Morris Minor II Series Manuals

Manuals and User Guides for Morris Minor II Series. We have 1 Morris Minor II Series manual available for free PDF download: Workshop Manual

Morris Minor II Series Workshop Manual (444 pages)

Brand: Morris | Category: Engine | Size: 31 MB

Contents
3
General Data
7
Engine (USHM2)
22
The Engine Components
23
Key to the Engine Components
24
General Description
26
Lubrication System
26
Draining the Engine Sump
28
Removal and Replacement of Sump
28
Removal of Oil Pump
29
Dismantling, Reassembling, and Replacing Oil Pump
31
Removal and Replacement of Piston and Connecting Rod
31
Dismantling and Reassembling Piston and Connecting Rod
32
Removal and Replacement of Piston Rings
32
Fitting Gudgeon Pins
33
Piston Sizes and Cylinder Bores
33
Removal and Replacement of Main and Big-End Bearings
34
Removal and Replacement of Engine
35
Removal and Replacement of Power Unit
37
Removal of Timing Cover
38
Replacement of Timing Cover
38
Removal and Replacement of Timing Chain
39
Removal and Replacement of Carburetor
40
Removal and Replacement of Inlet and Exhaust Manifold
40
Removal and Replacement of Cylinder Head
40
Removal and Replacement of Camshaft
41
To Refit the Distributor Drive Gear
42
Removal and Replacement of Tappets
43
Tappet Adjustment
43
Checking Valve Timing
44
Removal and Replacement of Flywheel
44
Removal and Replacement of Crankshaft
44
Regrinding of Crankshaft
44
Removal and Replacement of Valves
45
Decarbonizing
45
Grinding and Testing Valves and Seatings
46
Removal and Replacement of Valve Guides
48
Oil Pressure
48
Locating Troubles
48
If Engine Starts but Runs Erratically
49
If Engine Starts and Stops
49
If Engine will Not Idle or Run Slowly
49
Fitting Valve Springs
50
Engine Fails to Give Full Power
50
Engine Knocks
50
Engine Backfires
50
The Morris Minor (Seris II) Engine Lubrication
54
Engine General Description
55
Engine Lubrication System
55
Removal and Replacement of Sump and Oil Pump Pick-Up
56
Oil Pressure Relief Valve
56
The Component Parts of the Morris Minor (Series II) Cylinder Blocl, Cylinder Head, Etc.
58
Removal and Replacement of Water Pump
60
Main Bearings
60
Removal and Replacement of Inlet and Exhaust Manifolds
61
Removal and Replacement of Rocker Assembly
61
The Morris Engine (Series II) Moving Parts
62
Removal and Replacement of Cylinder Head Assembly
64
Refitting the Cylinder Head
64
Grinding and Testing Valves and Valve Seatings
69
Rocker Adjustment
70
The Fuel System of the Morris Minor (Series II)
113
Maintenance of the Fuel System
114
Air Cleaner
114
Induction Heaters
114
Dust-Proofed Carburetors
115
The Fuel System of the Morris Minor 1000
116
Oil Bath Air Cleaner
117
Dry-Time Air Cleaner
117
The Morris Minor 1000 Oil Bath and Air Cleaner Components
118
Preventing Carburetor from Freezing
119
Dry-Type Air Cleaner
119
HS2 Carburetor
119
Induction and Carburetor Suction Chamber Heaters
121
The Ignition System of the Morris Minor (Series MM)
122
The Ignition System General Description
123
Locating the Cause of Uneven Firing
123
Testing the Low-Tension Circuit
123
High-Tension Cables
124
To Locate Fault
124
Attention to Sparkling Plugs
125
Plug Inspection
125
Contact Breaker Mechanism
126
Distributor Lubrication
127
Removal and Replacement of the Distributor
127
Ignition Timing
128
Dismantling the Distributor
129
Condenser
129
Fitting New Distributor Bushes
129
Reassembling the Distributor
130
Later Distributor Mounting
131
High-Lift Cam
132
The Ignition System of the Morris Minor (Series II) and Morris Minor 1000
133
The Cooling System of the Morris Minor (Series MM)
141
The Cooling System of the Morris Minor (Series II)
146
The Cooling System of the Morris Minor 1000
151
The Clutch of the Morris Minor (Series MM)
153
The Flywheel and Clutch Components
154
Key to the Flywheel and Clutch Components
155
Clutch General Description
156
Driven Plate Assembly
156
Withdrawal Bearing Assembly
156
Cover Assembly
156
Removal of the Clutch
157
Dismantling the Clutch
157
Assembling the Clutch
158
Adjusting the Release Levers
159
Replacement of the Clutch
159
Servicing the Clutch
160
Starter Ring
161
Clutch Judder
161
Universal Clutch Gauging Fixture
161
The Clutch of the Morris Minor (Series II) and Morris Minor 1000
163
The Gearbox of the Morris Minor (Series MM)
169
The Gearbox Components
170
Key to the Gearbox Components
171
The Gearbox of the Morris Minor (Series II)
181
The Morris Minor (Series II) Gearbox
184
The Morris Minor (Series II) Gearbox Components
186
Key to the Morris Minor (Series II) Gearbox Components
187
Dismantling and Reassembling the Mainshaft
188
Dismantling and Reassembling the First Motion Shaft Assembly
189
Speedometer Drive Pinion
189
Second Speed Synchronizer
189
Bearing Packing Washers
189
The Gearbox of the Morris Minor 1000
191
The Morris Minor 1000 Gearbox Remote Components
192
Key to the Morris Minor 1000 Gearbox Remote Components
193
The Propeller Shaft of the Morris Minor (Series MM)
196
Attention to Universal Joints
197
Testing for Wear
197
Removal of the Propeller Shaft
197
Dismantling the Propeller Shaft
197
To Examine and Check for Wear
198
Reassembling the Propeller Shaft
198
Replacement of the Propeller Shaft
199
The Propeller Shaft of the Morris Minor (Series II) and Morris Minor 1000
200
The Rear Axle
202
The Rear Axle and Propeller Shaft Components
203
Key to the Rear Axle and Propeller Shaft Components
204
The Rear Axle General Description
205
The Rear Axle Lubrication
205
Removing and Replacing a Brake-Drum and Hub
206
Removing and Replacing a Brake-Plate Assembly
206
Removing and Replacing a Rear Axle Half-Shaft
207
Removing the Rear Axle from the Car
207
Important Points Concerning Attention
207
Dismantling the Axle and Removing the Differential Assembly
208
Dismantling the Differential Assembly and Crown Wheel
209
Examining Parts for Wear
209
Replacing the Differential Cage
210
Assembling the Differential and Crown Wheel
210
Replacing a Pinion
211
Fitting a New Axle Casing
213
Fitting a New Axle Housing Cover
214
Replacing a Crown Wheel and Pinion Having Markings Different to the Original
214
Reassembling the Axle
214
Refitting the Axle to the Car
215
Using Service Tool 18G 264
215
Lubrication
220
Removing and Replacing a Brake-Drum and Axle Shaft
220
Removing and Replacing a Hub
220
Renewing the Pinion Oil Seal
221
Removing the Differential Pinions
221
Replacing the Differential Pinions
221
Dismantling the Crown Wheel and Pinion
222
Assembling and Setting the Crown Wheel and Pinion Assembly
222
Setting the Pinion Position
222
Adjusting Pinion Bearing Preload
223
Setting the Crown Wheel Position
224
Adjusting the Backlash
227
Removing and Replacing the Axle
228
Modified Rear Axle Hub Bearing Nuts
228
Rear Hub Oil Seal
228
The Rear Road Springs
229
The Shock Absorber, Radiator, Exhaust System, Petrol System, and Rear Spring Components
230
Key to the Shock Absorber, Radiator, Exhaust System, Petrol System, and Rear Spring Components
231
The Rear Road Springs General Description
232
Removal and Replacement of the Rear Springs
232
Dismantling and Reassembling the Springs
233
The Steering Gear
235
The Morris Minor (Series MM and Series II) Steering Gear Components
236
Key to the Morris Minor (Series MM and Series II) Steering Gear Components
237
The Steering Gear Maintenance
238
Removal and Replacement of the Steering-Wheel
238
Removal and Replacement of the Steering-Column Assembly
238
Removal and Replacement of the Steering-Rack Assembly
239
Dismantling the Steering Gear
239
Reassembling the Steering Gear
240
Checking and Setting Wheel Alignment
240
Rubber Seal Steering Joints
241
Eliminating Steering-Rack Rattle
241
Modified Steering Ball Sockets
241
The Steering Gear of the Morris Minor 1000
242
Modified Steering-Column Assembly
244
Direction Indicator Switch
244
Steering Lock Ignition Switch
245
The Front Suspension
246
Trimming the Torsion Bars
249
Removing a Torsion Bar
250
Resetting and Replacing the Torsion Bars
250
Removal and Replacement of the Swivel Pin Assembly
251
Dismantling and Examining the Swivel Pin Assembly
253
Removal and Replacement of the Lower Suspension Arm
253
Removal and Replacement of the Brake-Drum and Hub
253
Removal and Replacement of the Brake Backplate Assembly
254
Modified Wheel Mounting
255
Front Suspension Rattle
255
Elimination of Rattle at Top Link
255
Fitting Rubber-Bushed Top Links
256
Modified Front Hub Grease Cap
257
Modified Swivel Pin Assembly
257
Swivel Pin Rethreading Procedure
258
Later-Type Brake-Drums and Hubs
258
Strengthened Swivel Pin Assemblies
258
The Hydraulic Dampers
259
The Hydraulic Dampers General Description
260
The Hydraulic Dampers Maintenance
260
Removal and Replacement of the Dampers
260
Testing Hydraulic Dampers
261
Topping up with Fluid
261
Modified Dampers
262
The Braking System
263
Arrangement of Hydraulic Brake System
264
Key to Arrangement of Hydraulic Brake System
265
The Braking System General Description
266
Master Cylinder
266
The Braking System Maintenance
266
Adjustment of the Brake Pedal
267
Brake-Shoe Adjustments
267
To Bleed the System
268
Removing the Master Cylinder
268
Dismantling the Master Cylinder
269
Assembling the Master Cylinder
269
Replacing the Master Cylinder
270
Brake Assembly
270
Removing the Wheel Cylinder
271
Dismantling the Wheel Cylinder
271
Assembling the Wheel Cylinder
272
Replacing the Wheel Cylinder
272
Removing the Flexible Hose
272
Removing and Replacing the Brake-Shoes
272
Relining the Brake-Shoes
273
Braking Irregularities and Their Causes
273
Brake Squeak
274
Hand Brake
274
Hand Brake Adjustment
275
Brake Fluid
275
Access to Brake Adjustment
275
Master Cylinder (Laser Type)
276
Rear Brake Backplate Abutment Pad
276
Brake-Drum Seals
277
Removing and Replacing Brake-Shoes (Laser Models)
277
Brake-Drum Dust Seals
278
Preventive Maintenance
278
The Electrical Equipment
279
The Electrical Equipment General Description
280
Battery Routine Maintenance
280
Storage
281
Initial Filling and Charging
281
Dynamo
281
Removing and Replacing the Dynamo
283
Dismantling the Dynamo
283
Servicing the Dynamo
284
Starter
286
Removing and Replacing the Starter
286
Servicing the Starter
286
Control Box
289
Cut-Out
290
Windscreen Wiper
290
Fitting Second Wiper Arm
291
Trafficators
293
Replacement of Trafficator Arm
293
Electric Horn
293
Fuses
293
Replacement Bulbs
294
Headlamps
294
Light Units
295
Removing and Replacing the Light Units
295
Renewing Headlamp Bulbs
296
Setting the Headlamps
296
Cleaning Lamps
297
Tail and Stop Lamp
297
Number-Plate Illumination
297
Panel Lamps
297
Ignition Warning Lamp
298
Lamp Warning Light
298
Location and Remedy of Faults
299
Charging Circuit
299
Starter Motor
300
Lighting Circuits
300
Pilot Lamps
300
Key to Cable Colours
300
Wiring Diagram
301
Installation of Traffic Indicators
310
Panel Lamps and Warning Lamps
311
Windowless Yoke Dynamo
311
Modified Control Box
311
Windtone Horn
312
Interior Lamps
312
Windshield Wiper
312
Direction Indicator and Horn Control Switch
312
Headlamp Beam Setting
313
Courtesy Light Switches
313
Dry-Charged Batteries
313
Modified Horn and Direction Indicator Controls
313
North Americal Sealed-Beam Light Units
318
Number-Plate Illumination Lamp
318
Sidelamps - Flasher
318
Lucas C40-1 Dynamo
318
Servicing C40-1 Dynamo
319
Modified RB106/2 Control Box
319
Modified North Americal Sealed-Beam Light Units
320
Pilot and Front Flashing Indicator Lamps
321
Stop, Tail and Direction Indicator Lamps
321
Ignition and Starter Switch
326
Bi-Metal Resistance-Type Fuel Gauge
326
U.K. Type Sealed-Beam Light Units
326
Testing the Alternator Charging Circuit in Position
327
Removing and Replacing the Alternator
328
11AC Alternator
328
Service Precautions
329
The Wheels and Tyres
331
Tyre Removal
333
Importance of Balance
334
Fitting Tyres and Tubes
334
Tubeless Tyres
335
Tubeless Tyre Valves
338
Service Tools
353
Body Alignment Checking Jig
416
Checking Body Alignment
417
Additional Checks Possible on Minor Models
418
Bright Trim
419
Seat Belt Anchorage Fitting Instructions
419
The Heater
426
The Heater Description
427
To Fit the Heater
427
Components of Morris Minor Car Heater and Water Pump Kit Set
430
Modified Demister Hose
434
Fitting the Heater Fresh-Air Conversion Kit
434
Fitting the Heater Masking Kit
438
Heater Masking Kit
438
Fitting a Later-Type Heater and Fresh-Air Intake
438
Special Repairs and Modifications
442
Securing Loose Baffles in the Silencer
443
Fitting a New-Type Chromium Grille
443

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Morris Minor II Series Workshop Manual (444 pages)

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