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Morgan Four/4 Series I | Morgan Four/4 Series II | Morgan Four/4 Series IV | Morgan Four/4 Series V | Morgan Plus/4 | Comprehensive Workshop Manual | PDF Download | carmanualsdirect

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

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

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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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