MORRIS Minor Series 2 1953-1955 Factory Workshop Manual | PDF Download

MORRIS Minor Series 2 1953-1955 Factory Workshop Manual | PDF Download

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

The information in this Workshop Manual is for the following models made from 1953 to 1955:

• Morris Minor Series II 2 Door Saloon
• Morris Minor Series II 4 Door Saloon
• Morris Minor Series II Convertible

The following is a list of information contained in this Workshop Manual. 

• General Data
• ENGINE 803cc
  
• Draining the engine sump.
• Removal and replacement of sump and oil pump pick-up.
• Oil pressure relief valve.
• Oil pressure.
• Removal and replacement of main and big-end bearings.
• Removal and replacement of water pump.
• Removal and replacement of carburetor.
• Removal and replacement of inlet and exhaust manifolds.
• Removal and replacement of rocker assembly.
• Removal and replacement of cylinder head assembly.
• Removal and replacement of piston and connecting rod.
• Dismantling and reassembling piston and connecting rod.
• Fitting gudgeon pins.
• Removal and replacement of piston rings.
• Piston sizes and cylinder bores.
• Removal and replacement of valves.
• Decarbonizing.
• Grinding and testing valves and valve seatings.
• Removal and replacement of valve guides.
• Removal and replacement of tappets.
• Rocker adjustment.
• Checking valve timing.
• Removal and replacement of timing cover,
• Removal and replacement of timing chain.
• Removal and replacement of engine.
• Removal and replacement of power unit.
• Removal and replacement of camshaft.
• To refit the distributor drive gear.
• Removal and replacement of flywheel (engine out of car).
• Removal and replacement of oil pump.
• Dismantling and reassembling oil pump.
• Removal and replacement of crankshaft (engine out of car)
• Leakage of oil into clutch housing.
• Oil leaks from sump and to clutch compartment.
• Oil leakage from cylinder head seal.
• Engine steady cable.
• Engine tie-rod,
• Oil consumption.
• Valve rocker modification.
• Modified timing marks.
• Accelerator cable adjustment.
• Rotary-vane-type oil pump.
• Modified exhaust valves and guides.
• Fitting flywheel starter rings.
• Fitting valve seat inserts.
• Fitting cylinder liner
• THE FUEL SYSTEM
  
• Maintenance of the fuel System
• Petrol pump maintenance
• Air cleaner.
• Induction Heater.
• Dust-proofed carburetors.
• THE IGNITION SYSTEM
  
• Description and specification of equipment.
• Locating the cause of uneven firing.
• Testing the low tension circuit
• High tension cables
• Sparking plugs
• Contact breaker mechanism
• Distributor lubrication
• Removal and replacement of the distributor
• Static ignition timing
• Dismantling the distributor
• Condenser
• Fitting new distributor bushes
• Reassembling the distributor
• Later distributor mounting
• High-lift cam
• THE COOLING SYSTEM
  
• Description or tho circulating System.
• Removing the radiator filler cap.
• Draining the coolant system
• Filling the cooling System
• Removal and replacement of the radiator,
• Dynamo fan belt adjustment.
• Removing the water pump.
• Dismantling the water pump.
• Improved water pump.
• THE CLUTCH
  
• General description.
• Running adjustments.
• Removal of the clutch.
• Clutch operating rod.
• Clutch relay and assembly.
• Respaced pedals.
• Modified clutch linkage.
• THE GEARBOX
  
• Removal and replacement of the gearbox.
• Dismantling and reassembling the gearbox.
• Dismantling and reassembling the main  shaft.
• Dismantling and reassembling the first motion shaft assembly.
• Speedometer drive pinion.
• Second speed synchronizer.
• Modified reverse gear.
• Bearing packing washers.
• THE PROPELLER SHAFT
  
• General description.
• Attention to universal joints.
• Testing for wear (in position).
• Removal of the propeller shaft
• Dismantling the propeller shaft
• To examine and check for wear.
• Reassembling the propeller shaft
• Replacement of the propeller shaft
• THE REAR AXLE
  
• Removing and replacing a brake-drum and axle shaft.
• Removing and replacing a hub.
• Renewing the pinion oil seal.
• Removing the differential pinions
• Replacing the differential pinions.
• Dismantling the crown wheel and pinion,
• Assembling and setting the crown wheel and pinion assembly.
• Removing and replacing the axle.
• Modified rear axle bub bearing nuts.
• Rear hub oil seal.
• THE REAR SPRINGS
  
• General description.
• Removal and replacement of the rear springs.
• Dismantling and reassembling the springs.
• THE STEERING GEAR
  
• Removal and. replacement of the steering-wheel.
• Removal and. replacement of the steering-column assembly
• Removal and replacement of the steering rack assembly
• Dismantling the steering gear
• Examine parts for wear
• Reassembling the steering gear
• Checking wheel alignment
• Rubber seal steering joint
• Eliminate steering rack rattle
• THE FRONT SUSPENSION
  
• General description.
• Maintenance.
• Trimming the torsion ban.
• Removing a torsion bar.
• Resetting and replacing the torsion bars.
• Removal and replacement of the swivel pin assembly.
• Dismantling and examining the swivel pin assembly.
• Removal and replacement of the lower suspension arm.
• Removal and replacement of the brake-drum and hub.
• Removal and replacement of the brake backplate assembly.
• Modified wheel mounting.
• Front suspension rattle.
• Elimination of rattle at top link.
• Fitting rubber-bushed top links.
• Modified front hub grease cap.
• Modified swivel pin assembly.
• Swivel pin rethreading procedure.
• Strengthened swivel pin assemblies
• THE HYDRAULIC DAMPERS
  
• General description.
• Maintenance.
• Removal and replacement or the damper
• Testing hydraulic damper.
• Topping up with fluid.
• THE BRAKING SYSTEM
  
• General description.
• Maintenance.
• Master cylinder.
• Adjustment of the brake pedal.
• Brake-shoe adjustments.
• To bleed the system
• Removing the master cylinder.
• Dismantling the master cylinder.
• Assembling the master cylinder.
• Replacing the master cylinder.
• Brake assembly.
• Removing the wheel cylinder.
• Dismantling the wheel cylinder.
• Assembling the wheel cylinder.
• Replacing the wheel cylinder.
• Removing the flexible hose.
• Removing and replacing the brake shoes
• Relining the brake-shoes.
• Brake squeak,
• Hand brake.
• Hand brake adjustment.
• Brake fluid.
• Access to brake adjustment.
• Rear brake back plate abutment pad.
• Brake-drum seals.
• Removing and replacing brake-shoes
• Brake-drum dust seals.
• Preventive maintenance.
• THE ELECTRICAL EQUIPMENT
  
• General description,
• Battery.
• Dynamo.
• Removing and replacing the dynamo.
• Dismantling the dynamo.
• Servicing the dynamo.
• Starter.
• Removing and replacing the starter
• Servicing the starter
• Control box.
• Windscreen wiper.
• Fitting second wiper arm.
• Trafficators
• Electric horn.
• Fuses.
• Replacement bulbs
• Separate pilot lamps.
• Trafficaton
• Panel lamps and warning lamps
• Windowless yoke dynamo.
• Windtone born.
• Interior lamp.
• Windshield wiper
• Direction indicator and horn control switch
• Headlamp beam setting.
• Courtesy light switches
• Number-plate illumination lamp.
• Sidelarnps-flasher
• Modified headlamps.
• Lucas C40-I dynamo.
• Dismantling C40-l dynamo.
• Servicing C40-l dynamo.
• Stop, tail, and direction indicator lamps
• Ignition and starter switch
• fuel gauge,
• Fuses
• Alternator.
• THE BODY
  
• Removal and replacement of windscreen
• Rear light.
• Door glass.
• Door handle and lock assembly.
• Front ventilators.
• Window regulators.
• Maintenance of Tourer hoods.
• Folding the hood
• Water leaks through bottom of doors.
• Water leaks between inner panel and trim panel.
• Waist rail weatherstrip.
• Water leaks at drip molding.
• Suspended roof liner
• Front wheel arch modification.
• Preservation of ash framework
• Removing and replacing the windshield
• Welding methods.
• Welding technique.
• Body alignment checking jig.
• Checking body alignment
• Bright trim.
• Seat belt fitting instructions

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