MORGAN Four/4 & Plus/4 1936-1968 Comprehensive Workshop Manual | PDF Download

MORGAN Four/4 & Plus/4 1936-1968 Comprehensive Workshop Manual | PDF Download

Easy step by step instructions for the home workshop mechanic or professional technician. 

This manual covers the following Morgan models made between 1936-1968:

• Morgan Four/4 Series I
• Morgan Four/4 Series II
• Morgan Four/4 Series IV
• Morgan Four/4 Series V
• Morgan Plus/4

The following Engines are covered in this Workshop Manual:

• Coventry Climax Engine
• Standard Ten OHV Engine
• Ford 100E Engine
• Ford 105E Engine
• Ford 109E Engine
• Ford 118E Engine
• Ford 1600 Engine
• Ford 1600 GT Engine
• Triumph TR2 Engine
• Triumph TR3 Engine
• Triumph TR4 Engine
• Triumph TR4A Engine

Below is a comprehensive list of topics covered in this Workshop Manual:

• THE ENGINES
• THE COVENTRY CLIMAX ENGINE
• To remove cylinder head
• Valve grinding
• Decarbonizing gasket set
• Induction pipe
• Rocker and exhaust tappet covers
• Tappets
• Valve timing
• Ignition timing
• Timing chain
• To remove the timing chain
• Adjust dynamo belt
• Removing the engine and gearbox
• Stripping the bottom of the engine (with engine removed)
• The crankshaft
• Connecting rods and pistons
• Camshaft drive
• Valves and tappets
• THE SPECIAL STANDARD TEN OHV ENGINE
  
• Lubrication
• Fitting new elements
• Decarbonizing
• Removing the cylinder head
• Replacing the valves and checking the clearances
• Ignition timing
• Valve timing
• Replacing the timing chain
• Replacing big end bearings
• Engine removal
• Renewing the main bearings
• THE FORD 100E ENGINE
• Removing the cylinder head
• Replacing the cylinder head
• Removing the valves
• Grinding-in the valves
• Reassembling the valves
• Removing connecting rods and pistons, etc.
• Reassembling connecting rods and pistons, etc.
• Cylinder front cover, sprockets, timing chain
• Engine lubrication system
• The oil pump
• Engine removal
• Dismantling the engine
• The oil filter
• Re-assembling the engine
• Replacing the distributor
• FORD 105E, 109E. 118E. 1600 and G.T. ENGINES
• Dismantling
• Removing the valves
• Reassembling the valves
• Top overhaul-reassembling
• Engine removal and replacement
• Engine compression
• Cylinder head
• Cylinder head gasket
• Cylinder block
• Intake and exhaust manifolds
• Engine sump
• Crankcase ventilation
• Pistons
• Piston rings
• Gudgeon pins
• Connecting rod and connecting rod bearings
• Crankshaft
• Flywheel
• Starter ring gear
• Camshaft
• Camshaft drive
• Valve timing
• Valves, valve springs and valve guides
• Valve tappets
• Valve-rockers and rocker-shaft
• Lubrication
• Oil pressure
• Oil pressure regulator valve
• Oil pump
• Oil filter
• Ignition system Ford '1600' engine
• Ventilation system
• THE VANGUARD, TR2 and TR3, TR4. TR4A ENGINES
• General description
• Service adjustments
• Decarbonizing-valve servicing
• Removing valve springs
• Decarbonizing the pistons. etc.
• Valves and valve guides
• Assembling head and valve gear
• Cylinder sleeves and pistons
• Piston rings
• Cylinder sleeve fitting
• Engine removal
• Engine dismantling
• Main bearings
• Camshaft bearings
• Timing
• Oil pump
• Engine sealing
• Starter gear ring
• CARBURETTERS & FUEL SYSTEMS
• The S.U. fuel pump
• The A. C. fuel pump (early type)
• Fuel pump-Four /4 Series IV, V, 1600 competition models
• Testing the fuel pump
• To remove fuel pump
• To dismantle fuel pump
• To reassemble fuel pump
• To refit fuel pump
• Fuel pump-Triumph engines
• To dismantle fuel pump
• Solex carburetors
• Slow running
• Slow running adjustment
• Adjustment of jets
• S.U. carburetors
• Effect of altitude and climate. etc.
• Carburetor jet needles
• To remove jet needle
• To fit needle
• Centralization of jet
• To assemble the carburetor(s)
• To adjust the fuel level in the float chamber
• Carburetor tuning
• Carburation defects
• Tuning twin S.U. Type HS6 carburetors
• Adjusting and servicing-jet centering
• Cleaning
• Float chamber level
• Needle size and position
• Dismantling and reassembling the S.U. type HS6 carburetor
• Zenith-Stromberg series 175CD carburetors
• Starting from cold, Normal running, Acceleration
• Dismantling carburetor assembly
• Float chamber fuel level
  
• Jet centralization Procedure
• Adjustment: setting the idle
• Adjusting and synchronizing twin carburetor installation
• Jet and throttle interconnection adjustment
• Crankcase breather valve
• Zenith downdraught carburetors Four/4 series IV and V .
• Dismantling
• Slow running
• Defects
• Double choke Weber carburetor Four/4 series V and 1600 competition models
• Slow-running adjustment
• Weber 42 DCOE H- Pius/4 Super Sports model
• Idling operation and progressive action
• Acceleration
• Starting device
• Fuel tank removal
• IGNITION SYSTEM
  
• DISTRIBUTORS
• Four/4 Series I
• Four/4 Series II
• Ignition timing
• Plus/4
• Contact breaker adjustment
• Contact breaker renewal
• To refit
• Distributor capacitor
• Overhauling the distributor-to remove
• To dismantle
• To reassemble
• Distributor timing
• Four 4 Series Ill. IV, V, Competition Model and 1600
• COOLING SYSTEM
  
• Maintenance
• Removal
• To dismantle water pump
• To reassemble water pump
• The thermostat Removal
• THE CLUTCH
  
• Four/4 Series I
• Four/4 Series II. Ill, IV. V. V Competition Model and 1600
• Operation
• Clutch master cylinder-before Oct. 1961
• Removal
• To dismantle
• To reassemble
• To refit
• The clutch operating cylinder
• To remove
• To dismantle
• To reassemble
• To refit
• Clutch master cylinder-after Oct. 1961
• To remove
• To refit
• The pilot bearing
• To remove
• To refit
• To remove
• To dismantle
• To reassemble
• To refit
• Plus/4
• External adjustments and lubrication
• The graphite thrust block
• Removal of the clutch from flywheel
• Replacement of the clutch to flywheel
• Dismantling the cover assembly
• To assemble cover assembly
• Inspection of cover assembly
• Adjusting the release levers utilizing the driven plate assembly
• Condition of clutch facings
• Reconditioning of driven plate assembly
• GEARBOX
  
• Plus/4
• To remove the gearbox
• Dismantling the gearbox
• Reassembling the gearbox
• Four/4 Series I
• To dismantle the early Moss gearbox
• Reassembling
• Four/4 Series II
• Dismantling the gearbox
• The synchromesh assembly
• Main shaft spigot bush
• Countershaft gear
• Dismantling the gear change housing
• Reassembling the gear change housing
• Reassembling the gearbox
• Reassembling the main shaft
• Four/4 Series Ill, IV, V, 1600 and Competition Models
• Dismantling
• Reassembly
• PROPELLER SHAFT, REAR AXLE AND SUSPENSION
• Rear suspension
• Propeller shaft
• Rear axle Moss type Four/4 Series I
• Rear axle removal Four/4 Series I
• Rear axle early Plus/4 and Four/4 Series II
• Later models Plus/4 and Four/4s
• Andrex rear shock absorbers (dampers)
• Girling shock absorbers
• Armstrong shock absorbers
• THE FRONT SUSPENSION
  
• The 'one shot' front suspension lubricator
• Front suspension-dismantling (Plus/4)
• Fitting new front suspension cross frame
• Fitting a new rebound spring
• Front shock absorbers
• Alternative method of measurement
• THE STEERING
• The Burman steering gear
• Testing for wear
• Assembly
• The drag link
• The track rod
• Swivel pins, bushes and hub bearings
• Steering gear removal
• Track rod adjustment
• Cam gear steering
• The Thompson track rod
• THE BRAKING SYSTEM
• Mechanical brake adjustment
• Mechanical brake relining
• Hydraulic brake adjustment
• Relining hydraulic brakes
• Disc brakes
• Friction pad replacement
• Caliper cylinder maintenance
• Reassembly
• Discs
• The handbrake
• The hydraulic system
• Master cylinder-non-integral tank type
• Servicing
• Dismantling
• Bleeding the hydraulic system
• THE ELECTRICAL SYSTEM
  
• Earth connection
• The battery
• The electrolyte
• Generator-to dismantle
• Field coils
• Commutator
• Brushes
• Bearings
• Reassembly
• Control box
• Cleaning contacts
• Voltage regulator-electrical setting
• Voltage regulator-mechanical setting
• Cut-out-electrical setting
• Cut-out relay
• To remove starter motor
• To refit starter motor
• Dismantling starter motor
• To renew field coils
• To reassemble field coils
• To renew bearings
• Commutator
• Brushes
• Starter drive
• To dismantle
• Wind tone horns, model 9H
• Windscreen wiper CRT15
• To remove head lamp bulb
• To replace head lamp bulb
• Headlamp beam setting
• Replacing a light unit
• BODYWORK
  
• Body removal
• Hood
• Side curtains

File Format: PDF 

Language: English 

Print: Print the complete manual or just the pages you require  

Bookmarked: Bookmarked for easy navigation

Requirements: We recommend using Adobe PDF Reader for best results 

Device: We recommend downloading to a PC or Laptop or visit our Download Help Page for further information regarding Smart Devices

Images are Copyright©Car Manuals Direct and are used for promotional purposes only.

Copyright©Car Manuals Direct 2018