox Loom
31
Coil
31
Electric Oil Gauge Sender
31
Overdrive Inhibit Switch
32
Fuel Pump
32
Overdrive Solenoid
32
Cooling Fan and Switch
32
Fog Lamp
33
Reverse Lamp
33
Brake Fluid Reservoir Wires
33
Starter Moto
33
Wheels & Tyres
34
Splined Hubs
34
Fitting Wheels
34
Body, Doors and Bonnet Fitting
34
7.1 Body
34
Preparing Wheels
34
Lifting on the Body
35
Bolting on the Bod
35
Body Tightening Sequence
35
Dashboard Stays
36
Bonnet
36
Final Body Mount Bolts and Spacers
36
Windscreen Wiper/Scuttle Bracket
36
Door Fitting
36
Bonnet Details
37
Bonnet Fitting/Cutting Advice
37
Preparing Centre Hinge
37
Preparing Outer Hinges
38
Positioning Top Hinge
38
Radiator Hoop and Long Stays
38
Radiator Shell
38
Securing Top Bonnet Panel
39
Marking the Bonnet Panels
39
Cutting the Top Bonnet Panels
39
Fitting Side Hinges
39
7.3 Painting
40
Fitting Bonnet Studs
40
Cutting Bottom Panels
40
Bottom Bonnet Beaded Edge
40
Refitting Body
41
Refitting Doors
41
Refitting Painted Bonnet
41
Body Fittings
42
Safe Storage
42
Floorboards, Handbrake and Seat Runners
42
Handbrake Cable
42
Rear Floorboard Upright Mount
43
Rear Floorboard
43
Rear Brake Access Panel and Tool Tray
43
Handbrake Lever
43
Windscreen and Wipers
44
Gearbox Cover
44
Sealing Floorboards
44
Wiper Spindle Holes
45
Mirror and Aero Screen Brackets
45
Fixing Windscreen
45
Windscreen Positioning
45
Remaining Body Fittings
46
Tenax and Lift the Dot Studs
46
Aero Screens
46
Wiper Arms and Blades
46
Front Valance and Dummy Starting Handle Eye
47
Fitting the Lamp Bar
47
Lamp Bar Stays
47
Wing Stays
47
Upper Steering Column
48
Lower Steering Column and Escutcheon
48
Throttle Pedal
48
Choke Cable
48
Fuel Cap, Adaptor and Link Pipe
49
Rear Reflectors
49
Spare Wheel Bracket
49
Rear Lamp Brackets
49
Running Board Strakes
50
Dashboard Fittings
51
Grab Handle
51
Fuel Switch (Dummy)
51
Wiring and Electrical Fittings
51
Main Earth
52
Main Power Feed
52
Stalk Switch
52
Relay Earths
52
Steering Column Ignition Key
53
Hazard Warning Lamps
53
Heater
53
Electrical Instruments and Automatic Gearbox Illumination
54
Low Charge Warning
54
Main Wiring Earth
54
Wiper Motor
54
Instrument Illumination
55
Ammeter
55
Headlamp Switch
55
Fuel Gauge
56
Windscreen Wiper Switch
56
Starter Push Button
56
Dashboard Ignition Key
56
Overdrive Switch
57
Tachometer
57
Spot Lamp Feed
57
Oil Pressure Gauge
57
Front Lamps, Horns and Alternator
58
Speedometer
58
Headlamps Type 40 and Horns
58
Headlamps QK596 and Horns
59
Flasher Lamps
60
Spot Lamps
60
Rear Lamps
61
Side Lamps Combined with Flasher Lamps
61
Alternator
61
Right Hand Lamp
62
Left Hand Rear Lamp
62
Fuel Gauge Sender
62
Earth Feed
62
Testing
63
Wiper Blade Fitting
63
Interior Trimming
64
Trimming
65
Final Body Fittings
66
Steering Wheel and Boss
66
Front Number Plate
66
Rear Number Plate and GB Plate
66
Luggage Rack
66
Ignition Settings
67
Ignition Setting, Carburetion, Testing Running and Tuning
67
Chassis Plate
67
Seat Belts
67
Carburetion
68
Carburettor Base Settings
68
Warm up
68
Dwell Angle
68
Setting Mixtures
69
Engine Checks
69
Test Running and Tuning
69
Driving and Service
69
Road Preparation
70
Wheel Alignment
70
Suspension Setting
70
Headlamp Alignment
70
Servicing
71
Tyre Pressures & Greasing Points
71
Speedometer Calibration
71
Electrical Systems
72
Wiring Loom Positions Key
72
Fuses
74
Line Fuses
74
Relay Fuses
74
Relays
74
Wiring Diagram
75
Key to Circuit Diagram
75
Wire Colour Coding
75
Optional Items
75
Figures
77
Puller for Differential Mounting Bushes
78
Setting Rear Wheel Camber
78
Exhaust System Assembly
79
Early XJ6 Upper Wishbones
80
Early XJ6 Lower Wishbones
80
Late XJ6 Lower Wishbones
80
Front Wishbone Identification
80
Peering of the Bonnet Panel Edges
81
Carburettor Pipe Location
81
Seat Runner Positions
82
Jig Tool for Marking out Lower Body Fixing Holes
83
Location of Throttle Pedal
83
Location of Door Latches
84
Location of Rear Reflectors
84
Strake Fitting
85
Cutting and Gluing Rubber Insert
85
Dashboard Layout and Grab Handle Location
86
Windscreen Fitting
86
Floorboard Fitting Kit
87
Picture to Left
87
Body to Chassis Fixing Locations
88
Heater Fitting Instructions
89
Heater Kit Contents
89
Loom Placement Diagram
90
Drilling Hole of Bonnet Hinges for Rivets
91
Headlamp Bar Fixings Positions
91
Steering Column Locating Jig
91
Cut out Holes in Gearbox Cover for Maintenance
92
Shock Absorber Height Adjustment
92
Wiring of Rear Lamps
93
Photographs
94
Rear Axle Components
94
Assembled Engine, Gearbox and Rear Axle
94
Rear Axle Fitted
95
Early Build Stages
96
Rolling Chassis
96
Stainless Steel Manifolds Fitted
97
Lucas Qk596 Headlamps
98
Different Headlamp Options
98
Type 40 Headlamps
98
Fluids, Lubricants and Maintenance Data
99
Tyre Pressures
99
Wire Wheels
99
Adjustable Shock Absorbers
99
Running in and Service Instructions
100
500 Miles
100
500 - 1000 Miles
100
1500 Miles
100
Suffolk Sportscars ANNUAL SERVICE
101
Speedo Calibration
103
RHD Brake Pipe Locations
104
Suffolk SS100 Dimensions
105
Suffolk SS100 Chassis Details
106
5
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Suffolk SS100 Specifications
General
Brand
Suffolk
Model
SS100
Category
Automobile
Language
English
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