DELOREAN WORKSHOP MANUAL - Free

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.-^" " > "^y*v - /\ *"*» / ^ ^ r* m *~ N ^=J ' **** ml ' x A>—^ »—^—^f ^^^si '• JL*-^ NN ,^ ~> v 3 If — ID __.' x/ -»J •~' Fig. 29 Fig. 31 Align the dismantling marks and fit the 1st-2nd sliding gear to the synchro hub. Install the synchro spring on the 1st speed gear so that it covers the three (3) notches. Install the 1st speed gear, synchro ring and needle roller half-bearings on the secondary shaft. Fig 30 —^ Fig. 32 NOTE: The 1st speed synchro ring is larger than the 2nd speed synchro. 8. Install the double taper roller bearing on the secondary shaft with the shoulder on the bearing race facing the threaded end of the shaft. (Fig. 32) ^l> IN^C ~ m / ^7 ^ ^ 1 - 0^ ' *^ * Fig34 -
r i r r r r r r r i r I DIFFERENTIAL ASSEMBLY DISASSEMBLY 1. Remove the O-rings from the axle shafts. 2. Remove the carrier bearing from ring gear side of the differential using a suitable puller. If it is necessary, remove some of the ring gear bolts to aid in the installation of the puller. (Fig. 33) 3. Remove the ring gear bolts and ring gear. 4. Remove the side gear. 5. Remove the shaft retaining pin and remove the spider gear shaft. (Fig. 34) 6. Remove the spider gears and concave washers. 7. Remove the side gear and thrust washer. 8. Remove the remaining carrier bearing. Retain any shims that may be located between the bearing and the carrier. (Fig. 35) 9. Remove the bearing outer race from the righthand half-case using Tool J23907. (Fig. 36) 10. Remove the driveshaft flange seal from the right-hand half-casing. 11. Remove the lockplate for the differential ring nut in the left-hand half-casing. 12. Remove the ring nut using Tool J28866. (Fig. 37) 13. Remove the seals from ring nut. 14. Remove the bearing outer race from the lefthand half-casing using a brass drift.
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DELOREAN WORKSHOP MANUAL PJ. GRADY
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r r r • i r I r r I I Issued by:
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SERVICE ORGANISATION In order to pr
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i GENERAL SAFETY HINTS 1. Use the c
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• • r r r r r General Data CONT
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A:01:02 IGNITION SYSTEM (Contd.) Sp
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General Data A:02:01 ENGINE TUNING
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A:03:02 General Data DESCRIPTION TR
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A:03:04 General Data TORQUE FIGURES
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A — Overall Length B — Wheel Ba
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U 1 n PRE DELIVERY INSPECTION After
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I r r General Data LABEL IDENTIFICA
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f&T$ , W*$ fewt r jfi^T LABEL IDENT
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r r \r*l r
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IMPORTANT Fuel Tank B:01:01 REMOVIN
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Fuel Tank B:01:03 •
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Fig. 7 Number of Cylinders Bore Str
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TIGHTENING TORQUES-Figs. 3 and 4 No
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VALVE GUIDES Bore (mm) 8-8,022 (0.3
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r r r r r r r r r i r r CAMSHAFT Th
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REMOVING Disconnect battery. Remove
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Remove coolant hoses at engine Remo
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pm> fpg3\ ff&n, 0&t RETIGHTENING-TI
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Tl^ty r •'•*'j "*& Fig. 27 SECO
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• ^ * ? Remove the cylinder head
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that the camshaft top is fully with
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ROCKER SHAFTS DISMANTLING The oilwa
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- f CHANGING The engine need not be
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W&\ rrw\ EXAMPLE-Fig. 51 First meas
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Check that each small end is lying
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r Proceed in the same way for assem
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IflTtl "
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Remove the timing chains RH first t
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C:07:06 Engine Fig. 79 Refit the cr
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C:07:08 Engine ANGULAR TIGHTENING O
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Fig. 91 Lubricate the cylinder head
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Fig. 99 J 28860 Smear the crankshaf
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REMOVING Main Bearing Oil Seal—Fl
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- r REMOVING Drain engine oil Remov
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T^T) ryift] 7^1 I •'•'l p*^ Oil
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p^ is*l £T-- ? >'I I'-TVN) 1^1 •
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NOTE: The arm has LH and RH threade
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© "&•• ? o 9 (S> O C ,s '*•*
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Fuel Emission and Exhaust System CO
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V D:01:02 COMPONENT LOCATION Mixtur
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D:01:04 Fuel, Emission and Exhaust
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D:01:12 v. Fig. 12 High Control To
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D:01:14 Fuel Emission and Exhaust S
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D:02:02 TEST GAUGE CONNECTION VALVE
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&Wy Fuel, Emission and Exhaust Syst
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Fuel, Emission and Exhaust System D
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Fuel, Emission and Exhaust System D
Page 113 and 114: Fuel, Emission and Exhaust System D
Page 115 and 116: Fuel, Emission and Exhaust System D
Page 117 and 118: f^ r^ P" 1 Jr*!> Fig. 31 Fuel, Emis
Page 119 and 120: f^ HÎ rm\ Pvf9| F/0. 34 Fuel, Emis
Page 121 and 122: 7^:5 r^ K ''-i f*f!*l SPECIFICATION
Page 123 and 124: D:05:02 Fuel, Emission and Exhaust
Page 125 and 126: D:05:04 Fuel, Emission and Exhaust
Page 127 and 128: Fig. 42 A purge valve located insid
Page 129 and 130: Fuel Emission and Exhaust System D:
Page 131 and 132: V Fuel Emission and Exhaust System
Page 133 and 134: t— ^ REMOVING Fuel, Emission and
Page 135 and 136: P"^ I I'f'M ~^"H «wi p v H GENERAL
Page 137 and 138: Fmr-i P7^> P pfff rfa^ iwSS( J Fig.
Page 139 and 140: pn fî r i tin*!) C*'"''-1 pfi^l n?
Page 141 and 142: ^T^H, ^ rrr^ • T?*!l REMOVAL Clut
Page 143 and 144: fF&H 0h BLEEDING SYSTEM 1. Top up c
Page 145 and 146: Note: Do not use any cleaning fluid
Page 147 and 148: CLUTCH PIPING The clutch pipe leadi
Page 149 and 150: 5fW| V "f»TJ - fr"h GENERAL DESCRI
Page 151 and 152: (TVS*) L I *W| M*J FFr^ff| GEAR RAT
Page 153 and 154: f •:' 1 Manual Transmission F:04:
Page 155 and 156: p"'4 /.•" iV-Ff r , ':'''^t TRANS
Page 157 and 158: Manual Transmission OVERHAULING TRA
Page 159 and 160: r r r r r r - r r r r r r r r r UNI
Page 161 and 162: 1 r p*^ fr^) fiFrtr) 28. Clean the
Page 163: r r r • - r r r r r Fig 26 Fig. 2
Page 167 and 168: Manual Transmission F:06:11 5. Remo
Page 169 and 170: CONTROLS DESCRIPTION AND OPERATION
Page 171 and 172: - r r r r Automatic Transmission CO
Page 173 and 174: G:01:02 Automatic Transmission achi
Page 175 and 176: G:02:02 Automatic Transmission LOCA
Page 177 and 178: DIAGNOSIS PROCEDURE 1. Road test th
Page 179 and 180: FAULTS ENGINE STALLS UNEVEN IDLING
Page 181 and 182: Automatic Transmission G:05:01 CHEC
Page 183 and 184: Automatic Transmission G:05:03 / h
Page 185 and 186: 5. Remove the solenoid mounting bol
Page 187 and 188: G:06:04 Automatic Transmission 8. R
Page 189 and 190: ' r v 1. Disconnect the negative ba
Page 191 and 192: r i r r i r - • r j r r r i r r /
Page 193 and 194: fT
Page 195 and 196: JWî !'••-'• f '^\ 7*$5 wm, r
Page 197 and 198: M pTÎ TRANSMISSION UNIT DISASSEMBL
Page 199 and 200: i f^) irm] 1 L /BTO BRAKE B-1 - Fig
Page 201 and 202: i ' M p77iT| F0*t\ |f^'^T\ Fig. 50
Page 203 and 204: r Fig. 57 C-1 PISTON SEALS Fig. 55
Page 205 and 206: r r / V Fig. 60 Automatic Transmiss
Page 207 and 208: v FINAL DRIVE DISASSEMBLY Automatic
Page 209 and 210: r r Automatic Transmission G:09:03
Page 211 and 212: ^ r \ Automatic Transmission G .09:
Page 213 and 214: J Fig. 78 SIDE GEAR TOOL Reassembly
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Automatic Transmission G:09:09 3. F
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fj*«r |" CONTENTS ft**? j GENERAL
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FW\ Location Lower column to univer
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H:03:02 Steering 5. Position and se
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REMOVAL - Fig. 7 1. Raise luggage c
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REMOVAL 1. Remove rack and previous
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Front Suspension J:01:01 GENERAL DE
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REMOVAL 1. Raise car on hoist. 2. R
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REMOVAL 1. Raise car on hoist. 2. R
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J REMOVAL 1. Raise car on hoist. 2.
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~ J REMOVAL Front Suspension J:08:0
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r r r r J REMOVAL 1 Raise car on ho
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REMOVAL 1. Raise car on hoist, and
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Contents GENERAL DESCRIPTION K.01.0
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r r K:01:02 Rear Suspension
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;v?f?*) REMOVAL 1. Raise car on hoi
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REMOVAL Rear Suspension 1. Raise ca
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REMOVAL 1. Raise car on hoist. TRAI
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' 1. Check rear wheels for rim run
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r i r r r r r r I r r r r r I V* RE
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i-rw-] r r The vehicle is equipped
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T^M- w^ ••rrrr] J 1 ""?^ t ; -'
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Brakes, Wheels and Tyres 10. 11. Br
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installed. If the cylinder bore is
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I r REMOVAL 1. Remove brake disc pa
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jpffi pTI^ #6§ n*wi REMOVAL-Fig. 9
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BRAKE MASTER CYLINDER/FLUID RESERVO
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Automatic transmission only, Instal
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r r r r r r i r r r Brakes, Wheels
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1.1^-1 pwrî jfrn^t ?TW$ r |!$P*I W
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'^WJ) p*sq pfl*V I The ignition sys
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J Electrical System and Instruments
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REMOVING - Fig. 7 DISCONNECT BATTER
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•jTv^ -ft'MWl rp9r\ REMOVING THE
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I r r r r r r r r r r r r r r r r r
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REMOVING - Fig. 17 1. Disconnect Ba
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REMOVING THE DIODE CARRIER - Fig. 1
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PF*1 f$&8) H*pi} T^JW) f^M MBQ) 1.
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M:05:02 Electrical System and Instr
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M :05:04 Electrical System and Inst
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State-of-Charge (Example) A complet
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X23C83U43 :C3H8C93!L153 JC4D1L10X16
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HORNS - Fig. 32 Twin high and low t
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i FÎ f Electrical System and Instr
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HEAD LAMP UNIT REMOVING - REFITTING
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Electrical System and Instruments J
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*TO| fW^ SIDE/HEADLAMP SWITCH REMOV
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PT5 |VfW) pr^ rfTWi Electrical Syst
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pwj fW\ nm?i ffWKTi F^*i ITl*fl) ->
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r Electrical System and Instruments
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r Electrical System and Instruments
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j .f?
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ffiytxy . J jffS^ Electrical System
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P 1 "^ IW'I r J f— V Electrical S
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|HW\ ^•r^n r^*i ^ Electrical Syst
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j •"fW'-wl . p^£\ I J Electrical
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j 1 :^' 1 ;! [fP*fl" "•y&i J Elec
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P'fTTB! '•5*TT) Electrical System
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i"^5r^ |WW| Electrical pw| L I \ I
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•wi »-;,^) J Electrical System a
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Pf*5j f^\ ,^wv 1 J fWW( JIM) p*B^ E
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p^?i jlfaj \vvtfl ffWrft J Electric
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I > P Heating and Air Conditioning
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The layout of the heater/air condit
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The temperature control should be t
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N:01:06 Heating and Air Conditionin
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v Heating and Air Conditioning SPEC
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Heating and Air Conditioning N:02:0
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N .03:02 Heating and Air Conditioni
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v Heating and Air Conditioning Air
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J Heating and Air Conditioning N:05
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J REMOVING HEATER/AIR CONDITIONING
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u a n ALL DIMENSIONS REFER TO WRENC
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Heating and Air Conditioning IM:08:
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J Heating and Air Conditioning N .0
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Heating and Air Conditioning ;3^\»
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J INSTALLING COMPRESSOR Heating and
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J 1 2 3 4 i 5 i 1 ! ! 1 ! ! I ; i i
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J Heating and Air Conditioning 3. D
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Heating and Air Conditioning N .08:
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NOT ENOUGH COOLING Move temperature
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The preceding Trouble Shooting Char
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Heating and Air Conditioning N:10:0
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Heating and Air Conditioning Step 6
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JTffi^ J Heating and Air Conditioni
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f: :' ! .-^.*VJ ^ J Heating and Air
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aî Fnff&J Ff^\ J CONTENTS GLASS RE
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STANDARD SECTIONAL REPAIR MOULDINGS
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(3) When completely cured, drill a
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FRONT FENDER, LEFT OR RIGHT - Rg. 1
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4. Install four screws securing rea
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2. Before fitting replacement, chec
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3. Mark angular position of torsion
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3. Remove handle and disconnect rel
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9. Move the interior locking contro
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3. Remove nut securing cable housin
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REAR WINDOW SUNSHADE LOUVRE Removal
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13. Position and secure front grill
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POWER WINDOW REGULATOR ASSEMBLY Rem
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" FIXED DOOR GLASS If replacement f
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j CONSOLE - Fig. 14 Removal 1. Disc
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J 6. Install either the left door p
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l» J CONTENTS GENERAL DESCRIPTION
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L ^ Chassis R:02:01 DIMENSIONS )
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A B C D E F G H 1 J K L M N 0 P 255
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• • ' ~ T »
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