Morgan (Ford Kent Engined)

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At every service: Check the master cylinder and reservoir for leaks (investigate at once if the fluid level is low), also assess the level and condition of the fluid.

Engine

Overhead valve (pushrod) in-line four-cylinder. 1598cc, 93 bhp (gross)

Valve Clearances

It is advisable to check/re-adjust the clearances approximately every 12,000 miles/annually. Screw and locknut adjusters are employed. The clearances (engine ‘hot’) for the inlet valves should be 0.012in; and for the exhaust valves, 0.022in. From the front of the engine, inlet valves are Nos. 1, 4, 5 and 8; the exhausts are Nos. 2, 3, 6 and 7. With valves Nos. 1 and 6 open, check/adjust Nos. 3 and 8. With valves Nos. 3 and 8 open, check/adjust Nos. 1 and 6. With valves Nos. 2 and 4 open, check/adjust Nos. 5 and 7. With valves Nos. 5 and 7 open, check/adjust Nos. 2 and 4.

Ignition

Firing order: Firing order: 1-2-4-3 (No. 1 at front of engine)
Spark plugs: Autolite AG22 or equivalent. Gap 0.023in. Check/clean plugs every 6000 miles (using a brassbristled wire brush); renew the plugs regardless every 12,000 miles. Every 6000 miles, examine the high tension leads, distributor cap and rotor arm. Sparingly re-lubricate the distributor’s shaft and mechanical advance mechanism (using a few drops of engine oil) and the distributor cam (very sparingly apply high melting point grease). Every 6000 miles, renew the contact points (check condition every 3,000 miles and re-gap if necessary); gap to 0.025in. Every 6000 miles, check ignition timing; initial static setting is 8 degrees BTDC (mark on crankshaft pulley). N.B. Slight re-adjustment may be required, subject to road test performance.

Fuel System

Every 3000 miles or annually (whichever comes first), examine the air filter element and renew if visibly dirty; renew regardless every 12,000 miles.Every 6000 miles/annually, assess all fuel system pipework. Renew at once any ailing pipes/securing clips. Every 6000 miles, check/clean the fuel pump filter. At every service, check action and re-lubricate the accelerator linkages. At each service, check/re-adjust carburetor settings (consult manufacturer’s literature). Re-set idle speed to approximately 700 rpm.

Lubrication

Engine oil: Ideally, change the oil and renew the filter at least every 3000 miles or annually (whichever comes first); first take the car for a run to warm the oil, to help purge the old oil and any debris from the sump. On fitting a new oil filter, coat the seal with a little fresh engine oil to prevent leaks. Always use a good quality lubricant, with a viscosity rating of SAE 15W40, SAE15W50 or 20W50. On completion, ensure that the engine is leak-free. Please dispose of the old oil in an environmentally friendly manner - local councils provide waste oil collection points. Sump capacity (including filter): approx. 7.2 pints (4.1 litres).
Transmission lubrication: At each service (at least every 3000 miles), with the vehicle horizontal, check the lubricant levels in the gearbox (SAE 90EP) and the differential (SAE90EP). Check for leaks and rectify at once. Where drain plugs are fitted to the gearbox/rear axle, approximately every 10,000 miles, after a long run (during which the lubricant will be warmed) drain the gearbox and final drive unit, and re-fill with fresh oil. Oil capacity, gearbox: 2.13 pints (1.2 litres). Oil capacity, differential: 1.75 pints (1 litre). At least every 3000 miles, re-grease the propeller shaft universal joints (one at each end of shaft; use lithium-based multi-purpose grease), and at the same time, check the joints for wear.
Running gear lubrication: Before applying fresh lubricant, check all joints for excessive movement and renew if worn. The original recommendation was to activate the ‘one shot’ lubricator (which covers re-lubrication of the front suspension’s sliding pillars) for a few seconds daily, or every 200 miles when touring. However,experience suggests that this may result in excessive oiling (plus puddles of oil on the wheels/floor!), and may be deferred a little (to perhaps every 1000 miles). However, regular lubrication is ESSENTIAL. It is advisable to carry out re-lubrication with the engine cool. (Note: If the sliding pillars are not regularly lubricated, a rusty film/ridges can form at their lower ends; this results in a ‘bouncy’ ride. To clear the rusty film/ridges (following re-lubrication), try driving over a rough road!). Additionally, at least every 5000 miles, re-grease (using lithium-based, multi-purpose grease) thefollowing points: Track rod and drag link nipples Handbrake linkage At each service, check the oil level in the steering box. If necessary, top up with SAE140P oil. At every service, apply engine oil to all brake linkage joints/pivots, also the clutch linkage pivots. Approximately every 5000 miles, check all hub bearings for wear, and sparingly re-grease as required (using grease specifically stated as being suitable for use in wheel bearings); take care not to over-fill these components. Each time the wheels are removed, check the condition of the hub splines; replace if worn. If all is well, apply a little copper-based anti-seize compound to the splines before re-fitting the wheels (to prevent seizure in future).

Brakes

At every service: Check the master cylinder and reservoir for leaks (investigate at once if the fluid level is low), also assess the level and condition of the fluid. Inspect all fixed and flexible brake fluid pipework; renew if damaged/corroded. Inspect the front brake pads, discs and calipers; renew the pads if the friction material is badly worn. Replace the discs in axle sets if their operating surfaces are seriously worn/scored/corroded. Investigate reasons for uneven pad/disc wear. Remove the rear brake drums and check for lining wear and fluid leaks; renew worn linings and weeping cylinders (IMMEDIATELY!) in axle sets. On re-assembly, re-adjust the lining to drum clearance (please consult manufacturer’s literature). Ensure that the ‘quick-release’ handbrake mechanism operates correctly and moves freely, and make sure that the rear brakes are locked with the handbrake fully applied, also that the rear wheels are free to rotate with the brake lever in the ‘off’ position (please consult manufacturer’s literature). Only re-adjust the handbrake cable (adjuster on rear axle) if lever travel is excessive after re-adjusting the brake shoe to drum clearances. At least every 24,000 miles/two years whichever comes first), renew the brake fluid.

Cooling System

Always use high quality anti-freeze mixture containing corrosion inhibitors; this should be maintained within the system all year round to protect against corrosion. Every 3000 miles/annually (whichever comes first), scrutinise the radiator, the fan, and all hoses plus their connections. At least every two years/20,000 miles (whichever comes first), drain the system, reverse-flush the cooling and heater systems, and re-fill with fresh anti-freeze solution (observe the dilution recommendations of the anti-freeze manufacturer).
Capacity: Approx. 12 pints (6.8 litres).

Dynamo Drive Belt

At every service, inspect the dynamo drive belt and renew if worn or damaged. Check that there is deflection of approx. 3/4in (19mm) under firm hand pressure applied midway along the longest belt run. Approximately every 5000 miles, apply a few drops of engine oil to the dynamo’s rear bearing.

Running Gear Components

Every 3000 miles/annually: Every 3000 miles/annually: Examine the front coil springs and the rear leaf springs, looking for sagging and for breakage/corrosion; renew in pairs. Check all shock absorbers for deterioration; replace in axle sets. Scrutinise all suspension/steering mounting bushes; renew if worn. Examine ball joint gaiters. Assess the steering system and ball joints for wear, and check for oil leaks from the steering box.

General

Every 3000 miles or annually (whichever comes first): Re-lubricate all hinges and catches (wipe off excess lubricant afterwards). Assess the cleanliness and security of all electrical connections; inspect all wiring for damage. Check the condition, security and tightness of the road wheels; closely examine the tyres. Inspect the chassis frame, rectifying any paintwork damage discovered. Check/re-tighten all ‘chassis’/underbody bolts/nuts. Examine the exhaust system. Check the clutch release arm free movement (approx. 0.1in. or 25.4mm.). Assess seat belt condition (where fitted). Check all fluid levels. Check/re-adjust headlamp beam alignment.

A Big thank you to…

For comprehensive and cheerful assistance with this feature, grateful thanks to Berrybrook Morgan of Dawlish Road, Exminster, Devon, in particular Sean Anthony (Managing Director) and Martyn Walters (Service Manager). Berrybrook can assist with all aspects of Morgan ownership, including new and used vehicle sales, spares supply, servicing and all types of repairs. Tel. (01392) 833301E-mail: .(JavaScript must be enabled to view this email address)