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Manuals
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Morris Manuals
Engine
Minor MM Series
Workshop manual
Morris Minor MM Series Workshop Manual
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
Contents
General Data
Engine (USHM2)
The Engine Components
Key to the Engine Components
General Description
Lubrication System
Draining the Engine Sump
Removal and Replacement of Sump
Removal of Oil Pump
Dismantling, Reassembling, and Replacing Oil Pump
Removal and Replacement of Piston and Connecting Rod
Dismantling and Reassembling Piston and Connecting Rod
Removal and Replacement of Piston Rings
Fitting Gudgeon Pins
Piston Sizes and Cylinder Bores
Removal and Replacement of Main and Big-End Bearings
Removal and Replacement of Engine
Removal and Replacement of Power Unit
Removal of Timing Cover
Replacement of Timing Cover
Removal and Replacement of Timing Chain
Removal and Replacement of Carburetor
Removal and Replacement of Inlet and Exhaust Manifold
Removal and Replacement of Cylinder Head
Removal and Replacement of Camshaft
To Refit the Distributor Drive Gear
Removal and Replacement of Tappets
Tappet Adjustment
Checking Valve Timing
Removal and Replacement of Flywheel
Removal and Replacement of Crankshaft
Regrinding of Crankshaft
Removal and Replacement of Valves
Decarbonizing
Grinding and Testing Valves and Seatings
Removal and Replacement of Valve Guides
Oil Pressure
Locating Troubles
If Engine Starts but Runs Erratically
If Engine Starts and Stops
If Engine will Not Idle or Run Slowly
Fitting Valve Springs
Engine Fails to Give Full Power
Engine Knocks
Engine Backfires
The Morris Minor (Seris II) Engine Lubrication
Engine General Description
Engine Lubrication System
Removal and Replacement of Sump and Oil Pump Pick-Up
Oil Pressure Relief Valve
The Component Parts of the Morris Minor (Series II) Cylinder Blocl, Cylinder Head, Etc.
Removal and Replacement of Water Pump
Main Bearings
Removal and Replacement of Inlet and Exhaust Manifolds
Removal and Replacement of Rocker Assembly
The Morris Engine (Series II) Moving Parts
Removal and Replacement of Cylinder Head Assembly
Refitting the Cylinder Head
Grinding and Testing Valves and Valve Seatings
Rocker Adjustment
The Fuel System of the Morris Minor (Series II)
Maintenance of the Fuel System
Air Cleaner
Induction Heaters
Dust-Proofed Carburetors
The Fuel System of the Morris Minor 1000
Oil Bath Air Cleaner
Dry-Time Air Cleaner
The Morris Minor 1000 Oil Bath and Air Cleaner Components
Preventing Carburetor from Freezing
Dry-Type Air Cleaner
HS2 Carburetor
Induction and Carburetor Suction Chamber Heaters
The Ignition System of the Morris Minor (Series MM)
The Ignition System General Description
Locating the Cause of Uneven Firing
Testing the Low-Tension Circuit
High-Tension Cables
To Locate Fault
Attention to Sparkling Plugs
Plug Inspection
Contact Breaker Mechanism
Distributor Lubrication
Removal and Replacement of the Distributor
Ignition Timing
Dismantling the Distributor
Condenser
Fitting New Distributor Bushes
Reassembling the Distributor
Later Distributor Mounting
High-Lift Cam
The Ignition System of the Morris Minor (Series II) and Morris Minor 1000
The Cooling System of the Morris Minor (Series MM)
The Cooling System of the Morris Minor (Series II)
The Cooling System of the Morris Minor 1000
The Clutch of the Morris Minor (Series MM)
The Flywheel and Clutch Components
Key to the Flywheel and Clutch Components
Clutch General Description
Driven Plate Assembly
Withdrawal Bearing Assembly
Cover Assembly
Removal of the Clutch
Dismantling the Clutch
Assembling the Clutch
Adjusting the Release Levers
Replacement of the Clutch
Servicing the Clutch
Starter Ring
Clutch Judder
Universal Clutch Gauging Fixture
The Clutch of the Morris Minor (Series II) and Morris Minor 1000
The Gearbox of the Morris Minor (Series MM)
The Gearbox Components
Key to the Gearbox Components
The Gearbox of the Morris Minor (Series II)
The Morris Minor (Series II) Gearbox
The Morris Minor (Series II) Gearbox Components
Key to the Morris Minor (Series II) Gearbox Components
Dismantling and Reassembling the Mainshaft
Dismantling and Reassembling the First Motion Shaft Assembly
Speedometer Drive Pinion
Second Speed Synchronizer
Bearing Packing Washers
The Gearbox of the Morris Minor 1000
The Morris Minor 1000 Gearbox Remote Components
Key to the Morris Minor 1000 Gearbox Remote Components
The Propeller Shaft of the Morris Minor (Series MM)
Attention to Universal Joints
Testing for Wear
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 Propeller Shaft of the Morris Minor (Series II) and Morris Minor 1000
The Rear Axle
The Rear Axle and Propeller Shaft Components
Key to the Rear Axle and Propeller Shaft Components
The Rear Axle General Description
The Rear Axle Lubrication
Removing and Replacing a Brake-Drum and Hub
Removing and Replacing a Brake-Plate Assembly
Removing and Replacing a Rear Axle Half-Shaft
Removing the Rear Axle from the Car
Important Points Concerning Attention
Dismantling the Axle and Removing the Differential Assembly
Dismantling the Differential Assembly and Crown Wheel
Examining Parts for Wear
Replacing the Differential Cage
Assembling the Differential and Crown Wheel
Replacing a Pinion
Fitting a New Axle Casing
Fitting a New Axle Housing Cover
Replacing a Crown Wheel and Pinion Having Markings Different to the Original
Reassembling the Axle
Refitting the Axle to the Car
Using Service Tool 18G 264
Lubrication
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
Setting the Pinion Position
Adjusting Pinion Bearing Preload
Setting the Crown Wheel Position
Adjusting the Backlash
Removing and Replacing the Axle
Modified Rear Axle Hub Bearing Nuts
Rear Hub Oil Seal
The Rear Road Springs
The Shock Absorber, Radiator, Exhaust System, Petrol System, and Rear Spring Components
Key to the Shock Absorber, Radiator, Exhaust System, Petrol System, and Rear Spring Components
The Rear Road Springs General Description
Removal and Replacement of the Rear Springs
Dismantling and Reassembling the Springs
The Steering Gear
The Morris Minor (Series MM and Series II) Steering Gear Components
Key to the Morris Minor (Series MM and Series II) Steering Gear Components
The Steering Gear Maintenance
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
Reassembling the Steering Gear
Checking and Setting Wheel Alignment
Rubber Seal Steering Joints
Eliminating Steering-Rack Rattle
Modified Steering Ball Sockets
The Steering Gear of the Morris Minor 1000
Modified Steering-Column Assembly
Direction Indicator Switch
Steering Lock Ignition Switch
The Front Suspension
Trimming the Torsion Bars
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
Later-Type Brake-Drums and Hubs
Strengthened Swivel Pin Assemblies
The Hydraulic Dampers
The Hydraulic Dampers General Description
The Hydraulic Dampers Maintenance
Removal and Replacement of the Dampers
Testing Hydraulic Dampers
Topping up with Fluid
Modified Dampers
The Braking System
Arrangement of Hydraulic Brake System
Key to Arrangement of Hydraulic Brake System
The Braking System General Description
Master Cylinder
The Braking System Maintenance
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
Braking Irregularities and Their Causes
Brake Squeak
Hand Brake
Hand Brake Adjustment
Brake Fluid
Access to Brake Adjustment
Master Cylinder (Laser Type)
Rear Brake Backplate Abutment Pad
Brake-Drum Seals
Removing and Replacing Brake-Shoes (Laser Models)
Brake-Drum Dust Seals
Preventive Maintenance
The Electrical Equipment
The Electrical Equipment General Description
Battery Routine Maintenance
Storage
Initial Filling and Charging
Dynamo
Removing and Replacing the Dynamo
Dismantling the Dynamo
Servicing the Dynamo
Starter
Removing and Replacing the Starter
Servicing the Starter
Control Box
Cut-Out
Windscreen Wiper
Fitting Second Wiper Arm
Trafficators
Replacement of Trafficator Arm
Electric Horn
Fuses
Replacement Bulbs
Headlamps
Light Units
Removing and Replacing the Light Units
Renewing Headlamp Bulbs
Setting the Headlamps
Cleaning Lamps
Tail and Stop Lamp
Number-Plate Illumination
Panel Lamps
Ignition Warning Lamp
Lamp Warning Light
Location and Remedy of Faults
Charging Circuit
Starter Motor
Lighting Circuits
Pilot Lamps
Key to Cable Colours
Wiring Diagram
Installation of Traffic Indicators
Panel Lamps and Warning Lamps
Windowless Yoke Dynamo
Modified Control Box
Windtone Horn
Interior Lamps
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This manual is also suitable for:
Minor ii series
Minor 1000
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