BRISTOL WORKSHOP MANUAL TYPE 407 And 408

ENGINE AN D/ OR TRANSMISSION RE MOVALFROM THE CAR It is possi ble to remove t he e ngine and trans m ission th r ough the e nginebay b u t s pec ial e quipment i s ne ede d t o rai se th e front of the engine t o an a c uteangl e to do rh is. Fo r p r actical purposes it i s best to r emove t he tran s mi ssionat the torque conve rter hou sing and then remove t he e ngine and to rque convert e ras an assembly.R emov in g Transm i ssionDrainTh is mu st be carrie d out from ins ide t he car. D ra in the cooling system.the tr 'l.n s m iss ion by detaching the transmi ss io n dipstick/filter tub e .Re m ove th e carpets, seats, tunnel and fl oo rboards. R e m ove the handbrake leve rand ratc he t. Di sconnect the propellor s ha ft . D isconnect the o il cooler t ub es, rhethrot tle linka ge and th e gearshift control cab le . Di sconn ect the nylon semi-rigidfu el pipe at the e ngine.Slacken the bolts attaching the e xhaust pipe s to themani fo l d a nd wit.hout remov ing the bolts run the nu ts to t he ex t reme end of thet hrea d. Disconnect t he heater pipe at e ngin e a nd di sconnect t he oil pressure pipe .Re m ove the a i r cleane r and carburettora ndattachthe e ngine lifting fixtureT ool C - 3466 to the ca rb ure tto r fl an ge stud s on t he intake ma n ifo ld .T a ke th e weight of the engin e with a ho i st and di sconnect the tran sm issionmounting to t he c hassis.Re m ove tb p. o il fill er ai r cl eane r andra ise the back of th e engine b y t h e u seo f s lin gs or ja cking suffi cie ntl y to allow th e t ra n sm iss ion to be clear of t he chassis.Support the transmission and remove the fou r bolts attaching it t o thetorque converte r casing. With adapted lifting tack le it can no w be removed fromt he car.Re m ov ing Eng in eR emove the bonnet . Drain t he cooling syste m and disconne c t the ba t tery .R e lease th ( nuts ho ld ing the fan assemblies to t h e radiator and allow the fan ands h roud a sse mbl iel:! to drop forward. Remove all ho ses, o il cooler l ines andt hermostat connection s and r e m ove t he rad iator. D isconnect the fueilin es ,l inkage a nd w ires a t tache d to t he e ng ine and r e m ove t he a i r cleaner and ca rb ure t t or. Attac h t he engi ne lifting fix t ure Too L C - 3466 tothe carb ure ttor flange s tud son the int a ke ma n ifold . Remove t he tra n s m iss ion a s described. Di sconn ect the e ngine mountingsat t he c hass is . Ra ise the e n gine and m anipulate it carefull y o ut of the e n gine bay .It ma y be necessary to remove the ge nera to r and water pu m p to allow t he engi neto go fo rwa rd s u ffic ie ntl y for the to r que converte r cas ing to clear the bulkhead andits controls.- 11-

ENGINECYLINDER BLOCKGENERAL DATAMaterialCast Iron.TypeCyI inder NumberingO.H.V. V.8 .L e ft Bank l - 3- 5- 7R ight Rank 2- 4- 6- 8(from Dr ivf"rs Seat - Front to Rear)Cylinde r Bo re - St andardBore Spacing (C/L to CIL)Cyl inde r Bo re Out- oF- round(Ma x. allowabl e b e fore reconditioning)Cylinder Bore Taper 3.875/3.877 inch.4.46 inch.0 05 inch .020 inch.(Max. allowab le before reconditioning)R econdi tioning Working Lim i ts(for Ta per and Out - oF- Round). 001 inch.Maxim um allowable oversize bore.040 inch . 905 - .9058 inch.Tapper Bo r e Diameter - StandardDistrihu tor Lowt: r DriQ"c Shaft Bushing(press fit in block)Finished BoreClearance - Shaft to Bush.0005 - .004 inch.4865 - .488 inch.0007 - . 0027 inch .Cylinder Borp sThe cylinder block is not s l ceved and can be rebored to . 005, .020 and.040 inch o vers ize for which pistons are availab l e .Bores should h e finally honed to s uit the piston u sing the following procedureto obtain t h e correct r unn ing clearance.U se a s pring s cale and a strip of inch wide fee l er s t ock .0015 inchthickness long enough to extend in to the cylinder bore to the full len gt h of thepi ston travel.A t no,· mal room tempt rature and with the cylinder bore and pi s tonp erfectly clean. coat the bore ltghtly with SAE lOW engine oil. In sert the pistoninto t he bore upside d own with the fee ler stock bt"tween the t h r u s t face of th epi s ton and the cylinder wall. Hold t he pi ston and draw the feeler s tock st raightout u sing a s pring scale . T he amount of pull required s hould be from 5 to 10 Ib s.Cam s haft Bearings moRI With th e e ngine complete l y dismantled, drive out the welch plug fronl therear cam s h aft bearing.- 12 -

Using Tool C-3132A fit t he correct size adaptor and horses hoe washer atthe back of each bearing shell to be removed and drive out the bearing shells.Fitting the Bearings Us ing the same tool, as for removal, lubricate the bearing and position itover the proper adaptor. Fit the horseshoe lock and carefully drive the bearingshell into place.Fit the remaining shells in a similar manner, carefully noting that No. 1.camshaft bearing shou ld be fitted 1/32 inch inward from the front face of thecylinder block and that the oil holes in the camshaft bearings and cylinder blockmust be in exact alignment to ensure correct lubrication. Inspect the oil holealignment with a pencil flashlight when the camshaft bearing oil hole should beperfectly aligned with the drilled oil passage from t he main bearing also Number4 bearing must index with the twopassagesto the cylinder heads. If the oil holesare not aligned remove and refit the bearings.Finally apply sealer to a new welch p lug and use Tool C-897 to fit it to therear camshaft bearing. Be sure that this plug does not leak.Distributor Drive Shaft BushingRemova lInsert Too l C-3052 into the old bushing and thread down until a tight fit isobtained. Hold the puller screw and tighten puller nut until the bushing is removed.Fitting the BushingSlide a new bush over the burnishing end of Tool C - 3053 and insert thetool and bush into the bore. Drive the bush and tool into position using a softhalnlncr.As the burnisher is pulled through the bush by tightening the puller nut, thebush is expanded tight in the block and burnished to the correct size . 00 NOTREAM THIS BUSH . -13 -

ENGINECYLINDER HEA D AND VALVE OPERATINGGENERAL DATACylinder HeadMa te ria lCast Iron . 002 inch .Val ve Seat Run - out (Max imum)Intake Valve Seat AngleSeat Width (finished)Ex hau st Valve Seat AngleSeat Width (fin ished)Cylinder Head Gasket Thickness compressed)Valve GuideReam for next oversize Valve Ste mStandard. 0050/8. 0150/8. 030 0/8Val ve Ste m diameterValve Stem to Valve Guide clearanceIntakeExhau::;tValve SpringsLoad when compre sse d (va lve closed)Loa d when compressed (valve open)Max. allowable out of plumbIn s tall e d Height ( spring seat to retainer)Valve TimingIntake opens0.060 - .085 inch.450. 040 - .060 inch.0 28 inch.Cast - in-Head. 374. 379. 389.404. 372inch .inch .inch .inch .inch.00 1 - .003 inch . 002 - .004 inch .1.11/16 inch 78-88 lbs.1.5/16 inch 170 - 184 lbs.1/16 inch.1.5/8 - 1.11 /16 inch.o13 B.T.D.C.055 A.B.D.C .o510 B.B.D.C.17 A.T.D.C.Intake clo s esExhau s t ope nsExhan s t clo s esCam s ha ftMa t eria lHardenable Cast Iron .Chain.002 - .006 inch.010 inch.DriveEnd PlayMax . allowableCamshaft J o u rnalsDiameter45 No.1.No.2 .No.3.No.4.No.5.-14-1.998 - 1.999 inch.1.982 - 1.983 inch.1. 967 - 1.968 inch.1. 951 - 1. 952 inch.1.5605 - 1.5615 inch.

Camshaft Sea dngsDiameter No. 1.No.2.No.3.No.4 No.5.Rocke r Shaft AssemblyClearance between Rocker Arm and ShaftTappetsTypeBody diameterClearance in BlockService Tappets available in standard2.000 - 2.00 1 inch .1. 984 - 1. 985 inch.1. 96 9 - 1. 970 inch.1.953 - 1.954 inch.1.5625 - 1.5635 inch.001 - .003 inch.Mechanica l .9040 - .9045 inch.0005 - .00 18 inch . 001, .008 and .030 incho/s .Operating Tappet Clearance (Hot) y linder. 010 inch Intake.018 inch Exhaust.HeadEXHAUST VALVE ROCKER ARMTOOl - .\ Fig , ICompressing EJlthaust Valve Spring-15 -

RemovalDrain the cooling system. Remove the carburettor air cleaner, fuel line,generator and distributor vacuum lane. Disconnect the water temperaturecapilliary and 's tow it carefully to prevent damage. Disconnect the throttlelinkage, coil leads and all hoses at the engine. Remove the distributor capcomplete with the sparking plug leads.eWhen the intake manifold is quite clear of all connections remove thesixteen attachment bolts and remove the manifold, carburettor and coil as anassembly.Remove the cylinder head rocker covers and disconnect the exhaust pipesfrom the manifolds.Using Tool C-3695 as shown in Fig. 1 (CS58) and making certain WWPOINT OF CAMSHAFT IS UNDER TAPPET compress the valve springs andremove the push rods.one side to do this.o7It may be necessary to shift the rocker arm slightly toooJoso9FRON T OF ENGINE8o24ooF ig, Z6o10oCy linder Head Bolt SequenceIn the correct sequence Fig. 2 (R215) progressively release the cylinderhead attachment bolts and remove them completely. Carefully manipulate thecylinder head, complete with rockers and exhaust manifolds, clear of the car.The exhaust manifolds can now be removed.Valves and Valve Spring Remove the rocker shaft locating plug and slide out the rocker shaft, at thesame time releasing the rocker arms and springs.Compress the valve springs, using Tool C - 3422A. Remove the valveretaining locks they are different for Intake and Exhaust), remove the tool andthen remove the valve spring retainers, oil shields (Intake valves only) and valvespnngs.-1 6-e

Remove any burrs from the valve stem lock grooves to prevent damage tothe valve guide when the valves are taken out. Valve InspectionClean the valves thoroughly and discard any burned, warped or crackedvalves.InMeasure the valve stems for wear. The valve stem diameters are givenGeneral Data and if the wear exceeds .002 inch the valve should be replaced.Remove the carbon and varnish deposits from inside the valve gu ide andmeasure the bores using the valve stern diameter plus the desired clearance inthe valve guide. as given in General Data.If the clearance is excessive. ream the guides and fit valve with the nextoversize valve s tern. Refer to special Tool list for Reamers.Refacing Valves and Valve Seats0The valve face angle is 45 and if the remaining margin of the head is lessthan 3/64 inch after refacing, the valve should be replaced.The width of the intake seats should be 1/16 to 3/32 inch and the exhaustseats 3/64 to 1/16 inch.The de s ign of the valve mechanism includes a safety factor to allow for alimited amount of wear and for the refacing of valves and seats. If this isexcessive the dimension from the valve spring seat in the cylinder head to thevalve tip should be measured with Gauge Tool C - 3927.If the valve stern extends above the gauge. grind the end of the stern to fallbetween the max imum and the minimum limits.Valve SpringsThe springs should conform to the dimensions and loading given in GeneralData.Using a square and surface plate, check the spring and reject it if the outof square exceeds 1/16 inch. Re-assembly - Valves to HeadCoat the valve stems with lubricating oil and insert them in the cylinderhead. Fit the oil shield (Intake valve only) spring and retainer. compress withTool C-3422A, fit the correct locks and release the tool.- 17 -

Measure the -installed height of the springs, fro m the bottom of t he s p r ingseat in the cylinder head to the bottom face of the spring retainer. If t he heightis g reater than 1.11 / 16 inch, dismantle the valve and fit a 11 16 inch spacer intot he cylinde r head counterbore to bring the spring height back to normal.Re - assembl y of Rocker Shaft and Rocke r ArmsSlide the rocker shaft into the bore of the cylinder head strut and at t hesame time engage the appropriate rocker arm, then the spring and a furthe r armunt il they are all fitted. Line up the half round grooves in the shaft with t hecy l inder head bolt holes, at the same time line up the rocker shaft locating pl ughole. Tap in a new locating plug.Fig . 3.'\ djusHng Mechanical Tappets- 18-

Tappets (Mechanical) T a ppets are easily removab le when the intake manifold and push rods arer emoved con seque ntl y tappet examination is best carrie d out during a deca rbonisi ng process and/or complete engine overhaul.During the latter service, tappets are availa bl e in the oversizes given inGenera l Data a nd T ool C - 3028 Tappet Bore Reamer should be used to control thebores.-FUEL PUMP ECCENTRIC C859 CHAIN CASE HOUSING DOWELSF i g, ITiming l\Iarks- 19-

Tappet Ad justmentTappet adjustment sho utd. be made after-che e ngine reaches normal o peratingtempe r at ure and with the e ngine sl ow running. Adj ust intake rocker arms to have.010 inch clearance and the exhaust rocker arms to have .0 18 inch clearance.Fig. 3 (CaS7 ). The ad justment is made at the self locking rocker arm ad justingscrew. This screw should have a m inimu m of 3 ft/ Ibs. te n sion as it is tu r ned.If less than thi s, replace the adjusting screw and, if necessary. the rocker arm. Timing MarksTiming marks are shown on the camshaft and crankshaft sprockets. Theyshould be positioned at their nearest point opposite to each ot her on the exactimaginary cent re line through both camshaft and crankshaft bores. Fig. 4 (C859).Timing marks are also given atthefrontof the engine by a zero line on thecrankshaft pulley and an indicator plate bolted to the chain case cover.Installing the Cylinder HeadAssuming t hat t he val ves have bee n fitted, and tha t t he cylinder head facei s perfectl y flat, fit the exhaust man ifolds with new gaskets. fina lly t ighte ning to30 ft/lbs. torque.Coat new cy linder head gaskets with Mopar sealer 11 22893 and position themon the block. Fit the cylinder head s and in sert all head attachment bolts.Progressively t ighten them using the sequence given in Fig. 5 (R215) f inallytightening to 85 ft/ lbs. torque.o7oo3oo95FRONT OF ENGINE8o42oo610ooR21SFig . 5Cylinde-r lI ead Rolt SequenceAgai n using Tool C - 3695 as s hown in Fig. 6 (C858) and making certainLOW POINT OF CAMSHAFT IS UN DE R TAPPET, compress the va lve sp rings andinsert the push rods. It may be necessary t o shift the rocker arm slightly to ones ide to do this. See that the rocker arm adjusting screw is seating in t he cup ofthe push rod.- 20 -

EXHAUST VALVE ROCKER ARMFig, 6Compressing Exhaust Valve SpringUsing new gaskets (four pieces) fit the intake manifold and p rogressivel ytighten t he 16 bolts to 40 ft/I bs. torque. Fit new gaskets a nd connect u p a ndtighten the exhaust pipe to manifold. Assuming that the sparking plugs have been given attention . fit t he dis tributor cap and the leads to the plugs and coil. Reconnect t he variou s hoseconnections, the water temperature capiUiary. the distribut or vac uum line, thefuel l ine and the throttle linkage. Fit the generator, adjust t he belt and f it thecarb u rettor air cleaner. When all connections are made, fi ll the cooling system,start the engine and run until the normal operating temperature is reached Adjust the tappets tothegivenprocedure. Fitthe rocker covers, using newgaskets and tighten the attachment bolts to 36 in/Ibs. Reconnect the smog packhose.- 21 -

ENGINECRANKSHAFT, PISTONS & CONNECTING RODS GENERAL DATACRANKSHAFTFull y Counterbalanced.D rop Forged Steel.TypeMaterialMain Bearing J ournal diameter(new )2,4995 - 2.5005 inch.Main Bearing available forServiceStd . 001, .002, .0 10 inch u/s.Connecting Rod Jou rna l diameter2.124 - 2.125 inch.(ne w)Connecting Rod Bearingsavailable for se rviceMaximum allowable out-of-roundor taper on all journalsMain BearingDiame tral C learance betweenJ ournal and BearingDes i re dStd . . 001, .002, .010, .020 inch u/s.001 inch.Steel Backed Babbitt.0005 - .0015 inc h.0025No.3 Main Bearing.002 - .007 inch.010 inch.Allowt:dThru st taken byEnd Pla yMaximum allowablePISTONSType Materia lCle arance in Cylinder BoreAluminium Alloy - Tin Coated.( with .0015 x inch feeler stock)Pistons for s ervice5 - 10 lb s . pull.Std . 005, .020, . 040 inch o/s .Piston Pin sTypeF ull Floating.9842 inch.2 . 995 inch.DiameterLengthC l earance in Piston(Tight thumb pu s h at 70 F).0000 - .0005 inch.00 4 .026 inch.0001 - .0004 inch.Std . 003, . 008 inch o/s.End PlayCle arance in RodPins for Service-22-

Piston Rings N umber of Rings per Pisto nCompression RingsOil Ring /'; with ExpanderPiston Ring GapsR i ng S id e C learanceTop and IntermediateOil (Se rvice Ring)Width of RingsCompression321.010 - .020 inch.001 5 - .003 inch.009 inch (Max).0775 - .0780 inch.1860 - .1865 inch.OilConnecting RodsLength (Centre to Centre)Side Clearance (two rods)Piston Pin Bore diameterConnecting Rod Bushing6.123 inch.006 - .014 inch.1.027 - 1.039 inch.Steel Back Bronze.Connecting Rod BearingsT ypeSteel Backed Grid TypeDl a mete rand WidthCl e arance between J ournal andBearing.De si r ed.Maximum allowable.2. 126 x .842 inch.0005 - .0015 inch.0025 inch.PISTONS AND CONNECTING RODSPiston RemovalPistons and connecting rods must be removed from the top of the cylinderblock. When removing the piston and connecting rod assemblies from the enginerotate the crankshaft so that each connecting rod is centred in the bore.R e move the top ridge of the cylinder bores with a reliable ridge reamerbe fo re r e moving che piscon from the block taking care to cover the tops of thepiscon s during chis operation. Wich the e ngine oil pan (sump) and ti m ing c hain removed followed by cheoil pump, cube and s trainer, ma r k all bearing caps as necessary for correctre - l ocation. R e move the conneccing rod cap. Fit Tool C - 322 1 on one connectingrod bolt and fit the protector over the other bole, che n pu s h each piston and roda sse mbly out of the cylinder bore . After removal fit each bearing cap to itsrod.-23-

Piston (Gudgeon) PinsRemove the piston pin reta ining rings and press out the pin s .The pi ston pins fit in t h e connecting rod and the p iston s hould be a tight0t humb pu sh fit at normal room temperature 70 F. If t here is e xce ss ive clearance between the piston pin and piston use Tool C - 3049 and ream t he pi s ton andconnecting rod to the next oversize, as given in General Data. If there i sexces s ivp clf'arancp between the piston pin and the connecting rod bush repla cethe bu s h and size it to s uit the pin. New pistons are s uppl ied with fitted pin s . Assembly of Pistons and RodsAssemb le pi ston s and rods for the L.H. cylinder bank 0 - 3- 5 - 7) with thepi ston boss ma r ked ' FRONT ' and indent on piston head on the same s ide a s thelarge chamfer on the large end of the connecting rod.A sse mble pi stons and rods for t he R.H. cy linder bank (2 - 4 - 6- 8) with'FRONT ' and inde nt opposite the large chamfer on the large en d o f t he connectingrod .PistonRing; Measu re the piston ring gap about 2 inche s from the bottom of the cylinderbore in wh ich it is to be used . An inverted piston can be used to pus h the ringsdown into position to ensure them being exactly square with t he bore. The ringgap should be from .010 to . 047 inch for the compression rings and .015 to .062inch for the oil ring st eel rails in standard size bores (for new ser vice rings).Install t he oil ring in the low er ring groove using the instructions on thepackage. Using Tool C - 3586 fit the comp ression rings into the m iddle and topgrooves wit h the si de marked 'Top' up.Fitting Pistons and Rods to Bore sBefore fitting the piston and rod assemblies to the bore s position t he oilcontrol ring gap in line with the oil hole in the connecting rod. Po sition the gapin the compression rings opposite each other w it h neither in line with the oilcontrol ring gap.Immerse the piston head and rings in clean engine oil, slide the ringcompressor Tool C - 385 over the pi ston and tighten with the special wrench. Besure th e position of the rings does not change during t hi s o peration .With. the connecting rod bearing cap removed, screw the connecting rod boltprotector (part of Tool C - 3221) on one rod bo lt, and insert t he rod and piston intothe cylinder bore. Rotate the crankshaft so that the app ropr iate connecting rodjou rnal is on the centre of the cylinder bo re.-24-

The notc h or groove on the top of t he piston mu st be painting toward thefro nt of t he e ng ine and the larger cha mfer of t he connecting rod bore must bef

LIST OF CONTENTS Page VIEW OF BRISTOL TYPE 407 CAR III VIEW OF BRISTOL TYPE 408 CAR v SPECIFICATIONS VI RECOMMENDED LUBRICANTS 3 ENGINE R.H. View of Engine and Transmission 6 L.H. V iew of Engine and Transmission 7 Engine Special Tools 9 Engine and Transmission Torque References