Morgan Morgan Aero User manual

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1 – INTRODUCTION
Welcome to the world of Morgan. Your car is as individual as you are, and employs traditional coach-building
techniques, using only the highest quality materials – leather, aluminium and seasoned ash. Each Morgan is
built to an individual specification. The Morgan Aero uses the latest engine technology, using a lightweight
powerful engine meeting all the current standards in emissions and fuel economy.
Morgan Aero – Driven at Heart
This handbook has been produced in order to give the owner a good understanding of how best to use and
enjoy their Morgan car. The owner/driver should read and understand all that is in this handbook before using
the car, and the handbook should then be kept in the car for reference at any time. It should be passed on to
new owners if and when the car changes hands. Contained within the handbook are important safety warnings
and instructions. These warnings are to prevent any risk of injury being caused to you or others. This book is
intended to give an understanding of the operating procedures and general servicing instructions as well as
technical information. It is not intended to give comprehensive technical details and full servicing procedures.
To ensure maximum pleasure and performance are delivered it is important to keep the Morgan well maintained
and serviced at the correct intervals. It is the responsibility of the owner to ensure the vehicle is serviced at the
correct periods. If any adjustment is required we request that you contact a Morgan dealer for advice before any
work is carried out. Alterations from the standard specification are not recommended as this may affect the
performance and safety of the vehicle.

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2 - VEHICLE IDENTIFICATION
It is advised that the Vehicle Identification Number (VIN) is recorded in this section along with other records that
may be useful when requesting or ordering replacement parts.
VIN:
Your VIN number is visible through the windscreen from the driver’s side of the vehicle.
Other Information
Body Colour:
Trim Colour:
Hood Colour:
Radio Code:
Door Key Code:
Ignition Key Code:
Fuel Cap Key Code:
Supplying Dealer Information:

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3 - TECHNICAL INFORMATION
Engine
Cylinders 8 in V
Capacity 4799cc
Bore mm 93
Stroke mm 88.3
Compression ratio 10:1
Firing order 1-5-4-8-6-3-7-2, 1 front LH
Power net kW(BHP) 270(362) @ 6300
Torque Nm (lb/ft) 490(361) @ 3600
Valve operation 4 overhead camshafts, Chain driven
Valve timing Variable valve timing system
Fuel system
Type Electronic fuel injection
Fuel pressure Kpa (psi) 350 (50)
Fuel pump Kpa (psi) 1000 max. (145)
Fuel type 98 or 95 RON unleaded petrol
Ignition system
Type Digital electronic
Operation ECU controlled, direct coil
Spark plug NGK BKR5-EQUP or equivalent
Spark plug gap mm Multi point plugs

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Cooling system
Type Engine driven water pump, electronically controlled thermostat,
radiator, twin electric cooling fans
Operating pressure bar normal 1.1, maximum 2
Operating temperature 85 – 120°C
Capacities
Fuel Tank (approx.) 55 litres (14.5 US Gall)
Windscreen washer bottle 5 litres (1.3 US Gall)
Cooling system 11 litres (2.9 US Gall)
Engine oil with new filter 7.5 litres (2.0 US Gall)
Gear box Permanently filled.
Rear Axle 1.7 litres (0.5 US Gall)
Oil and Fluid Specifications
Engine 5W – 30, 5W – 40, 0W – 30 or 0W – 40, synthetic oils of the highest grade.
Gearbox Permanently sealed
Rear Axle 80W – 140, 75W – 140 synthetic oils of the highest grade.
Power steering ATF
Engine Coolant Water/antifreeze mixture
50:50, long life specification with corrosion inhibitor for aluminium engines
all year round.
Brake Fluid DOT 4
Air Conditioning 700g charge of air conditioning fluid.

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Transmission (manual)
Gear Box 6 forward speeds and reverse
Clutch Hydraulic operation, self-adjusting
Differential Hydratrac limited slip, Ratio 3.08:1
Gear Ratios
Gear Gearbox Overall
1st 4.05 12.47
2nd 2.40 7.39
3rd 1.58 4.86
4th 1.19 3.67
5th 1 3.08
6th 0.87 2.68
R 3.68 11.33
Performance
Mph/1000 rpm (approx)
6th 27.76
5th 24.16
4th 20.27
3rd 15.31
2nd 10.07
1st 5.97

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Transmission (auto)
Gear Box 6 forward speeds and reverse
Clutch Hydraulic operation, self-adjusting
Differential Hydratrac limited slip, Ratio 3.08:1
Gear Ratios
Gear Gearbox Overall
1st 4.17 12.84
2nd 2.34 7.21
3rd 1.52 4.68
4th 1.14 3.51
5th 0.87 2.68
6th 0.69 2.12
R 3.40 10.47
Performance
Mph/1000 rpm (approx)
6th 34.94
5th 27.71
4th 21.15
3rd 15.86
2nd 10.30
1st 5.78

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Suspension
Front Upper: Cantilever arm,
Lower: Wishbone, inboard combined coil damper unit
Rear Upper and lower: Wishbone, combined coil damper unit
Castor 10°
Camber Front: 0° – 0.5° negative.
Rear: 0° – 0.5° Negative
Toe in/out Front: 10’ toe in.
Rear: 0° toe in
Brakes
Front 6-piston aluminium calliper, 348 x 32mm ventilated disc
Rear 2-piston aluminium calliper, 332 x 26mm ventilated disc
Handbrake Cable operated, rear calliper brakes
Operation Hydraulic with vacuum servo assistance, ABS standard
Wheels and Tyres
Wheels 8.5” x 18”, aluminium alloy
Tyres Front: 225/40 ZR 18
Rear: 245/40 ZR 18
Tyre pressures: 25psi/172 kPa all round

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Dimensions
Chassis
Wheelbase 2535mm (100 in)
Track (Front) 1522mm (60 in)
(Rear) 1480mm (58.5 in)
Ground clearance 95mm (4 in)
Turning circle 10m (32 ft)
Overall
Length 4100 mm (161.5 in)
Width 1785mm (70.25 in)
Height (with hood) 1222mm (48 in)
Technical Information
Vehicle in running order (Including fuel) 1145kg
Maximum permissible gross weight 1351kg
Maximum weight per axle Front: 625kg
Rear: 738kg
Maximum luggage capacity in boot 35kg
This vehicle is not designed for towing.

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Fuel consumption and carbon dioxide emissions (Manual)
Urban conditions 17.6 l/100km
Extra – urban conditions 8.6 l/100km
Combined 11.9 l/100km
CO2 Combined: 286g/km
These figures have been determined in accordance with EEC standard (1999/100/EC).
Engine power is determined in accordance with (1999/99/EC)
Fuel consumption and carbon dioxide emissions (Auto)
Urban conditions 16.3 l/100km
Extra – urban conditions 8.1 l/100km
Combined 11.1 l/100km
CO2 Combined: 267g/km
These figures have been determined in accordance with EEC standard (1999/100/EC).
Engine power is determined in accordance with (1999/99/EC)

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4 - SAFETY INFORMATION
Throughout this handbook there are important safety warnings as well as safety warning labels located on your
Morgan Aero. These safety
Warnings are there to help you make informed decisions and reduce the risk of
accidents causing possible injury or death to yourself or others. There are also
Notices to assist you in making
decisions to avoid damage to your Morgan Aero or other property.
Important safety warnings
Always ensure that your car is in a roadworthy condition. It is the responsibility of the driver to ensure that the
vehicle is in a proper and roadworthy condition.
The driver and passenger must be seated correctly and should ensure that all safety restraints are used properly
and are free from obstructions.
Check that the tyres are in good condition with no excessive wear or damage.
Ensure all windows and mirrors are clear and positioned correctly before driving.
Ensure that all doors and hoods are fastened/shut correctly.
Check all lights and signalling devices are operating correctly before use.
Always wear your seatbelt
Wearing seatbelts is the best form of protection against injury or even death in the case of an accident, however
big or small. Although your Morgan Aero is supplied with air bags they are designed to work with seatbelts and
are not designed to take the place of a seatbelt. Make sure that you and any passengers travelling in your
vehicle always wear a seatbelt.

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Do not carry children in your Morgan Aero
Morgan Motor Company strongly recommend that you do not carry children in your Morgan Aero and you should
on no occasion carry children using a child seat in the vehicle. The Morgan Aero is fitted with air bags; in the
case of an accident they may inflate causing injury or even death to children travelling in the car.
Air Bag Dangers
Your Morgan Aero is fitted with driver and passenger air bags. Whilst air bags can save lives they can also be
dangerous and may cause serious injury or even death if occupants are sitting too close to the air bags or are
not properly restrained when the air bags deploy.
Harmful substances
Some components used in the manufacture of cars contain or emit chemicals known to increase the risk of
cancer and birth defects as well as increasing the risk of reproductive harm.
Exhaust gases contain carbon monoxide (CO). This gas cannot be seen or smelt and can cause
unconsciousness or even death. If you suspect exhaust gases are entering the cockpit of the car do not drive
the car until a qualified engineer has rectified the fault. Never park in a garage with the engine running and the
garage door shut.

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Engine system
If the engine malfunctions in any way Morgan Motor Company recommends you have the fault diagnosed and
repaired by a qualified engineer before using the vehicle. Continuing to drive the car with an engine misfire
could cause the catalytic converter to overheat, with possible heat damage to other car components, and an
engine bay fire.
Do not park or drive the car in areas where combustible material, such as dry grass or leaves, could come into
contact with the hot exhaust system as this may ignite fires.
Do not tamper with the electrical system whilst the battery is connected.
Do not enter the engine bay when the engine is running.
Do not use the car if a fuel leak is suspected. Ensure that a qualified engineer or service agent repairs the fault
before starting or using the vehicle. Leaking fuel may cause fires or explosions.
Do not touch or approach any part of a hot exhaust system. Failure to comply with this may result in you
receiving severe burns.
Any work to be performed on your Morgan Aero must be performed by a qualified engineer or Morgan service
agent.

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5 - LOCKS, KEYS AND SECURITY
5.1 Keys
Your Morgan Aero is supplied with 3 keys for the vehicle ignition system (1 extra profile key), 2 keys for the fuel
filler cap and 2 keys for the door locks and 2 door lock plipers. Contained within the ignition key is a chip used
to disarm the engine immobilisation system. Your Morgan Aero can only be started with a key containing the
correct chip corresponding to that vehicle. Upon receipt of your vehicle and keys you will find a code located on
a tag attached to your keys; it is important to record the manual ignition key code before removing and
discarding the tag.
Warning
There is no alarm system supplied on your Morgan Aero.
Do not leave your car unattended with the keys in the ignition.
Do not leave your vehicle with any animals or children in the car when the keys are in the ignition or when the
engine is running, accidental operation of the vehicles controls could cause an accident resulting in serious
injury or even death.

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5.2 Door Locks
To unlock the door from outside the vehicle, insert the key into the lock and rotate in an anti-clockwise direction
until the stop is reached, then remove the key. The door is now unlocked. To lock the doors ensure the door is
fully latched shut. Insert the door lock key into the lock and rotate in a clockwise direction until you reach the
stop. Remove the key and the door is now locked.
To lock the doors from inside the car push the locking lever down and the door is now locked. To unlock the
door pull the lever upwards and the door is now unlocked.
Warning
Never lock a vehicle when a person or animal is inside the vehicle.
Never leave you vehicle unattended and unlocked.
Do not force the lock mechanism. The key will only fit in the lock in one direction. If the key will not go into the
lock or the lock will not operate lubricate with light grade oil. If the problem persists consult a qualified
engineer.
5.3 Remote Central Locking (RCL)
Your Morgan Aero is supplied with RCL that is activated by pressing either of the buttons on the RCL pliper. To
lock the doors press the button on the pliper for approximately 1 second, the indicator lights will flash to
indicate the locks have changed position. To unlock the doors press the button on the pliper for approximately
1 second and again the indicators will flash to indicate the locks have changed position.
The range from which the pliper will operate the locks will vary depending on environmental conditions and the
pliper battery condition.

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5.4 Engine Immobiliser
Your Morgan Aero is fitted with an integrated engine immobiliser. This means that the engine can only be
started using the correct keys with the correct transponder chip installed in the key.
Notice
Due to the nature of your Morgan Aero, it is easy for thieves to gain access to the inside of the vehicle. Do not
leave items in the vehicle as they may be easily stolen.
5.5 Boot Opening
Pushing the boot release button located on the instrument panel opens the rear
boot. The boot release button will only operate when the ignition is in the on
position. There is a manual release Tab located inside the rear of the space behind
the seats. Pull the tab, supporting the trim panel with your hand to open the boot.
Boot Release Tab

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6 - SEATING AND SAFETY RESTRAINTS
6.1 Seats
The seats in the Morgan Aero are adjustable fore/aft and should be adjusted to suit. To adjust the fore/aft
position of the seats, raise the lever located under the front of the seat. This will allow the seat to slide fore/aft.
Once in the desired position release the lever and the seat will be engaged in position. It is important to check
that the seat is engaged in position and attempting to slide the seat fore/aft with the lever not being touched
can do this.
Warning
It is important to sit as far away from the air bag as possible whilst ensuring that full control of the vehicle is kept
at all times. Sitting too close to an air bag when inflated can cause serious injury or even death.
Do not adjust the seat position whilst the vehicle engine is running.
Ensure that no objects can be trapped when the seats are moved/adjusted.
6.2 Seatbelts
Seatbelts should be worn at all times when in the vehicle. It is a proven fact that wearing seatbelts reduces the
risk of injury or death in the event of an accident. It is a requirement by law in most states for seatbelts to be
worn when travelling in a vehicle. When the ignition is turned on there will be a warning light and buzzer that
will remain lit/audible for 8 seconds reminding you to fasten your seatbelt.
The seatbelt units fitted to your Morgan Aero are inertia reel seatbelts. The seatbelts will lock automatically
when the vehicle is subjected to braking, acceleration, cornering and impact forces. The seatbelt unit may also
lock if the vehicle is tilted in any way.

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When fastening the seatbelt sit in the seat erect and fully back. Take the buckle tongue in your hand and draw
the belt diagonally across the body and fasten into the buckle lock. Ensure the buckle is secured and correctly
engaged; this will be apparent by a click sound when fastening the buckle tongue into the buckle lock. Ensure
that belt sits across the front of the pelvis and across the chest and shoulder.
To release the belt push the red button on the buckle. The belt will automatically retract.
Warning
Driver and passenger seatbelts should always be worn properly. Wearing a seatbelt incorrectly increases the
chance of serious injury or death in a crash, even with airbags.
When fastening the seatbelt, ensure that the belt is not twisted or entangled in the door or seat mechanism.
Seatbelts are designed to bear upon the bone structure of the body and should be worn low across the front of
the pelvis, and across the chest and shoulder. Wearing the lap section of the belt across the abdominal area
must be avoided.
Improperly positioning the seatbelts can cause serious injury or death in a crash. Ensure the seat belts are
correctly positioned before driving.
Seatbelts should be worn what ever your condition, especially in the case of pregnant women.
The shoulder portion of the belt must never be worn beneath the arm or behind the back.
Each seatbelt assembly is designed for use by one occupant of adult build, and should not be used by children
unable to meet the requirements set forth herein.
A child seat must never be used in a Morgan Aero.
Never use one belt around two people, or allow a child to be carried on a driver or passenger’s lap.
No modifications or additions should be made to the seatbelt assemblies.

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The seatbelt should be replaced if components are frayed, contaminated or damaged. Inspect regularly.
The seatbelt system must be replaced if the vehicle has been involved in a severe impact, even if no damage to
the assembly is visible. Seatbelt anchorage points must also be checked.
Not checking or maintaining seatbelts can result in serious injury or death if the seatbelts do not work properly
when needed. Check the belts regularly and have any problem corrected immediately.
Notice
When cleaning the seatbelt assembly, care should be taken to avoid contamination or damage to the system.
Do not use any substance that may contaminate or damage the webbing material. Never use bleach or dye,
only clean with a mild detergent and ensure the system is completely dry before using the vehicle. Ensure the
entire system is kept free of dirt contamination. Do not disassemble the system for cleaning purposes.

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6.3 Air Bags
Your Morgan Aero is fitted with driver and passenger air bag systems. The driver air bag is contained within the
steering wheel; the passenger air bag is fitted into the dashboard directly in front of the passenger when seated.
The air bag system is a supplementary system designed to operate when the vehicle is involved in a moderate
to high, frontal or near frontal collision. The air bag system is designed to work with the seatbelt system.
Seatbelts are the primary form of occupant protection in the event of a collision and so must be worn at all
times. When triggered the air bags will inflate in a fraction of a second to assist in occupant protection and then
deflate to minimise obstructions to the occupants.
Many parts of the air bag system are designed only to be used once and you should contact a Morgan dealer or
service agent for the replacement of the required parts before the vehicle is driven.
Warning
Seatbelts must be worn at all times; the chances of you being killed or seriously injured in the event of a crash
are higher if you aren’t wearing a seatbelt. Air bags are designed only to inflate in moderate to high frontal or
near frontal impacts.
Air bags are designed to work in conjunction with a seatbelt system. Sitting too close to the air bag will increase
the risk of being injured or even killed if the air bag were to inflate. Wearing seatbelts keeps you in the correct
position before and during the event of a crash. Sit as far away from the airbag as is comfortable whilst
maintaining full control of the vehicle.
No objects should be placed between the air bag system and the occupants of the vehicle. In doing so this will
cause the air bag system to not inflate and perform correctly reducing the protection to occupants.
Inform your passengers of all information within this section.
Do not attempt to modify or adjust any part of the air bag system. Doing so may result in disabling or affecting
the performance of the air bag system.

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6.4 Air bag deployment
The air bag system fitted to the Morgan Aero is an electronically air bag system. In the event of the air bag being
deployed there may be a release of powder from the bag; which may appear like smoke; although the powder is
not harmful do not inhale the powder and exit the vehicle as soon as is safe.
Warning
The air bag system must only be serviced and maintained by authorised Morgan dealers.
Further information relating to the use of the air bag system can be found on stickers located on the sun visors
of the vehicle.
Child seats must not be used in your Morgan Aero.
A Morgan dealer must dispose of deployed air bags.
6.5 Children
Morgan Motor Company strongly recommends that children be not carried in your Morgan Aero. If a child is
positioned too close to an air bag when it inflates it may cause serious injury or death.
You must only carry people in your Morgan Aero who are able to use the seatbelts as intended without any
modification or seating aid. Child booster seats are not recommended for use in a Morgan Aero.
Warning
Children must not be carried in a Morgan Aero.
There’s no provision in your Morgan Aero to disarm the air bag system.
Child seats must not be used in a Morgan Aero.
Children who are not properly restrained may be seriously injured or killed in the event of an accident.