MORGAN Four/4 & Plus/4 1936-1968 Comprehensive Workshop Service Manual | PDF Download
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
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Language: English
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