Bristol Cars 100B Instruction manual

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WORKSHOP MANUAL
for the
BRISTOL 2 LITRE
TYP ES 100B AND 1 0082
ENG I NE, GEARBOX AND OVERDR IVE
URISTOL CARS, f ILTO N, BRI S TOL , ENGLAND

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Key
1. Gearbox remote control.
8. Vibration damper.
2. Gearbox filler plug. 9. Engine front mounting.
3. Exhaust ro c ker cover.
10. Starter .
4. Throttle co ncrol layshaft.
11. Exhaust manifold.
5. Carburettors . 12. Clut ch operating lever.
6. Water pump thermostat.
7. Dynamo coo ling fan.
13 . Reversing light switch.
14. Rear mounting .
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T y pe 1 00 8 Ent<:in~ with BWCR7 Gearbox. R.H. Side
1

25
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
2.
" " "
20
Fan.
Water pump.
Inlet rocker cover .
AII' intake manifold.
H. T. leads.
Air clea ner.
19
Petrol feed pipe (pump to
carbs L
Oil feed pipe co rockers .
Gearbox remote co ntrol.
Rear mounting.
Speedome rer drive .
Cylinder drain coc k.
Petrol pump.
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Key
17
14.
15.
16.
17.
18.
19.
20.
21.
22 .
23.
24.
25 .
26.
"
Torque buffe rs.
Sump drain plug.
Engine breather pipe.
10
Oil thermometer conn ec .tio n.
Dipstick.
Oil filter.
Oil pressure relief valve.
Engine speed indica~or
drive.
Oil return pipe separator.
Engine fronc mounting.
Dynamo.
Vibration damper.
Gearbox l evel plug.
Type 100B Engine with BWCR7 Ge:.l,bo,.. L.H. Side
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Type [00/B2 Engine and 8WCR" Gellrboll. R.H . Side
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Type loofBt En ,t:ine ~nd B WC RII Ge~rbo" . L. H. Side
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En l'! "''' ::'pce,flc anOOl ll
J){'cnrbol'I1zmg .••
Kcm o vll1g Engme
Engine As se mbly I'r0Cedllrc
CYLINDER BLOCK GROUP
Spares 1l1u ~HI'B(Lo n s
Block. Ma, n Beari n gs
Camshaft Dr ive Cover Su mp
General Data
Repla cements
Rebo ri ng and Kcslcev "'B
Ca",,,I,,,I, Bc url ngi'! ".
Rcplacltlg I kll"H 'S Caps ...
Replacing D,stnb",or Drive B""h
RemOVIng and Refiulng Sump
Engine
List of Co nte nt s
CYLINDER HEAD AND VALVE OPERAT I "'G CROU P
Sp are s 11 1, uur31 ' ous
Cyl lll dcr He ad Group
Valve Op er ati ng G, - oup
Cen"r,,! Data
Repla ce m ents
Replacement of VlIlvc Sca ts
h[{tn B i{cpillcemelu Valve Guides
Rcpl"Clllg R oc ker B ushes
Valve T" ", ng ...
Replacmg [he T ,m lllS Cham.
Rcmov lO g and Refuti ng Camshaft
CRAKKSHAFT GROUP
Span,s Ill usl r31 io " s
Crankshaft Groups
Gcne,.,,] Ollln
Rcpl"ccrncn(~
1"';P",Cll0/1 of Crank,;hafl In Sl["
R cmo v!ng Cran ks haf l fr om Lnglflc
I
"o; p ccllo n of Crn nb .hnf ~ __
Rq ~rll1d ," j.( the J O ll ,- na l,,___
Page
1 ,
7 8
8
10
11
13
13
13 &. 14
14 &. 15
15
15
15 &. 16
18
19
21
21
21
21 &. 22
22
22
22
22 - 24
26 &. 27
"
30
30
30
30 &. 3 1
31

List of Co nt e nt s
CRANKS HM 'T G ROOP ( Cont.),
Nilriding '"
Ih'f i lting Cn tn kshaft to the E ngine
Pist o ns and Con n ecllng Rods
RemOVIng a P.ston or P"IIons wuh En g. ne In Situ
F LtlLng New P"stons With Eng ine D Is ma ntled
Con neclI ng Rods
Gudgeon P,n Bushe s
Big End fkar . nFt
PIs ton SIzes
Flywheel and Starte ,' Ring
OIL
PUMP , RE LJ EF VALVE AND OIL FI LTER
Spa r es !!Iustra oon9
011 Pump and Pllter
Engine L uhrlcafLon '"
AdJustmg 0,1 Pressu "e
Removing and RcfLltLllg Reli ef Va l ve
at! Fther '"
Eng,ne Lurwication Dlagr~ms
Od "pump '"
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SOLE X CARBURETTORS, AIR M ANIFOLD, CARBURETTOR Co. "lTROLS, PETROL PUM P,
EXHAUST MANIFOLD ,'ND AIR CLEAK'ER
Spare" II[ustratlo ns
So[e)(
Carhs, A,r Mani fold, Petro l Pt pe '"
Petrol Pump, E~haust Mamfo ld, At I' Cleane r
Eng i ne Cont r ols
Re mo v.ng and RefUti ng Corhu reff or s .. ,
Carburettor Type .. and Sett ings
Ill_Stat'rer .. ,
Slo w Running
Main Throttle Range
D.smantl l ng Carhurettore
Recondltiomng Ca , 'hul'ctto rs".
Rc-Assembly of Carburettors
Carburettor Tu ", ng and Syn chronll ;at ion
All' Cleaner
Petrol Pump
Removmg the Pump from the Engine
Dismantling to Replnee the D iAphragm
RcflttLng thc Pump to thc Engine .. ,
ENGINE
ELECTR I CAL GROOP
Spa re s Jll ust rat ioo l8
D
ynamo, Stllr t Cr, I)ls[".buto r , COL I
General Data
RcnlOving I)Istl'L buro,' DrIve CasIng ASfiembly",
Page
31
31 - 33
33
33
34
34
34
34
34
34
& 35
38
39
39
39
39
40 &- 41
42 & 43
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4 9 &. 50
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51 &. 52
52
52 &. 53
53
_ 56
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57
57
57
60
61
61
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List of Contents
ENGINE ELECTRICAL GROOP (Cont.).
Dismantling and Re_Assembling the Distributor Drive Casing Assembly
Ignition Timin8"
Distributor Contact Breaker ...
Setting the Poim ...
Distributor Cover and Rotor ...
Checking the Ignition System
Replac i ng Condenser
Sparking Plugs ...
P ...
61 &. 62
62
62
62 &. 63
63
63
63 &. 64
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Engine Specifications
Decarbonizing
Removing the Engine
Engine Assembly Procedure
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Engine Specifications Decarbonizing
Removing the Engine
Engine
Assembly Procedure
The T ype 100B and B2 engine of'BrjslOl' manufacture
IS an overhead valve sixcylinderunitof2 litres capacily.
Bore G6 m/m (2.598 inch), Stroke 96 m/m (3.779 inch).
Capacity 1971 c.c. CompI'c8sion Ratio 8.5 to 1. RAC
raling 16.2 H,P. Maximllm power 105 bhp. at 5.000 rpm.
Cylinder Block fitted with ' 8rivadium' dry liners.
Aluminium alloy cylind er head w ith steel 'shrunk-in'
inserts for valves and bronze insert" for sparking plugs.
Polished hemispherical combustion chambers. Overhead
valve inclined at 80° operated by vertical anderass_head
rods. K.L.G. P. TEN. L.70 Sparking Plugs.
Camshaft mounted in four pressure 1 ubr;ested bearings
and driven by a duplex chain.
Three multiple jet down draught carbu r ettors fined
with air cleaner.
Aluminium alloy pistons and forged steel connecting
rod s . Forged steel c rankshaft. nitride hardened and
statically and dynamically balanced. Fitted with lead in_
dium shell type steel backed bearings. Torsional vib_
ration damper incorporating fan drive fined to front end
of crankshaft.
Fan and positive pump water Clrculat10n coohng
systenl with thermostatic control. Thermo syphon CIr_
culation f rom head to block.
High pressure lubrication by Hobourn Eaton type oil
pump to all engine beari n gs via full flo w oil fil t er w ith
provision for external oil cooler.
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Maintenance of the engine is de alt with in two
categones.
Decarbonizing.
Each component Or section of t he engine in its detailed
form.
Decarbonizing
recommen d ed that the following
should be obtained before starting
N.310200
N.321310
N.321330
N.321970
N.3228BO
N.350240
:-.1.350250
N.360740
N.370030
:Joint Push Rod Covcr.
Joint _ Rocker Box Section.
Joint - Rocket· Box - Exhaust.
Joint _ Rocker Bo x -Inlet.
Gasket _ Cylinder Head.
Jo int _ Water Pump-Head .
Joint _ Water Pum p - Pump .
Joint _Oil Filter.
Gasket -Exhau st Manifold (2)
joints and
this work .
N.370 170
N.373320
N.380110
Joint _ Carburettor Adaptor (3)
Joint - Carburcttol ' (3)
Joint - Distributor Drive Casing.
This set of Gaskets is known as DEC.3. and can be
ordered as such from a 'Bristol' Distributor or agent or
direct from the work s .
Dismantling, Decarbonizing and Reassembly
Disconnect the negative terminal from the battery.
Drain the water from the engine by opening the drain
tap on the radiator and the drain tap on the left hand side
at the rear of the cylinder block.
Remove the Hose connections betwe en the radiatOr
and the water pump.
Withdraw the sparking plug leaqs.
Detach the oil feed pi pe and the revolution drive cable
fr om the distributor clrive casing by unscrewing the union
nuts.
Detach the distributor drive casin~ complete wi th the
Distributor by removing th e tWO 5/16 BSF Bolts and the
two lower nuts & washers.
NOTE. Care must be taken to ensure that (he distance
p:iece behind the casin~ at the bolt location is nOl mislaid.
This is selective for t ickness .
Disconnect the throttle and mixture controls from the
engine cnd .
Disconnect the fuel pipe connections from the carbu r_
ettors.
Detach the return spring On the carbure ttor control
.. haft unit and slacken off both fulcrum adjusting screws
until the ball ends of the scre ws are clear of the sockets.
Detach the three carburettors. together with the three
jOint washer s by removing the six 5/16" BSF nuts and
spring washers. The H.T. clip can also be removed at
this "tage.
Detach the two f,dcrum brackets and the centre
adaptor unit together w' ith the three jOint wash ers by re-
movi ng the six 5/16" BSF countersunk head screws.
Continuation of Rrocedure after Carburettor s have
been removed.
Detach the oil transfe r pipe con nectin g the cy lind e r
head and block..

Oetacl, the e xhaust e"pes from the cylinder h ea d.
/{em;'ve the fall belt.
Unscrew and remove the fo urteen nuts sec uring the
cyl Lndc r head w the block u si ng special spanners
N.6001 2l Box Spanner (with Tommy Bar N.60013l) and
1\.600161 Ring Spanner and the se quence given in Fig.l
for tightening and loosening the nuts.
@J @J
@J
@J @J
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@J @J
@J @J @J @J
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Fig. I. Sequence of cy linder head nurs
Work ,he cylinder head loose ge nt ly and lift off, ca , 'e
being taken to ensure that the push rods "emain In
position in the block otherwise they may be damaged if
caught up in the head.
Remove and discard the Cylind er Head gas ket.
Remove the Water Pump Th,s 's nOt essential but will
conSIderab ly facilitate the handling of the cylinde ,' head
on the bench.
Using special Plug Spanner N.600010 (with To mmy
' Ba r N.60013l) remOve the sparking plug s.
Detach the rocker coven. by unscrewing the eight
knurled hand nurs. Remove the joints and the sm all rubber
seals at the ends of the cylinder head.
Detach the seven rocker spindle ca p s, secu ring each
rocker shaft by removing the fourteen " pecial nuts.
Lift out the. rocker shafts holding the rocker's at each
cnd 10 prevent them from being pushed outwards aga,nst
the action of the compressIon spr·ings. After remo val
,nsert a pin into the hole at each cnd to "etain the rockers
On the shafts.
Remove the auxiliary pus h rod ...
Using a valve spring lifter com pres s the va lve springs
and remove the split val, 'e cotte rs, the valve springs . the
valve spri ng seatings and the valves.
All of the parts nf this assembly should be retained
together and sh ould be assembled hack into its identical
position a, a later date.
With all r.he "alve r emoved pt'oceed to remOve carbon
from the combustion and exhaust po,·ts of the cylinder
head.
Remove the cad xltl from the va lve guides using a
sma ll bristle hrllsh.
Remove the ca "bon from the valves whic h should then
be polished.
Using a rubbe,' suction cup and suitab le 'coarse' and
'fine' val vc grinding paste, grind tn ,he val ve ensu ring that
a matt finish is obtained on the valve seating~. Bright
"in gs or any signs of'pitting' On the seatings would not be
good enough.
T he maximum width of the searing should be .060
Inch Inlet and . 080 inch Exhaust and if in excess of this
the valve seats s hould be recu t.
When the valves are satisfactory it would be advisable
wherever possible to lap tbe face of the cylltlder head .
Using a medium grade J apping compound {not coarse
wh ich will sco r e the aluminillml on a s urface plate lap
[he face until a good even matt finish is obtained.
T he ca"bon should be removed from the top of the
pistons the surrounding cylinder block being carefully
covered to prevent the ca,'bon depoSit from falling into
any par·t of the engine.
P arr s sho uld then be washed t horou g hly and all trace s
of grinding compound or any foreign matt e " should be
removed.
Assembling
All valve s prin gs and rocker compression springs
should be carefully exami ned fo r fracture s or damage.
Jf considere d necessary the val ve .spri ng s could be checked
to the fi gures given In the data of the valve operating
group.
Replace th e valves back into their original po .. itions
In the cylinder head and fit Ihe spring ... sealings and
coners. Sec ,hat the variable pitch valve springs arc
a ssemb led close-coiled end downward s .
In
se rt the auxiliary pus h rods.
Fit the exhaust rocker assemply 10 the head using
assembly plates Fig.2 and ensure- that the spindles locate
on the dowel in the f"ont of the cylinder head and with the
dowel hole in the shaft. A slot is prOVided at the rear cnd
of each sh aft and a screwdriver can be used to rotate the
shaft for po si,io ning. The shaft should then be secured
by the seven ro cket· spindle caps.
Fig . 2. Rocker shaft assemhly showi ng US" of plal"s.
The Ass embly plares Can be made up to ,he dimens,on
given tn Fig. 3
The Inlet" rocker assembly can be assembled ro [he
head llsing the Same procedure as the exhaust side and
finally attached wi tb the seven rocker spindle caps.
Clean and check thespal·kingplugs wl' kh . ,~o ol' have a
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gap of .0)8 inch to .020 inch and SCl'CW
head.
,, 4"
them inlO the
M.S. 22 SW .G.
Fig. 3. Asscrnblr plate sketch.
Attach the Water pump to the head us,ng new joints
slighdy smeared with grease.
Before fitting Ihe c y linder head to the block the twelve
vertIcal push rods should be removed and also each of the
lappet bodies. Frequent! y tappets may be removed by hand
two holes beIng provided for a simple hook extraelO!".
However. a carbon depos1t may form around the base of
the tappet In which case a special extractor tool is
illustrated in use at Fig.4 and a fully d,mensIOned draWing
at the end of this Engine Section.
J
Fig . 4. Tappet withdrawing.
. ,.
EKamtne the tappet base and very slight ininai pining
which may have taken place early in the life of the enw"e
IS not consid"r"d to be serious but it is important to
e xamine whether even this slight pitting is deepor whether
there is any l,kelihood of minut" p,,,ces haVing been
broken away. in which case a neW tappet should be fitted.
In all cases of extensive pitting new tappets should be
fi tted.
Refit the tappets and th e vel·tlcal push rods .
Fit a new cylinder head gasket and fit the cylinder head
to the block. carefully ensu ring that the vertical push rods
are nOI damaged or bent as the head IS lowered into
POSitIOn.
When the auxiliary and vertlcal pu"h rods are posit-
ioned and the cylinder head is seatingon its face, replace
and ughten the fourteen holding down nuts gradually
using the correct spanners (as for loosemng) and the
correct sequence gIven. The nuts should first be tight_
ened so that they are just pinching th" head and there-
after one sixth of a turn at a time through the sequence
given until all nUls arc fully tightened .
A torque loading fIgure is not considered practical due
to the inaccessabilllY of the cylinder head nuts and it is
therefore recommended that rhe correct 'Bristol' ring and
box spanners should be used.
The valves can now be adjusted to the correct seltlngs,
The correct clearance between the rockers arms and the
valve IS mOst important. Valve clearances should be Bet
to .005 when cold. This setting shouldgivea clearance of
.012 which should be checked on the E xhau st and Inlet
sides when the en~ne has anained an indicated lClT)per-
alure of 70
0C
to 75 C.
Turn the engine with the sta rting handle unul No.6
Inlet Valve is fully open . No. l Inlet Valve will then be
fully closed. Slacken the Iocknut on No.l Inlel valve
rocker screw and adjust the scre w to obtain a clearance
of .005 between the rocker arm and the face of the valve.
See Fig.5 Hold the adjusting screw. tighten the locknut
and recheck. Check the remaining valves in a similar
manner. The valve open and closed posiuons being given
on Page 6.
Fig. j. Tappet adjustment .
When the valv" s"lllngs have been f,nally adjusted re-
place the half round "ubber seal s in the ends of Ihe
p.

cylinder head. Using new joints assemble the rocker
covers Into position and secure with the ~ ei ght hand nuts.
Inl et
Exhaust
Valve op eo
Valve closed Valve open
Valve closed
No.6 No.l
No.6
No.l
No.S No.2
No.s
No.2
No.4 No.3
No.4 No.3
No.3
No.4
No.3
No."
No.2 No.S No.2 No.S
No .l No.6 No.l
No.6
Valve open and closed positions.
Fit the fan belt and adjust 10 the correct tension of
I" deflection inwards, by hand, on its upward run see
Fig.6
7
C 143/10
Fig. 6. Fan !>eh adju stment .
Using new gaskets attach the e xhau st manifolds,
Attach the oil transfer pipe connecting the cylinder
head wuh the block,
Attaah t he carburettors by reversing ' the procedure
gIven for removing.
Connecl the fuel pipe 10 the carhureHors,
Connect the mixture and throtde controls,
Attach the Distributor and its drive shaft assembly to
the block and head. Use a new Joint On the l",wer faCing
and ensure that the driving tongue of the shaft is meshing
correctly before tightening the nuts. See also that the
selecti ve distance piece is correct! y posItIoned behind the
top bolt location before tightening the two bolts Fig. 7
Fig. 7, Distributor d,h 'e distance piece.
Check and adjust the contaCt pointstogivea clearance
of .014 to .016 lOch,
Attach the spark plug adaptors to the plugs.
Anach the hose connections to the radIator and water
pump.
Fill the radiator with water and conneCt ,he negal1ve
ternlinal to ,he battery.
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Removing the Engine
O"a", [he WaHT from the cooling syStem at the
radiator and c),linder block taps.
Di~connect Ihe bane,'Y'
Remove t.he sump drain plug and allow the oil 10
drain. Refit (he plug. Remove Ihe oillemperature therm_
omete,· bulb f"om the su mp and SlOW it. with it" capilliary
t.ube On the chas"is frame to avoid darnage.
Dlscnnnect the leads from th" dynamo.
Disconnect the coil ft.T. and L.T. Iead~ from the
d'Stnbu(Qr and tic them to the bulkhead clear of the
engine.
Disconnect thc tachometer d,'ive from rear end of the
dislributor drivc casing.
Disconnect: the oil pressure gauge pipe from its union
lust aft of the dipMick.
Slacken Ihe dynamo mounTing and ad justing bolts. press
the dynamo as far as possible (Qwards the engine and
remove rhe fan belt. Do nOT a~emp.t to ride the belt off
!.hf:...l1ulleYli: Or the core of the belt may be damaged. Re_
tighlen Ihe bolts .
Disconnect the mixture control wire.
Turn off Ihe fuel tap to p"event possible tank syphoning
and disconnect the flexible pipe.from the frontof the fuel
pump.
Disconnect both Radiator hoses from the water pump
and ,·adiator. Disconnect the rear heater connection and
remove ,he copper pipe complele with it" connection" and
the radiator hose. Disconnc-ct the Trico windscreen
wa sher connection from the f!'Ont of the cylinder head.
Break the locking wire and sl acken the exhaust down
ptpe ring nulS but do not release them.
Di~connec[ the water thermometer bulb unit from the
side of the cylinder block (between ,he exhaust manifolds)
and StOW il wilh the capillary tube on the chassIs face to
avoid damage.
Relllove [he venical throttle control rod {passing
t.hrough the rear manifold} and replace (he nuts on their
respective ball joints fOI' safe keeping.
Disconnect the cable from the stane,· motor.
On earlier can; [he radiator has a fixed fan guard
luning out from the header tank and if (hi,; should be the
case it will be necessary tn completely remOve the Water
pump.
On later Cars the fan guard of the radiator is de!aeh~
able. This should be removed and the water pump allowc-d
to remain 1[' position.
Unscrew the ring nuts from [he exhaust down pipe s .
It
i~ advisable to Sllpport these pipestoprevent straimng
the f"ont silencer loinl'" when th" lower clip is released
subsequently.
Fitting the Engine Sling
Fit the engine lifting sling TFN.5029 to a ho ist a col'l_
venient height abov e [he engine. Pass the free end of the
short {frond cable around the from end of the crank-shaft
(behmd the pulley) and hook it to (he from ring of the
lifting bar. Pass the free end of the long (rearl cable
beneath the ""mp at [he rear just forward of the cllItch
housing and hook to Ihe rear of the lifting ba,·. Sce Fig .
S
rig. 8. Engine lifting sling in use.
Raise the hoi"t umil Ihe weight of the engine i" laken
On the "ling.
Kemovc the gearbox from the car as described ,n
Section 5.
R emove the nuts and bolts ""curing Ihe f rant engine
mounting blocks to the chassis.
Raise the engine ca"efully from the Car and manoeuvre
cleat· while lifting.
To instal the actual engine reverse the removal
procedure.
To in"'tal a replacem ent engine it $hould be prepared

for InslaJlallon In a ccord an ce w it h the removal procedure
I.e. removal of the w ate r pump If the ,· adia tor ha !:! a filted
fan guard an d removal of [he fan bdt with the dynamo in
Us fllllelSl ,"wa ,, ·d polS ill on.
Referring to Modlflca " ons ,n th, !:! boo k tt IS important
to no te that an cn glne with a VISCOU!:! damper may not fit
mlO any Type 404 Car or any Type 405 Car lip to Chassis
4051. At Chass,s 40 52 t hc front cros!:! member and fro nt
IIpri ng auachmem was redesIgned 10 proVIde clearance
for the VISCOUS Damper .
Engine Assembly Procedure
Assunllng that an engtne 18 being completely rebuilt
uSIng a ne wo r re condit IOned CylInder BlockorCrankshaft
then the follow\1\& seque nce of operations should be
broadly used. The various operations are dealt with in
detaIl throughout this section of the manual.
With the cylinder bl oc k resting on its top face:
(1) Check the cran k"haft end nOat by fnung the c rank-
shaft and a temporary sleev e to the front cnd.
It IS nOI usual for [h,S e nd n01l1 10 be outside of the
hmlts bUI " is recommended that this is chec ke d
should [he crankshaft o r the block ha vc 10 be re j ected.
(Z) Check the cams h aft end (JOllt.
When these chec ks ha ve been mad e and a re sa ti !:!_
factory [he part s should be r emoved and th e cylInder
block thorough ly washed off.
-&
(3) FIt the camshaft and the d,stributo r drive pinion.
(4) SWIng the Connecting Rocisonthecrankshaftjournals
without the pistons and when saosfactory remove
thenl.
(5) Aasemble th e P"HOnS to the co nn ec tin g rods.
(5) Chec k the pis ton rin g gaps in the oore and as!:!emb le
to the pi ston.
(1) FIt the piston and connecting rod assemblies to rhe
block.
(8) Fit the crankshaft.
( 9) Fit the drive IIpl·ockets, chain, cams hafrdriv ecover
and engine damper and assemble the co nne c ting rods
to the crankshaft.
(10) Fit the Oil Pump and Sump comp l ete with baffles.
(11) Fit lhe Flywheel and Clutch Cover ass embly.
(1Z) Reverse the engine to rest on the sump.
(l3) Fit the Cylinde r Head wHh the carbureltors and Air
Filter manIfo ld.
(14) Ft! the
Dis t ributor Drive assembly andA irC l eaner.
(15) Fit the Ot! Ftlter, Petrol Pump, Sump Breath I ng
Syste m. Dynamo. St arter etc.
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• Cylinder
Block Group
•

CYLINDER BLOCK GROUP
BLOC K M AI N BEA IH N GS
P." No.
Item
[)"c';Plj~n
No. 011
Pa" No _ h em Desc"p<j"n
No .o lf
~fC.f pe, e. ,
N.3104~
,
Core PI ,IS" large
, N
.312BOO
" """
- Oil
Cle .. ""t
2
N. 312750 2 Cylinder Liner 6 N.312600
35
"od
""
""'"
2
N. 311540 3 'Thenno Lnion , N ,3 10:'.80
36 Tabwuher -
Oil P"",
2
11".3\1760 3 lhenno Union Wa~l>et
,
mS .361/J " m.nIt
Plug
- Oil Gallery
,
N 31M90 5
wre P hIS" -- " 2
ms ,361iP
'"
Bi&nk Ph'@ - Oil G.llery
,
N.3 US6 0 6 St-ud -
Cyl
Ilc.d s.,c "ri ,,<!, - short
,
11".311360
"
c-..h"fl \le.ring _ Mid-Front
,
N.31242O , Wuh~r Cyl inder 1I".d " N.312410
'"
,....... h.fl &oring
Front
,
N. 3116-80
•
,,,
Cyli".-I;;r He.d
" N.313590 "
Thmsl Plat e - Top Half
2
N,314550 9
"od
Cyl.
IIe.cl Securing
. ,
..
, N.313770
Thru.t Plate _ Top tlalf + .0025
thick"" " ·
ms .361lG " Blank Plug
, N. 313790
TI,rusl Plo~ e _ Top lIalf
• 005
thickne u · •
N 310910 n
"!I'a .her (Ln ion ) 3 ;0,.313600 "
Th r ust W ... I",r -Bott"" Ha lf 2
N. 311730 "
Un'OII
3 ~,313780 Thru st ll' ul>e r -
Bott"'" Half •. 0025 lhickneu
N.311520 "
Oil TUlI, fer Pi pe Uni~
,
;/ .31:'.800 Tht" .t Vi uher Bott"'" Half.
005 thidm~u
N.31H20
"
SI ....... PIlV;' - c-.haft !Searing , N.313130 " Ma in a..ring Front St ... Lo 8 rd
2
N. 310680 " Cm.sh8ft & aring n. ••
, N.31322O Moin
&ni1lS
.
Ftont .010 I.' ,,"' rs i,~
·
N,311370 " c..rnshaft &u ;ng -Mid- Rear
,
It 313230
· Mam
&ar Ing Froot
.020 \:,,,\er8i.e
FS. H19/4Jl
"
9/16" Se~8cr~w
, N,314470 ·
M.in Dearing front
.030 I.IuIer8i.e
N 310510
'"
Al <In. 'II'a ,her
, N.314480 · M"in
&aring front
040 I.IuIer8i.e
Flli . 37Q/G6
"
u, _,
Bearul/I Co.p & OU\.ch Ca .ing
'"
N. 313940 "
~Ioin l3caring
Gent""
Starboard
3
N.31201O
'"
Dr.in Tap , N.31432O
M.in De.ting _
Gentre
.0 10 lhdersi.e
·
Flli.515
" W
•• her
Dtoin "fop
, N.
3\4..13O
·
~Ioin l3c~ring -
Centre .020 lnd~ r .i.~
·
FN.IOSIL 22 Nut Petrol P<InJl & OiI
"""
, N.314510
""'in lle~rin s -
Gentre
. 030 lhd~ni.e
·
1ili.585/E 23
Spring W asher _ !'.:t.rol I""",
2 ;/ ,31 45 20 ~lain &aI'l"<!' -
Gen~,.., .040 tl"lersi.~
·
N.3125RO " &od P~trol P'""P ,
IUl.1930 <5
~!ain &acing -!Sear _ Star\::.oord 2
N.310450 25
lllank Plug - Oil Gall ety
, N.314300 Main
&ari"t!' -
"'"'
. 010 UndersiZe
·
N.310460 " ","sher
Blank PhIS" _ Od Gallery
2 N.314310 Main lle~ring -
"'"'
. 020 I.IuIersi.e
·
N 313370 " Cylinder Block Unit
, N
.31 4490 ·
Mun & ar ing -
n. ••
030 \Jndeui."
N.311580
'"
r~J"h _ Dip~tick
, N.314S\XJ · Main
Beanng -!l.;ar 040 Under.,i."
·
fN.I04/L
,.,
Nut - Di.tributor llr o.c ket 2 N,313580 36
Slud _ ~1Bin &aring
Front
2
ftGS.585/D 30
Spring Washer -- Distrlbutor, [lnck~l
, ;0,.312680 "
S!.I>.I -Main [leating 6
N. 312590 3>
St,,,,
Di str ibutor Il.- "" ket
, N
.3!0360
"
Tab..-uher _ ~lain &sting
•
N.310710
32
D l ~trll>utor Dri,'~ Gear llush ,
N,312700 39
'"' M
.. in Ileacing
•
,VB 585/t· " Spring 'll·aol-.er 2
15 14
40
~
•
41
~
... ~ ..
~ .
4S
~
47
44
"
..
43
@> 48
(2) 48
~ ..
® 49
. ,"

Pa", No.
Item o.- . c,ipt ;on
l'Io.o U
Pan No. I"
em
No.of f
~fC'"
Q.eacription
•• co,
~ .II H 50
,
Sencr .... -P..., h Rod
Co'"r
" N.310160
I ~
J oint
-f
ront
- ...
,
.,; sa SID
2 Spru'lf "
ashe.
" N
3132110 Joi nt
-
Inl etS . de .~
,
N 430371
" f,b,..,
"' · as .....
" N.312360 " J o
.n l -H
ur • So.op
,
N 31 11 30
,
~:'''I! P l al,,- - ~'l"OOl
,
1IoS .1OS/ l~J
" Setaer_ -
s...., ""- or , ,
~ 311 1 40
•
et . al .... " Of! PI ne
, N
.3 1U40
"
Solt -s..p "
\IIlIl).\tID
S 80ll -
c...h.lt Or ,.", Coy.,. ,
IU 1 31SO
"
s...., Uu t ,
ill )12551)
6 r" LL To u ",", . ,
116 . 105/ 1 00 13
"",
-
...
-
"' ., ,
Ued up to a.U.SI~ 4\36
\if l 105/180 "
"" ,
'"
-
... ., ,
• N 31
3910
r"ll Wuhe.
,
\10 10!> /90 3S
"'''
- ... -
flu , ,
~h.oo ."' \ aft n 0,. 8. ;5 4131
m i517
36
fi .. he r . The..., ~ i ""
,
:'1 311181 7
h.oh Or ••" Co. ". , N.31
44S0 37 ""'snet. c o.-. in PI "8 c....,iete .. it h . .. her ,
~.d "" t u o,uu . 4136
N 312240
" n..,...,
u...0fI
,
N 314440
Ic-Iwo fl 1)1"> .... Co •• r , N.313320
39 s...., P<pe G...i<el
,
Uoed "" IIJ'Id aft ". o. .u i ~ 4137 N
.313630
"
Or .. n Pi !", . s"po.u tor BoK to s,,,,, ,
,'1311170 • J'Hnl -
c-h.ft Dr IV e Co.u
, -
..
ClLp _ J ub i! "" 1'1<. 1 ,
N J 1OZOO
, .]"".t P\>;h l\od
(.,.cr
, N
313690
" l\oee _
o.. .. n r rca Sep ... to r ,
.~ 3 1HI O .. Pu ah IW Co>H , N
313&50
" s.,por
Rt.o,. Do " ,
. ~ 310930
.. th ps uck e nlt
,
1'0 .3 13700
" ,10,n
l. Waa her • H1.tJ bo.r ,
1'0.3145<\0
"
Ihpn . cX Unn . UV Cau Of\ly
, m
1~ / 12D
"
~ ~!!S ' Bo lt
,
1'0311 4 90
"
~"' unt ' ''!! Ur 8cl<et • NearsIde , -" !.(" ShoJee p roof '11' "" 10 ,,,. ,
N 311500 ~.1rlw't , ng Ik ac l< el • O ff ~ ld e
,
f N . lO ~ /L
"
Nu t !.( " Un . 2
" 7 16"
Sllakcproof 'II' n hol ,.
,
1'0 3142BO
..
E xtro c lor P, pe II.H.O. ,
FS 1076/) " 7 16"
l~' Set"" r" ...
,
IUI4290 Extrac t or Pi"" L,H. O,
-
l\.311 270
" Ib m!'l
,,!! Bl ock 2
tu 10 4/ 81)
'"
Dolt !.( ~ usr
,
FN 105 L " 5,'16"
IN' ~ut
,
1'0 .3 1 3740
;0
Cllp c~ l et.e
,
, 'GS 565,1':
"
Srr , "6 "p uh e r • "
Ij' "Spr>,,!! 'ras her
,
l\ 31 2370 .. RI.,,~'ng P)"tr
.. ., , N
313710
"
11 0"", • f.xu.ct.or P ip"
,
N.313670
" S...
.J for s.,porot.or lIox ,
Idl366(l
20
~tOln ' ''6 Nut , 0"
Iner Ens.n" •• long Di p st ick .....
N3112~0
"
or""" Duffe ,. Bracht
, ,nt.rodue<:d t.os"lt-",r . i
th • a ip . nd
N 3llWl
"
or ", ... i)"rr er , l '!ensed f.x l raclo r pI P<'
ffi 10"1 l " 7 16" Il5f Nul
,
!CS sas G "
$pr " '« "·.,.her •
N.31465O
-
Ihpa to c. ,
FK 2071.
" 7
1 6 ~ [ISf" Ucl.mlt
-, .314660 -
Cl ip ,
10 13290
" o,
nt • Exhaust S,de
" ...
I , .314640
Ex t racto r P i""
,
~~M
, , ~ '
~ - ;r ,
, I .
-'
~ "
•
• •
· 11 ·

•
•
Cylinder Block Group
General Data
Material
Cylinder Liners
Int erference of Liner in Bo re
Load r e quir ed to pre ss in
L i ntc',- s
Finished Bore size
Camshaft Bearing Material
Cast Iron.
'Brivadium Dry'
. 003 to .004 inch
( 0.080 to 0.1 m/m)
4 to 6 tons.
(4.06 to 6 . 09 tonnes)
Cont rolled by PislOn
Sec P iston Clearance.
Crankshaft Group.
Phosphor Bronze
Camshaft Bearing location in Piston Block.
From
Mid-Front
Mid_Rear
Rear
1.675 + ,0007 inch.
(42.55 + .018 m/m)
1.695 + .0007 inch.
(43.05 + .018 m/m)
1. 715 + .0007 inch .
(43.55 + ,018 m/m)
1. 735 + ,0007 inch
(44.05 + .018 m/m)
Interferene"" fit of Camshaft f3ca r ings in Cylinder Bl ock .
Front, M id-Front. &.
Mid-Rear
Rear
.0016 inch to .0028 inch.
(.04 m/m to ,07 m/nil.
.0026 inch to .00 38 inc h.
1.065 m.m to .096 m.m).
Finished Bo re of Camshaft Bearings.
Front
Mid -From
Mid-Rear
Rear
1.460 + . 001 inch.
( 37.084 + .02~ m/m),
l. HO + .00 1 inch.
(36.576 + .025 m/m),
1.420 -+ .001 inch.
(36.068 + .025 m/m).
1.260 + .001 i nch.
( 32.00 + .025 m/m ).
(
sce s ectional view of Cylinder l3lock)
Replacements
Service replacement Cyli nd er Blocks are available
from the manufacturer. They a re supplied subject to the
return of the removed cyli nd er block which is accepted
for normal wear only. Cracked cylinder blocks. even
con .. idered repairable. are n Ot accep te d in exchange .
A
works reconditioned cylinder bl ock is su pplied
comp l ete w it h all bushes and studs and wi th the exception
of the insertion of sO me studs (om itte d for transport
purpo ses) the block is ready to fit to the engine. If
pi sto ns arc required they s hould be ordered w ith the
r e placement block in order to control the specified
piston clearance.
Reboring
Cylinder l iners may be rebored to one oversize only
which is .010 above nominal size and pistons arc avail-
able fo" this size. For general checking pu rposes. to
sce if the bore will 'clean up' " size of 2.608 inch
(66.25-1 m/m) should be used hut the finished bore should
be honed to give the specified piston clearance. See
Re-sleeving.
Re -S leeving
( A)
(8)
The cylinder liners Can be removed by twO methods.
_ ,. ()( ,-_ "0('_
.. ~
~ ,, 00 T - ''''''--
() ' 00 '
-"
,
..
!i <I [
.. j. --
.. _-
.
~
-
!, , !
~ 1 . ! , ,
• • " . ! , ! ,
, , r
.. . 1,< '"
........
Fig. 9. Spigot for re mnving liner8.
Using a hand press only and a special spigot Fig . 9
as illu strated in F'g.lO
By offsetting the ho"e in boring machine and cutting
down the side of the li n er u nt il it Can be collaps ed
and taken out. It should be noted that the walllhick-
nes s is only approximately .050 in ch (1.27 m.m)
when new and careful boriog is necessary to avoid
cu nin g past the liner into the cyj, n der block.

Fi tting New Cy lin der Liner s
Cht'ck the cyltoder bores and If necessary carefully
slOne any scores .
Check t he internal diameter of the bore and the
cxt C "nal diameters of the new Itner to ensure that Ihe
recommended ,nterference given in General Data is
obtaine d.
Lightly at! the cyltnder borc and the external surface
of the Itner and with ,he assembly beneath the ram of a
press capable of exert,ng the load given mGeneral Data,
press the Ime r ste adily into the cylmder Ix)!"e un,,1 level
with Ihe cyli n der bloc k face. Sec Fig.IO
After fitting the liners, skim grind the top face of the
block to ensure a flal face.
Carefully blend each valve head cut-away, 10 a good
surface finish, to conform with that of the cylinder block .
Sce Ftg.ll Machine Ihe tWO connecting rod clearance
.sl ots, in each liner, inside the cylinde r bloc k.
Bore and hone the liner to give the correct Pi ston
clearance as follo w s:
Clearance m cylinder bore
checked cold on thrust face
al bottom of skin. .0022 to . 0026 inch
(. 0:;6 to .066 m/m)
FmalIy attention should be paid to the cleanliness of
the block and in particular to the oil w ays.
Camshaft Bearings
If resleeving of the Cylinder Bloc k is being car r ied
Out due 10 normal w ear then it w ould follow that the
Camshaft bearings would need attention . Check the bores
as given in General Data and if the clearance for the
camshaft jo urnals IS in ex cess of .002 to ,003 inch
(.0:;1 to .076 m/m) they should be repl a ced to avoid low
od pressure,
To replace Ihe bearings proceed as follow s :
(I) Unscre w the blanktng plug from the rea,' bearing.
(2) . Using a suitable drift, drive Out Ihe bearings .
(3) Chec k tha t each bearing location is clean and free
from scores and burring .
(4) Chec k the outer diameter of each neW bush and its
r elevant bore in the cylinder block to ensure that the
correct interference is ob la ined. Sce General Data .
Fig. 10. R emoving and re fi tting cylinder liners. Camshaft Bearings . 002 (. 051 m / m) oversize on the
.,
.j .••
'(
"' ....... "_ '''' . _. u' , ,/1 _
",,' . .. os i" "'",~OI • ...x..
,
,
I.
Fig . 11 . Cylin d er block seCTion.
,]4 -
•
FBS 361 /G
NJl06BO l N3Jl720 ~"":.:~ ~3
NJI1420
•
•