Morris Minor MM Series

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Contents3
General Data7
Engine (USHM2)22
The Engine Components23
Key to the Engine Components24
General Description26
Lubrication System26
Draining the Engine Sump28
Removal and Replacement of Sump28
Removal of Oil Pump29
Dismantling, Reassembling, and Replacing Oil Pump31
Removal and Replacement of Piston and Connecting Rod31
Dismantling and Reassembling Piston and Connecting Rod32
Removal and Replacement of Piston Rings32
Fitting Gudgeon Pins33
Piston Sizes and Cylinder Bores33
Removal and Replacement of Main and Big-End Bearings34
Removal and Replacement of Engine35
Removal and Replacement of Power Unit37
Removal of Timing Cover38
Replacement of Timing Cover38
Removal and Replacement of Timing Chain39
Removal and Replacement of Carburetor40
Removal and Replacement of Inlet and Exhaust Manifold40
Removal and Replacement of Cylinder Head40
Removal and Replacement of Camshaft41
To Refit the Distributor Drive Gear42
Removal and Replacement of Tappets43
Tappet Adjustment43
Checking Valve Timing44
Removal and Replacement of Flywheel44
Removal and Replacement of Crankshaft44
Regrinding of Crankshaft44
Removal and Replacement of Valves45
Decarbonizing45
Grinding and Testing Valves and Seatings46
Removal and Replacement of Valve Guides48
Oil Pressure48
Locating Troubles48
If Engine Starts but Runs Erratically49
If Engine Starts and Stops49
If Engine will Not Idle or Run Slowly49
Fitting Valve Springs50
Engine Fails to Give Full Power50
Engine Knocks50
Engine Backfires50
The Morris Minor (Seris II) Engine Lubrication54
Engine General Description55
Engine Lubrication System55
Removal and Replacement of Sump and Oil Pump Pick-Up56
Oil Pressure Relief Valve56
The Component Parts of the Morris Minor (Series II) Cylinder Blocl, Cylinder Head, Etc.58
Removal and Replacement of Water Pump60
Main Bearings60
Removal and Replacement of Inlet and Exhaust Manifolds61
Removal and Replacement of Rocker Assembly61
The Morris Engine (Series II) Moving Parts62
Removal and Replacement of Cylinder Head Assembly64
Refitting the Cylinder Head64
Grinding and Testing Valves and Valve Seatings69
Rocker Adjustment70
The Fuel System of the Morris Minor (Series II)113
Maintenance of the Fuel System114
Air Cleaner114
Induction Heaters114
Dust-Proofed Carburetors115
The Fuel System of the Morris Minor 1000116
Oil Bath Air Cleaner117
Dry-Time Air Cleaner117
The Morris Minor 1000 Oil Bath and Air Cleaner Components118
Preventing Carburetor from Freezing119
Dry-Type Air Cleaner119
HS2 Carburetor119
Induction and Carburetor Suction Chamber Heaters121
The Ignition System of the Morris Minor (Series MM)122
The Ignition System General Description123
Locating the Cause of Uneven Firing123
Testing the Low-Tension Circuit123
High-Tension Cables124
To Locate Fault124
Attention to Sparkling Plugs125
Plug Inspection125
Contact Breaker Mechanism126
Distributor Lubrication127
Removal and Replacement of the Distributor127
Ignition Timing128
Dismantling the Distributor129
Condenser129
Fitting New Distributor Bushes129
Reassembling the Distributor130
Later Distributor Mounting131
High-Lift Cam132
The Ignition System of the Morris Minor (Series II) and Morris Minor 1000133
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 1000151
The Clutch of the Morris Minor (Series MM)153
The Flywheel and Clutch Components154
Key to the Flywheel and Clutch Components155
Clutch General Description156
Driven Plate Assembly156
Withdrawal Bearing Assembly156
Cover Assembly156
Removal of the Clutch157
Dismantling the Clutch157
Assembling the Clutch158
Adjusting the Release Levers159
Replacement of the Clutch159
Servicing the Clutch160
Starter Ring161
Clutch Judder161
Universal Clutch Gauging Fixture161
The Clutch of the Morris Minor (Series II) and Morris Minor 1000163
The Gearbox of the Morris Minor (Series MM)169
The Gearbox Components170
Key to the Gearbox Components171
The Gearbox of the Morris Minor (Series II)181
The Morris Minor (Series II) Gearbox184
The Morris Minor (Series II) Gearbox Components186
Key to the Morris Minor (Series II) Gearbox Components187
Dismantling and Reassembling the Mainshaft188
Dismantling and Reassembling the First Motion Shaft Assembly189
Speedometer Drive Pinion189
Second Speed Synchronizer189
Bearing Packing Washers189
The Gearbox of the Morris Minor 1000191
The Morris Minor 1000 Gearbox Remote Components192
Key to the Morris Minor 1000 Gearbox Remote Components193
The Propeller Shaft of the Morris Minor (Series MM)196
Attention to Universal Joints197
Testing for Wear197
Removal of the Propeller Shaft197
Dismantling the Propeller Shaft197
To Examine and Check for Wear198
Reassembling the Propeller Shaft198
Replacement of the Propeller Shaft199
The Propeller Shaft of the Morris Minor (Series II) and Morris Minor 1000200
The Rear Axle202
The Rear Axle and Propeller Shaft Components203
Key to the Rear Axle and Propeller Shaft Components204
The Rear Axle General Description205
The Rear Axle Lubrication205
Removing and Replacing a Brake-Drum and Hub206
Removing and Replacing a Brake-Plate Assembly206
Removing and Replacing a Rear Axle Half-Shaft207
Removing the Rear Axle from the Car207
Important Points Concerning Attention207
Dismantling the Axle and Removing the Differential Assembly208
Dismantling the Differential Assembly and Crown Wheel209
Examining Parts for Wear209
Replacing the Differential Cage210
Assembling the Differential and Crown Wheel210
Replacing a Pinion211
Fitting a New Axle Casing213
Fitting a New Axle Housing Cover214
Replacing a Crown Wheel and Pinion Having Markings Different to the Original214
Reassembling the Axle214
Refitting the Axle to the Car215
Using Service Tool 18G 264215
Lubrication220
Removing and Replacing a Brake-Drum and Axle Shaft220
Removing and Replacing a Hub220
Renewing the Pinion Oil Seal221
Removing the Differential Pinions221
Replacing the Differential Pinions221
Dismantling the Crown Wheel and Pinion222
Assembling and Setting the Crown Wheel and Pinion Assembly222
Setting the Pinion Position222
Adjusting Pinion Bearing Preload223
Setting the Crown Wheel Position224
Adjusting the Backlash227
Removing and Replacing the Axle228
Modified Rear Axle Hub Bearing Nuts228
Rear Hub Oil Seal228
The Rear Road Springs229
The Shock Absorber, Radiator, Exhaust System, Petrol System, and Rear Spring Components230
Key to the Shock Absorber, Radiator, Exhaust System, Petrol System, and Rear Spring Components231
The Rear Road Springs General Description232
Removal and Replacement of the Rear Springs232
Dismantling and Reassembling the Springs233
The Steering Gear235
The Morris Minor (Series MM and Series II) Steering Gear Components236
Key to the Morris Minor (Series MM and Series II) Steering Gear Components237
The Steering Gear Maintenance238
Removal and Replacement of the Steering-Wheel238
Removal and Replacement of the Steering-Column Assembly238
Removal and Replacement of the Steering-Rack Assembly239
Dismantling the Steering Gear239
Reassembling the Steering Gear240
Checking and Setting Wheel Alignment240
Rubber Seal Steering Joints241
Eliminating Steering-Rack Rattle241
Modified Steering Ball Sockets241
The Steering Gear of the Morris Minor 1000242
Modified Steering-Column Assembly244
Direction Indicator Switch244
Steering Lock Ignition Switch245
The Front Suspension246
Trimming the Torsion Bars249
Removing a Torsion Bar250
Resetting and Replacing the Torsion Bars250
Removal and Replacement of the Swivel Pin Assembly251
Dismantling and Examining the Swivel Pin Assembly253
Removal and Replacement of the Lower Suspension Arm253
Removal and Replacement of the Brake-Drum and Hub253
Removal and Replacement of the Brake Backplate Assembly254
Modified Wheel Mounting255
Front Suspension Rattle255
Elimination of Rattle at Top Link255
Fitting Rubber-Bushed Top Links256
Modified Front Hub Grease Cap257
Modified Swivel Pin Assembly257
Swivel Pin Rethreading Procedure258
Later-Type Brake-Drums and Hubs258
Strengthened Swivel Pin Assemblies258
The Hydraulic Dampers259
The Hydraulic Dampers General Description260
The Hydraulic Dampers Maintenance260
Removal and Replacement of the Dampers260
Testing Hydraulic Dampers261
Topping up with Fluid261
Modified Dampers262
The Braking System263
Arrangement of Hydraulic Brake System264
Key to Arrangement of Hydraulic Brake System265
The Braking System General Description266
Master Cylinder266
The Braking System Maintenance266
Adjustment of the Brake Pedal267
Brake-Shoe Adjustments267
To Bleed the System268
Removing the Master Cylinder268
Dismantling the Master Cylinder269
Assembling the Master Cylinder269
Replacing the Master Cylinder270
Brake Assembly270
Removing the Wheel Cylinder271
Dismantling the Wheel Cylinder271
Assembling the Wheel Cylinder272
Replacing the Wheel Cylinder272
Removing the Flexible Hose272
Removing and Replacing the Brake-Shoes272
Relining the Brake-Shoes273
Braking Irregularities and Their Causes273
Brake Squeak274
Hand Brake274
Hand Brake Adjustment275
Brake Fluid275
Access to Brake Adjustment275
Master Cylinder (Laser Type)276
Rear Brake Backplate Abutment Pad276
Brake-Drum Seals277
Removing and Replacing Brake-Shoes (Laser Models)277
Brake-Drum Dust Seals278
Preventive Maintenance278
The Electrical Equipment279
The Electrical Equipment General Description280
Battery Routine Maintenance280
Storage281
Initial Filling and Charging281
Dynamo281
Removing and Replacing the Dynamo283
Dismantling the Dynamo283
Servicing the Dynamo284
Starter286
Removing and Replacing the Starter286
Servicing the Starter286
Control Box289
Cut-Out290
Windscreen Wiper290
Fitting Second Wiper Arm291
Trafficators293
Replacement of Trafficator Arm293
Electric Horn293
Fuses293
Replacement Bulbs294
Headlamps294
Light Units295
Removing and Replacing the Light Units295
Renewing Headlamp Bulbs296
Setting the Headlamps296
Cleaning Lamps297
Tail and Stop Lamp297
Number-Plate Illumination297
Panel Lamps297
Ignition Warning Lamp298
Lamp Warning Light298
Location and Remedy of Faults299
Charging Circuit299
Starter Motor300
Lighting Circuits300
Pilot Lamps300
Key to Cable Colours300
Wiring Diagram301
Installation of Traffic Indicators310
Panel Lamps and Warning Lamps311
Windowless Yoke Dynamo311
Modified Control Box311
Windtone Horn312
Interior Lamps312
Windshield Wiper312
Direction Indicator and Horn Control Switch312
Headlamp Beam Setting313
Courtesy Light Switches313
Dry-Charged Batteries313
Modified Horn and Direction Indicator Controls313
North Americal Sealed-Beam Light Units318
Number-Plate Illumination Lamp318
Sidelamps - Flasher318
Lucas C40-1 Dynamo318
Servicing C40-1 Dynamo319
Modified RB106/2 Control Box319
Modified North Americal Sealed-Beam Light Units320
Pilot and Front Flashing Indicator Lamps321
Stop, Tail and Direction Indicator Lamps321
Ignition and Starter Switch326
Bi-Metal Resistance-Type Fuel Gauge326
U.K. Type Sealed-Beam Light Units326
Testing the Alternator Charging Circuit in Position327
Removing and Replacing the Alternator328
11AC Alternator328
Service Precautions329
The Wheels and Tyres331
Tyre Removal333
Importance of Balance334
Fitting Tyres and Tubes334
Tubeless Tyres335
Tubeless Tyre Valves338
Service Tools353
Body Alignment Checking Jig416
Checking Body Alignment417
Additional Checks Possible on Minor Models418
Bright Trim419
Seat Belt Anchorage Fitting Instructions419
The Heater426
The Heater Description427
To Fit the Heater427
Components of Morris Minor Car Heater and Water Pump Kit Set430
Modified Demister Hose434
Fitting the Heater Fresh-Air Conversion Kit434
Fitting the Heater Masking Kit438
Heater Masking Kit438
Fitting a Later-Type Heater and Fresh-Air Intake438
Special Repairs and Modifications442
Securing Loose Baffles in the Silencer443
Fitting a New-Type Chromium Grille443

Morris Minor MM Series - User Manual

Table of Contents

Morris Minor MM Series Specifications

Brand	Morris
Model	Minor MM Series
Category	Engine
Language	English