DELOREAN WORKSHOP MANUAL - Free

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\ r - J Due to the material used in the construction of the body unit, cases of severe damage can be economically repaired. When determining which replacement mouldings are required, make sure the new sections will be attached to firm G.R.P. material, avoid badly grazed and badly burnt areas. Fire damage is the most difficult to assess but generally only the obviously burnt or charred sections will need to be replaced. Before cutting away the damaged parts or ordering replacement sections the method of repair, positioning of joint lines, overlaps, should be clearly defined and understood. BODY REPAIRS REQUIRE SPECIALISED KNOWLEDGE OF G.R.P. TECHNIQUES AND ON NO ACCOUNT SHOULD ANY REPAIR WORK BE CARRIED OUT BY AN INEXPERIENCED OPERATOR. METHOD 1. Cut off the damaged portion after marking for re-positioning of the new section. 2. Clean and prepare both existing and new section paying special attention to removal of all contamination. 3. Check, and if necessary, cut the new section to fit. Abraid the interior surface of the two parts to be joined up to 90 mm from the joint line, using a sander with a 50 grit disc or use the 50 grit by hand. Remove all surface shine to provide a key for the repair. 4. Mate the two parts to be joined using packing as necessary to achieve a perfect match. Joining plates (of angled section) should be attached (as required) to the exterior of the panel across the joint to hold the join together with the aid of self tapping screws. 5. Wash abraided surfaces with acetone or methylene chloride. Using chopped strand glass fibre mat of 1 % sq. ft. (450 g/m 2 ) weight together with pre-accelerated hand lay up polyester resin containing approximately 2% of Trigonox 51 Akzo Chemie (Acetyl Acetone Peroxide-Catalyst) lay up 3 layers of the glass mat wevon-wet to the abraided interior joint. 6. Stagger the three layers to overlap each side of the joint by 35 mm, 55 mm, 75 mm, respectively. Do not stray onto any unprepared areas. 7. Leave to cure (harden) in a temperature of not less than 15°C. When the repair has fully cured remove the joining plates from the exterior surface. Make good the exterior joint by filling with a Polyester body filler and add up to 5% black pigment. Allow to cure, sand down with carborundum paper to the original contour. 8. Where foam sections have been cut through the following technique should be used when bonding together: — 9. Before mating sections cut existing G.R.P. away to expose 100 mm of foam nearest the joint line. Completely remove exposed foam to reveal the inside surface of the G.R.P. to be bonded. Abraid this surface. The sections may now be mated and bonded together as described above. After bonding the foam is then replaced by free foaming in situ in the box formed by the repair using a Polyurethane Two Part Hand Mixed foam. When the foam has hardened cut back excess to original contour. 10. Laminate exposed foam with three layers of chopped strand mat and lap onto surrounding G.R.P. Prepare and laminate as described above. PREPARING OF REPLACEMENT SECTIONS REINFORCED WITH FOAM BEAMS In order to replace the foam section of the beam, the following procedure should be adopted. (1) Remove foam at least 2-3" (50-75 mm) from beam thus creating a cavity. (2) Bond in new panel as described above.
(3) When completely cured, drill a one inch diameter hole in the area to be refilled with foam on a horizontal face and refill with Polyurethane two part mix foam. (4) When the foam has completely cured, remove any excess foam from the area above the hole and finally seal with three (3) laminants of chopped mat and resin, then sand to contour. CAUTION: The Styrene fumes given off due to catalytic action are hazardous to health and also highly flammable. Therefore extreme caution should be taken when carrying out any G.R.P. repair. Goggles and protective clothing should be used at all times. In the event of Resin or catalyst entering the eyes, quick medical attention is essential. G.R.P. repairs must be carried out in a well ventilated area. The resins and catalysts must be stored in a cool area. i-.-vj ! 0 1 WBM 11'' j ( • 1
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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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f^ r^ P" 1 Jr*!> Fig. 31 Fuel, Emis
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f^ HÎ rm\ Pvf9| F/0. 34 Fuel, Emis
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7^:5 r^ K ''-i f*f!*l SPECIFICATION
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Fig. 42 A purge valve located insid
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Fuel Emission and Exhaust System D:
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V Fuel Emission and Exhaust System
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t— ^ REMOVING Fuel, Emission and
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P"^ I I'f'M ~^"H «wi p v H GENERAL
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Fmr-i P7^> P pfff rfa^ iwSS( J Fig.
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pn fî r i tin*!) C*'"''-1 pfi^l n?
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^T^H, ^ rrr^ • T?*!l REMOVAL Clut
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fF&H 0h BLEEDING SYSTEM 1. Top up c
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Note: Do not use any cleaning fluid
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CLUTCH PIPING The clutch pipe leadi
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5fW| V "f»TJ - fr"h GENERAL DESCRI
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(TVS*) L I *W| M*J FFr^ff| GEAR RAT
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f •:' 1 Manual Transmission F:04:
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p"'4 /.•" iV-Ff r , ':'''^t TRANS
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Manual Transmission OVERHAULING TRA
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r r r r r r - r r r r r r r r r UNI
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1 r p*^ fr^) fiFrtr) 28. Clean the
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r r r • - r r r r r Fig 26 Fig. 2
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r i r r r r r r r i r I DIFFERENTIA
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Manual Transmission F:06:11 5. Remo
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CONTROLS DESCRIPTION AND OPERATION
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- r r r r Automatic Transmission CO
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G:01:02 Automatic Transmission achi
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G:02:02 Automatic Transmission LOCA
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DIAGNOSIS PROCEDURE 1. Road test th
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FAULTS ENGINE STALLS UNEVEN IDLING
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Automatic Transmission G:05:01 CHEC
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Automatic Transmission G:05:03 / h
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5. Remove the solenoid mounting bol
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G:06:04 Automatic Transmission 8. R
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' r v 1. Disconnect the negative ba
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r i r r i r - • r j r r r i r r /
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fT
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JWî !'••-'• f '^\ 7*$5 wm, r
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M pTÎ TRANSMISSION UNIT DISASSEMBL
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i f^) irm] 1 L /BTO BRAKE B-1 - Fig
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i ' M p77iT| F0*t\ |f^'^T\ Fig. 50
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r Fig. 57 C-1 PISTON SEALS Fig. 55
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r r / V Fig. 60 Automatic Transmiss
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v FINAL DRIVE DISASSEMBLY Automatic
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r r Automatic Transmission G:09:03
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^ r \ Automatic Transmission G .09:
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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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N:01:08 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
Page 363 and 364: N .03:02 Heating and Air Conditioni
Page 365 and 366: v Heating and Air Conditioning Air
Page 367 and 368: J Heating and Air Conditioning N:05
Page 369 and 370: N:06:02 Heating and Air Conditionin
Page 371 and 372: J REMOVING HEATER/AIR CONDITIONING
Page 373 and 374: u a n ALL DIMENSIONS REFER TO WRENC
Page 375 and 376: Heating and Air Conditioning IM:08:
Page 379 and 380: J Heating and Air Conditioning N .0
Page 381 and 382: Heating and Air Conditioning ;3^\»
Page 383 and 384: J INSTALLING COMPRESSOR Heating and
Page 385 and 386: J 1 2 3 4 i 5 i 1 ! ! 1 ! ! I ; i i
Page 389 and 390: J Heating and Air Conditioning 3. D
Page 391 and 392: Heating and Air Conditioning N .08:
Page 393 and 394: NOT ENOUGH COOLING Move temperature
Page 395 and 396: N:09:04 Heating and Air Conditionin
Page 399 and 400: The preceding Trouble Shooting Char
Page 401 and 402: Heating and Air Conditioning N:10:0
Page 405 and 406: Heating and Air Conditioning Step 6
Page 407 and 408: JTffi^ J Heating and Air Conditioni
Page 409 and 410: f: :' ! .-^.*VJ ^ J Heating and Air
Page 411 and 412: aî Fnff&J Ff^\ J CONTENTS GLASS RE
Page 413: STANDARD SECTIONAL REPAIR MOULDINGS
Page 417 and 418: FRONT FENDER, LEFT OR RIGHT - Rg. 1
Page 419 and 420: 4. Install four screws securing rea
Page 421 and 422: 2. Before fitting replacement, chec
Page 423 and 424: 3. Mark angular position of torsion
Page 425 and 426: 3. Remove handle and disconnect rel
Page 427 and 428: 9. Move the interior locking contro
Page 429 and 430: 3. Remove nut securing cable housin
Page 431 and 432: REAR WINDOW SUNSHADE LOUVRE Removal
Page 433 and 434: 13. Position and secure front grill
Page 437: POWER WINDOW REGULATOR ASSEMBLY Rem
Page 440 and 441: " FIXED DOOR GLASS If replacement f
Page 442 and 443: j CONSOLE - Fig. 14 Removal 1. Disc
Page 444 and 445: J 6. Install either the left door p
Page 446 and 447: l» J CONTENTS GENERAL DESCRIPTION
Page 448 and 449: L ^ Chassis R:02:01 DIMENSIONS )
Page 450 and 451: A B C D E F G H 1 J K L M N 0 P 255
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