Engine, Gearbox, Exhaust System, Cooling System & Initial Wiring; Engine, Gearbox & Prop-Shaft; Engine Brackets And Timing Pointer; Gearbox Mount Plate, Rubber Mount And Adaptor - Suffolk SS100 Build Manual

SS100 Build Manual (Export Edition)
Connect the fuel lines to the suction and discharge connections of the pump using the 5/16" fuel hose and
hose clips. The installation of an in line filter between the tank and the fuel pump is a wise, added
precaution although the pump does have its own filter, Suffolk Sportscars fit a filter under the bonnet before
the carbs where it is easier to see and clean when full.
Important Note - If your build continues for more than a month after the fuel tank has been received then
problems can arise from slight rust forming inside the tank. To avoid this the following precautions should
be observed:
1. Clean the tank and seal before installation or remove to do so.
2. Before using the tank fill with fuel and drain.
3. If reusing the fuel refill the tank through a fine gauze filter.
5 Engine, gearbox, exhaust system, cooling system & initial wiring
5.1 Engine, gearbox & prop-shaft
You will need the following parts for this operation:
Engine and gearbox assembly fully refurbished comprising:
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o
Engine complete with inlet manifold, carburetors & throttle linkage, air filters, exhaust
manifold, water pump, modified thermostat housing, thermostat, mechanical fan, distributor,
coil, ignition leads & plugs, oil filter, clutch, clutch slave cylinder, starter motor, oil pressure
and water temperature senders (if electrical gauges are used or adaptors if mechanical
gauges are used), gearbox including overdrive & inhibitor switch if fitted, reversing light
switch and polished aluminium gear knob.
Engine mounting brackets (RH & LH specially made for the Suffolk SS100).
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Engine mounting rubbers (3) 2 for the engine and one for the gearbox.
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Special threaded adapter for gearbox mounting.
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Throttle cable & bracket.
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Alternator mounting bracket and mounting bolts.
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Fan belt tensioner & mounting bolt.
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Propshaft.
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3/8"UNF special shouldered bolts for propshaft (8) and nyloc nuts (8).
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Gear lever knob.
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Gearbox mounting plate (part of chassis kit).
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5/16"UNF x 11/4" bolts, plain washers & nyloc nuts (4).
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3/8"UNF nyloc nuts (5).
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3/8" mudguard washers (5).
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7/16"UNF x 11/4" bolts & spring washers (7).
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2 ft length of 3/8" ID vacuum hose plus hoseclips.
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5.1.1

Engine brackets and timing pointer

Attach the RH & LH engine mountings to the engine using the 7/16"UNF bolts & spring washers. Tighten to
50ft-lbs. Fix a rubber engine mount to each bracket and secure each with a 3/8" mudguard washer and nyloc
nut, leave loose at this stage. Turn the crankshaft to TDC using the pointer. Undo and withdraw the two
lower most bolts (3/8"UNF) on the offside of the timing cover and attach the alternator bracket. Retighten
the bolts to 25 ft-lbs ensuring that the pointer is set back at TDC. Withdraw the top nearside bolt on the water
pump flange attach the fan belt tensioner and screw back but do not tighten at this stage.
5.1.2

Gearbox mount plate, rubber mount and adaptor

Attach the gearbox mounting plate to the 2 chassis brackets using the 4 5/16"UNF x 11/4" bolts, plain
washers & nyloc nuts with the plate offered up on top of the brackets and the nuts facing downwards. Screw
the special threaded adapter into the rear underside of the gearbox and screw a rubber engine mount into the
adapter.
Page 27
Rev 10 November 2013