ROADSTER1stInformation2

ROADSTER I DEALER INFORMATION
AND DRAFT OWNERS MANUAL

Chassis:

The roadster chassis is based on the Plus 8, the gearbox rails have been modified to take the new gearbox. The exhaust bracket holes have been moved for the new silencer. Holes have been added for O2 sensors. The rest of the chassis is the same.

If you have not already noticed on 4/4 and Plus 8, some small additions have been made to the area around the front rear spring hanger. This is the modification, along with the door bars for the European side impact.

Frame Front:

The frame front is a standard 4/4 specification.

Suspension:

The front and rear suspension is the same as the last Plus 8, 110 lb/in blue front springs and 6 leaf rear.

Wheels:

The standard wheel will be the 6.5 x 15 alloy, used on the Plus 8. The optional wheel will be a 7 x 16 stainless wire. This is not the same wheel as the Plus 8 used. The off set and in set are different.

Metal front and Valances:

These are unique to the Roadster.

Engine:

The engine is the Ford ST220 engine, using the “Black Oak” fuel system. Modified water system, clutch, drive belts, alternator, Ignition set-up to fit in car.

Exhaust system:

Tubular manifolds, specially made catalyst, silencer and tail pipe.

Air cleaner:

Specially made glass fibre unit.

Gearbox:

This is a Jaguar 5 speed manual. The remote system is unique to Morgan Motor Company

Gear Box Cover and Shaft Cover:

This is specially made for the Roadster.

Water Pipes:

These are all unique to the Roadster. The overflow bottle is the same as 4/4 Focus.

Throttle Cable:

This is the same as the 4/4 Focus. Both the rh and lh accelerator pedals are unique to the Roadster

Engine mountings and gear box mounting:

These are specially made for the Roadster. The rubber mounting will be used on the New Aero 8.

Fuel Tank:

The fuel tank is the same design as the 4/4 and size. It is however made in aluminium. This is partly due the EU regulations, which prevent the use of Lead Coated Steel.

Fuel Pipe:

The fuel pipes and filter are special to the Roadster. There is no fuel return on the Roadster. The charcoal can is mounted in the back above the tank.

Fuel Pump:

The fuel pump may look the same as the 4/4, but it is not. The fuel return is operated within the fuel tank and pump.

Fuel Filler:

This is the same as the 4/4. As is the pipe.

Body Frame:

The body frame is basically a Plus 8, but you may notice the rear wheel arch bottom rail has been moved from under the wheel arch inner to the side. This has strengthened the wheel arch from the outside.

Front Wings:

These are unique to the Roadster. The width and length has changed. The headlight position on the wing has been made the same as the 4/4. The wing stays are Roadster.

Rear Wings:

These are basically the same as Plus 8.

Bonnet:

These are similar to the Plus 8, but with the side louvers turned in. This is to improve cold airflow to the engine intake.

Steering Shaft:

The UJ shaft for the Roadster has been reversed, with the rubber joint at the top.

Trim:

The gearbox cover, shaft cover and front carpets and end mats are all changed on the Roadster. All other trim is the same as Plus 8.

Dash Board:

The dash board in the same as the CLM 4/4 and Plus 8, but has been angled back at the base to give more clearance behind the dash and improve the appearance.

The speedometer and small gauges are the same as Plus 8, the Tachometer is unique.
The dashboard wiring has been change. The main harness connects to two boxes. One controls the instruments and converts signals from the Ford system. The second box controls the MIL light and fuel system information going into the Ford system.

From the instrument control unit a sub harness connects to the instruments.

The warning light and switches have been combined onto a PCB. These are effectively one unit.

An additional fuse box has been added to safe guard the battery brown wires. This is mounted through the metal front on the right hand side under the bonnet.

Wiring Harness:

This is unique to the Roadster.

Cooling fan/radiator:

These are the same as the Plus 8, as are the brackets

Service Information:

Oil Filter: Ford Part, not the ST220 one.

Air Filter: Ford ST220 standard.

Oil: SAE 5W-20 – Ford standard WSS-M2C913-B or ACEA A1/B1

Spark Plug: AGSF 22 FSCM or direct equivalent check at 20,000 miles

Axle: As in dealer circular for sintered cone type.

Gearbox: Sealed type, 50,000-mile change.

Our thanks to Mark Aston for his help! May 2004

LISTED BELOW ARE MAIN DETAILS FROM THE HANDBOOK

GENERAL SPECIFICATION

Engine Ford MEBA

Bore of cylinder (mm) 89

Stroke (mm) 79.5

Cubic capacity 2967cc

Firing order 1, 4, 2, 5, 3, 6

Maximum engine rpm 6700 (Never exceeded)

Power EEC @ rpm (BHP) 166 kw @ 6150 (226PS)

Torque EEC (ft/lbs) 280 NM (206 lb ft) @ 4900 rpm

Valve operation Double overhead camshaft per bank, chain driven,
hydraulic tappets, 4 valves per cylinder

Oil capacity:
Engine (refill) 5.6 Litres incl filter
Gearbox Permanently filled (1.9 Litres)

Rear axle 1.0 Litres

Water capacity 11 Lts

Cooling system Water pump, radiator, thermostat and electric fan

Petrol 95/98 Octane unleaded only Caution The use of leaded fuel in a catalyst engine will severely affect the operation of the engine and destroy the catalyst.

Tank capacity 55 Litres / 12 Imp Gallons (at “E”)

Engine Managment System

Type Ford programmed electronic

Ignition timing Module Controlled

Spark Plug types Motorcraft AGSF22FSCM or equivalent

Spark Plug gap 1.27mm to 1.3mm

Fuel System type Ford indirect multi-point injection

Front Wheel Alignment and Suspension
205/60 15 or 205/55 16 tyres
Castor angle 4°

Camber 0.5° NEG + 0.5°

Kingpin inclination 2°

Toe-in 0 to 3.2mm)

Transmission

Clutch Diaphragm spring mechanical, Single dry plate

Operation Hydraulic

Clutch release free play 2.54mm

Rear axle Three-quarter floating, Hypoid crown wheel and pinion - Ratio 3.08:1

Gearbox Ford: Five speed and reverse, synchromesh on all forward gears

Gear ratios Gearbox Overall

1st 4.23 13.03
2nd 2.52 7.76
3rd 1.67 5.14
4th 1.22 3.757
5th 1 3.08
Reverse 3.51 13.09

Performance data (205 60/15 Tyres) 3.08

Miles per hour/1,000rpm

5th 23.67
4th 19.41
3rd 14.18
2nd 9.39
1st 5.59

Fuel Consumption and carbon dioxide emissions to EEC 1999/100:

Urban conditions 13.91 l/100 km (20.3 mpg)

Extra urban conditions 7.40 l/100 km (38.17 mpg)

Combined 9.77 l/100 km (28.9 mpg)

CO2 231.8 g/km

General Dimensions

Wheelbase 2490mm

Track (front) Wire 1290mm, Alloy 1300mm
(rear) Wire 1440mm, Alloy 1390mm

Ground clearance (unlaiden) 100 mm

Turning Circle 10m

Tyre size 205/60 15 or 205/55 16

Body Dimensions - 2 Seater

Seat to hood 890mm

Width at elbows 119.5mm

Height of seat from floor (front) 220mm

Leg room 450-630mm

Door width at waistline 710mm

Luggage Space: Length (Max) 1035mm

Width (Max) 500mm

Depth (Max) 225mm

Overall Dimensions Maximum - 2 Seater

Length (Bumper) 4010mm

Width (Wire Wheel) 1720mm

Height (hood erected) 1220mm

Weights (Minimum)

Complete with tools and petrol 1000 kg

Maximum Permissible: 1400 kg (F560kg, R840kg)

Immobiliser
The Roadster is fitted with an engine immobiliser system which acts on the engine management system. The system is operated automatically by the keys of the ignition lock.

Operation
When the engine is turned off, the warning light in the central instrument panel will start to flash. This indicates that the system has been armed.
On returning to the vehicle, the warning light will continue to flash until the key is turned forward into the ignition position. At this point the light will stay on. When the engine starts the warning light will go out.

Important
On the key ring there will be several keys. ONE of these is marked as the master key. This key must be kept safely as it is the only way further keys can be configured to the unique system on the car. If the key is lost, the engine management system will have to be changed.

INSTRUMENTS AND CONTROLS

Speedometer
The electronic speedometer indicates the vehicle speed when in motion. The distance recorder indicates both total mileage and trip mileage on the same screen. To change from total mileage to trip, press the button at the base of the instrument. ‘trip’ will appear at the below the display when in trip mode. To zero the trip, hold the same button down for a few seconds. This can be done when either display is showing.

Oil Pressure Gauge
This indicates the engine oil pressure when the car is running. The pressure will run at 6 – 8 bar when first started from cold. When the engine is full warned through the pressure will normally run between 2 – 4 bar. At idle speed the pressure will fall, to 0.7 - 1 bar. If no pressure registers when the vehicle is started, check engine oil level. If this is correct, consult your Morgan Dealer immediately.
Caution: Do not run an engine with low or no oil pressure. Have it checked. It is best to wait for the oil pressure to reach the normal running pressure before hard acceleration.

Voltmeter
This instrument indicates the condition of the battery on a voltmeter principle. A reading above the 15 volts which continues after 10 minutes running is too high and should be investigated. A reading below 12 volts indicates the battery charging system requires attention. To avoid battery discharge, switch off unnecessary electrical equipment when stationery.

Water Temperature Gauge
This is electrically operated, acting only when the ignition is switched on. The normal reading, when running on the road, should be between 90 0 and 120 0 The temperature will change when driving conditions vary.

Fuel Gauge
Operates only when the ignition is on, the tank capacity is shown in the General Specifications. The roadster tank will hold 60 litres when dry. The “E” on the gauge is set so that 5 – 10 litres are still in the tank, to avoid run out. When reading empty the tank will normally take 55 litres
Caution: The gauge is a guide to fuel level and is affected by the angle of the vehicle. It is advisable to avoid running out of fuel often, as this may damage the fuel pump.

Revolution Counter
Shows engine speed in revolutions per minute and is calibrated in divisions of 100. It is of the electronic impulse type. The engine safe maximum is 6700rpm. The fuel system if fitted with a limiting control, which reduces the fuel flow as the engine reaches maximum RPM.
Caution: Never allow the engine to exceed this speed.

WARNING LIGHT UNIT
(Placed centrally in the dash board listed from the left):

(1) Ignition warning light (red)
This serves the dual purpose of reminding the driver to switch off the ignition before leaving the vehicle and of acting as a no-charge indicator. With the ignition switch ‘on’, the warning light should be illuminated only when the engine is stopped or turning over very slowly. As the engine accelerates the light should dim and eventually go out at a fairly low engine speed. Failure of the light to behave in this fashion will indicate a broken alternator drive belt or other fault in the charging system.

(2) Headlight warning light (blue)
Glows when headlights are on main beam, no light when dipped.

(3) MIL light (yellow)
The ML warning light will be activated when there is a failure in the ignition or fuel system of the engine, which causes a change to the emissions from the vehicle. If this light is activated during the running of the vehicle. The car should be taken immediately to the nearest Morgan Dealer. When the car is first started, the ML light will illuminate with the ignition light and once the car starts to run correctly, this light will disappear.
No vehicle should be driven with any form of misfire as this will seriously damage the catalyst and cause fire.

(4 / 5) Direction indicators monitor (green)
The left-hand indicator glows green when the steering column combination switch is moved to signal left-hand turn; the right-hand indicator operates for a right-hand turn.

(6) Brake warning light (red)
When the ignition is switched on with the handbrake applied the indicator should glow. Should failure of the front or rear brake lines occur, or the brake fluid level be too low, the indicator will also light up.
Caution: Never drive a car with the brake warning light on. Have it checked.

(7) Seat belt warning light (when connected) red
This light will illuminate when the seat belts have not been correctly fitted and the engine is started. Connecting the buckle with the socket will extinguish the light.
Caution: Never drive the car without correctly fitting the seat belt and making sure any passengers have done so.

(8) Air conditioning light (when fitted) yellow
When the air conditioning is switched on this light will light up. If the fan has not been switched on the light will flash to indicate this.

(9) Sidelight warning (green)
Will show when the light switch is turned and the lights are on

(10) Inertia Switch Warning Light (yellow)
In the event of an impact the inertia switch will operate. This is indicated by this light. The light will go out when the switch is reset.
Warning: Before re-setting the inertia switch the vehicle must be checked for damage, especially to the electrical and fuel system.

FOOT OPERATED CONTROLS

Accelerator
The pedal is connected by a cable to the injection throttle.

Foot Brake Pedal
Actuates the brakes on all 4 wheels hydraulically, and also closes the circuit to the rear brake lights. These only operate when the ignition is switched on.

Clutch
Press pedal to disengage drive from engine to gearbox. Do not rest your foot on the pedal when driving or hold the clutch out to freewheel as this will cause unnecessary wear.

HAND OPERATED CONTROLS

Handbrake
This is the ‘fly-off’ type To operate the handbrake pull backwards, the lever is fixed in the ‘on’ position by pressing the cap on top of the lever which engages the paul in the ratchet. To release brake pull the lever to the rear and allow to go forward to the full extent. Red warning light shows until handbrake is ‘off’. It is advisable to engage 1st gear when the vehicle is parked on inclines. Disengage 1st gear before starting.

Heater
This is located behind the dash board and the hand brake lever, above the gear box cover. The temperature is controlled by the knob on the right, bottom of the front of the box. Moving the knob to the top increases the heat and to the bottom reduces the heat. Hot or cold air can be directed by the use of two sets of vents on the heater.
1) On each side of the heater box are round vents. These can be used to direct air into the car. The vents are opened by pressing on the larger of the flaps. These vents can be rotated to direct airflow.
2) On the front of the heater above the control knob, are two round vents. These can be used to direct air into the car. The vents are opened by pressing on the larger of the flaps. These vents can be rotated to direct airflow.

Defrost/Demist
An electrically heated windscreen is fitted to your car to clear the screen in poor weather.
To operate the screen, first start the engine as described, then press the switch on the dash board showing the screen symbol. This will heat the eliminates and the screen. In heavy frost, the screen may take longer to clear, but should show signs in approximately 2 minutes.
The screen can be used at all times when the engine is running, but it is advisable to switch off the screen when clear.
Important
Switch off the screen BEFORE switching off the engine, as this will drain the battery if the ignition is on.

Light and Indicator switch
The left hand control stalk behind the steering wheel operates the direction indicators and the vehicle lights.

Indicators
Press the control downwards until it clicks in place for the left hand indicators and lift the control upwards for right hand indicators. The stalk is fitted with a self cancel system which should turn the switch off. In certain cases this may not work if the wheel has not passed through 90 deg.

Lights
The end of the left hand control can be rotated upward to operate the lights.
Position: 1: Lights Off
2: Sidelights and Dash Board
3: Main Beam/Dip Beam

Dip Switch
The same control stalk operates the dip switch. To change the Head Light setting, pull the stalk toward the wheel until it clicks. To change again, repeat the action.

Windscreen wipers/washers:
The right had stalk behind the steering wheel operates the wiper and the washer system.

Wipers
To operate the wipers the end of the control is rotated upward.
Position: 1: Wipers Off
2: Intermittent Wipe
3: First Speed Continuous
4: Second Speed Continuous

Intermittent Wipe: With the main switch in the first position, the screen will be cleared once at a set period. This period can be varied using the rotary control on the inner part of the stalk. The bottom stop is the longest delay and the top the shortest.
Single Wipe: If the complete stalk is pressed downward, the screen will be swept once. The control will return automatically.

Washers
To wash the screen, the control should be pulled toward the steering wheel. The stalk will return automatically. Each time the washer is operated, the wipers will sweep the screen three times.
Caution: Always switch the wipers off before turning off the ignition. In frost or snow, always check that the wipers are free before operation. Not doing so will damage the wiper system. At all times use an additive in the washer system and prevent freezing. Do not use wipers on a dry screen.

Gear Lever
Caution: Always select neutral position before starting the engine. ONLY select reverse when the vehicle is stationary.
R 1 3 5

2 4

To select reverse move the lever to the left and then forwards.
Do not press or lift the lever, or rest your hand on the lever while in motion.

Steering Lock, Ignition and Starter Switch
This switch is located on the steering column and has 4 positions.
Important:
Take note of the key number.

1st position Steering wheel lock in operation and ignition off, key can be extracted in this position.

2nd position Moving clockwise ‘garage lock’. Ignition off, but steering unlocked which allows the car to be moved and steered by hand.

3rd position Ignition on.

4th position Is spring loaded and brings in the starter motor.
Caution: Never allow the car to move unless the lock is deactivated.

Horn
The horn button is located in the centre of the steering wheel on standard cars. On air bag cars the horn is on each side of the top bar of the wheel.

Push Buttons:

Rear Red Fog Lamps (Yellow)
These lights will only operate when other lights are switched on. The switch is only lit when the fog lamps are on. When the ignition is turned off the switch will automatically turn off and will need to be turned on if needed. DO NOT USE REAR FOG LAMPS IN GOOD

WEATHER

Hazard Switch (Red)
This switch when depressed operates all direction lights and should only be used when the vehicle is stationery in an emergency situation.

Fan Heater Switch (Yellow)
Operates fan blower motor in the car heater system.

Defrost/Demist (Yellow)
When pressed this will turn on the electrically heated screen.

Instrument Illumination Rheostat (behind dash board by steering column)
Turn knob left to illuminate the instruments at high intensity and right to reduce the intensity.

Seat Controls
There are two types of seat available
1: Fixed Back Bucket
2: Reclining
All seats have forward and aft movement, controlled by the bar under the front of the seat cushion.
The reclining seat has an adjusting lever on the side of the back rest, which allows changes to the angle of the back rest when raised. The seat can also be tipped forward when the lever is up.
Important:
Be sure the back rest locks in place when raised back up. The locking point will vary with the angle set on the wheel.

Steering Column
The steering column can be adjusted by use of the lever on the left hand side of the unit. To move the column, press up or down on the wheel and push the lever upward, the wheel can be moved through an arc of 10 deg.

Airbag (when fitted)
The airbag system is mechanically activated and totally self contained within the steering wheel hub and dash board on the passenger side. In the event of an impact a spherical sensor moves within a cylinder releasing a firing pin. This initiates a chemical reaction, generating a gas (nitrogen) which inflates the airbag. The whole sequence of events from sensing the impact to full inflation of the bag takes place in a fraction of a second. As the occupant restrained by the seat belt moves forward the head and chest come into contact with the inflated bag which then deflates in a controlled manner, via vent holes in the rear of the bag, to absorb the remaining energy of the impact.

The airbag is designed to inflate in severe frontal collisions. It will not deploy at very low speeds or in side and rear impacts. Protection in these instances is provided by the seat belts. The severity of the collision is a function of the relative speed and weights of the vehicle or objects colliding. The noise and gas associated with the deployment of the airbag are not hazardous to health.

Note: No objects whatsoever should be attached to the centre cover of the steering wheel or dashboard.

All work on the airbag system, including replacement after deployment and replacement at the end of its service life must be carried out by an authorised Morgan Dealer. In the event of an airbag equipped vehicle being scrapped, disposal instructions for the airbag module can be obtained from an authorised Morgan Dealer. The airbag label fitted to the vehicle contains the following statement:

ATTENTION: SEAT BELTS SAVE LIVES
THIS VEHICLE IS FITTED WITH AIRBAG SUPPLEMENTARY RESTRAINT SYSTEMS FOR BOTH DRIVER AND FRONT SEAT PASSENGER. FOR MAXIMUM PROTECTION ALL OCCUPANTS SHOULD WEAR THEIR SEAT BELTS WHEN THE VEHICLE IS IN USE.
CHILD SEAT AND
PASSENGER AIR BAG
USE ONLY FORWARD FACING CHILD SEATS WITH PASSENGER SEAT IN THE FULLY REARWARD POSITION

WARNING - As with all airbag systems it is vitally important that passengers are correctly restrained by the seat belts.
No rearward facing child seats must be used in airbag vehicles
Young or small children must not be carried in airbag vehicles unless the seat is fully back and they are using the seat pads required to ensure they are correctly held by the seat belt.

Short drivers should take great care. Sitting too close to the steering wheel can be dangerous if the airbag is deployed. .Never remove air bag systems. The car is specially modified to make then work correctly.

SEAT BELTS

Wearing
Never attempt to wear the belt other than as a complete lap and diagonal assembly. Do not try to use the belt to more than one person at a time, even with small children. Ensure that the belt webbing is not twisted when in use, and that the belt is adjusted to the correct tightness.

Using the harness
Take hold of the chrome connecting end, draw over the shoulder and across the chest. Push the tab firmly into the buckle unit nearest to the wearer, until a positive click is heard. Ensure that the harness is safely locked (see fig. A). To release the buckle press the red button on the centre unit downward, and make sure the belt retracts into the rear (see fig. B).

Adjusting
The belts fitted are of the inertia reel type. Adjustment is automatic and the belt will move to allow freedom in the car. Free movement may be restricted when cornering or braking, as the locking mechanism is operated by the pitch of the vehicle. In the event of an accident the belts will lock, preventing forward movement. The lock will release automatically when the car is stationary.

Cleaning the webbing
No chemical cleaners should be used on the webbing. If it becomes soiled, sponge with warm water, using a non-detergent soap, and allow to dry naturally, not by artificial heat or direct exposure to the sun.

NEVER ATTEMPT TO EITHER BLEACH OR DYE THE WEBBING.

Warning
1. Never at any time wear the lap belt loosely as this reduces its protection.
2. Periodically inspect the webbing for abrasion, paying particular attention to the anchorage points and adjusting devices.
3. In the event of an accident any safety belt which has been subject to a shock load should, in the interests of safety, be renewed.
4. Alterations or additions to the kit which might impair the efficiency of the assembly should not be carried out. In the case of doubt, or suitability of a particular model, consult the manufacturers list.
5. Small children should only be carried if properly restrained. If they are too small for a seat belt, a correct, good quality child seat should be used. Your dealer can confirm the recommended seats.

Mirrors
Caution: Always adjust mirrors before moving off. The image in the mirrors may not be true. Accustom yourself to the type of mirror fitted before driving. The interior mirror gives the best image of vehicles behind.

Interior Mirror
This is simply adjusted by moving the head. The position on the screen is set by the Department of Transport.

Exterior Mirror
The head can be adjusted by means of the small screw in the rear of the mounting.
Caution: Do not overtighten after adjusting.
The height on the mirrors can be adjusted by the nut fitted part-way down the stem.

Windows
These simply slide forward to open; backward to close.
Caution: Do not push the two parts of the window together, this will scratch the lenses. Do not push the screen open when it is frozen, this may break the lenses.

Door Locks
To open, lift handle upward. It will automatically spring down after operation. To lock, push locking knob upwards, or downwards, depending on the lock type.
Caution: If the lock will not engage, do not force it, it may mean the door is not properly closed.
Never close the door when the lock catch is closed. If it has come down, simply open the handle to lift the catch.

Fuel Filler Cap
The fuel filler cap is a flip type. To open press in the back part of the latch at the top of the cap. When fitted with a lock, the key must be turned before the catch is opened. The key cannot be removed when the cap is unlocked.
Caution: Never close a locking cap with the key or lock in the locked position, this may bend the lock bar and prevent opening.

Fuel Types
The Roadster must be run on UNLEADED FUEL ONLY – 95 or 98 Octane premium grades.
Caution: The use of LEADED FUEL or incorrect grades will seriously damage the engine and catalyst.
Warning: Petroleum Spirit is highly flammable and in confined spaces is toxic and explosive. Never fill the tank with the engine running, or near naked lights or hot surfaces. Do not inhale fumes. Have possible fuel leaks checked by experienced personnel. Do not use any other fuel than standard petrol. Do not over-fill the tank. Always ensure that the filler cap is properly closed before starting the car.