Delorean DMC Instruction manual

DELOREAN
WORKSHOP
MANUAL
PJ. GRADYINC.[phone](800)350-7429FAX[phone]
J

I
r
r
r
r
r
r
r
r
PJ.GRADYINC.[phone](800)350-7429FAX[phone]

r
r
r
r
•
i
r
I
r
r
I
DELOREAN
WORKSHOP
MANUAL
PanNo. 113096
I
Issuedby:
TechnicalPublicationsDepartment
DeLoreanMotorCars(1982)Ltd.
DunmurryIndustrial Estate
DUNMURRY, Co.Antrim
N.Ireland,BT179JJ
Copyright Reserved

I
I FOREWORD
r
r
r
r
EverypossiblecareistakenduringthemanufactureofDeLorean
carstoensuretheyleavethe faciory capableofgiving many
milesoftroublefree motoring. Properservicingisabsolutely
essentialifsatisfactoryperformanceistobemaintained.
_ IndexingSystem
The various unitsandsystemsofthe vehides aredealtwithin
sectionsdesignatedbya letter.This is furtherdividedinto
subsectionswhichareidentifiedbya numberanda pagenumber
withinthesubsections.
Pag*
A:01:12
Subsection
r
i
Eachsectionopenswitha contentsandinaexpagesothatany
particularoperationmaybeeasilyreferredto.
F
I
I
I
I
r
GeneralData
Comprehensive informaiion regarding dimensions tolerancesand
weightsaregivenatthebeginningof The manualandatthestart
ofeachsection.Dimensicnsaregiveninbothmetricandimperial
units.

SERVICEORGANISATION
Anycommunicationrelatingtoa DeLoreancarshouldstatethe
VehicleIdentificationNumber (VIN) whichcanbefoundby
lookingthroughthedriver'ssideofthewindshield,oronthe
driver'ssidedoorshut.
DELOREANGENUINEPARTS
DeLoreangenuinepartsareidenticaltothehighqualityfactory
partsinstalledinnewDeLoreancars.
•
-
In ordertoprovidethebestpossibleserviceforowners,the
dealerorganisationthroughouttheworldforma linkbetweenthe
ownerandfactory.Allproblemsrelatedtotheservicingand
repairofcarsaredealtwiththroughthatorganisation.
DealershavethebackingoftheNationalDistributorandthe
factoryServiceDepartment. ]
1
1
1
1
1

r
F
r
r
r
r
r
r
r
DELOREANSPECIALTOOLS
Certainserviceoperationsaremadeeasierbytheuseofspecially
designedtoolsmanufacturedbyKentMooreLtd.
ThesetoolsareessentialtoachievetheFlatRate(ManHour
Schedule)Timesapprovedbythefactory.
Theuseofthetoolsisdescribedundertheappropriatesections
andtherelevanttoolsarelistedatthebeginningofeachsection.
r

•
i
GENERALSAFETYHINTS
1. Usethecorrectspannerordriverforallfastening.Whenfitting
newfasteningsensurethethreadsizeiscorrect.Metric
fasteningsarepredominantly,butnotexclusivelyused.—
2. Neverwalkundera carunlessitisproperlysupportedbystands.
3.Makesurejacksorstandsarepositionedsafelyandwherethey
willnotcausedamagetothecar.
4. Alwaysdisconnectthebatterybeforeworkingonelectrical
componentsorwiring.
5.Whenworkingintheenginecompartmentorunderthecarmake—
suretheenginecannotbestartedaccidentally.
6.Keephandsandclothingclearofelectricallyoperatedfanseven —
whentheignitionisOFF.
7.Takecarenottoinhaledustfrombrakepads— it contains
asbestoswhich is a healthhazard.
I
8.Treatgasoline(petrol) with greatrespect— avoidanysortof
sparkorflame.Donotstartsyphoningbymouth;drainfuel into
aclosedcontainer.
LEGISLATIONREQUIREMENTS
Mostcountrieshavestringentregulationsgoverningthedesignand
manufactureofcars,aimedmainlyatmaintainingstandardsof
safety,noiseandpollution.DeLoreancarsconformtothe
homologationspecificationsrequiredinthecountriestowhichthey
aredistributed.
Alterationstothecarafterpurchase— bychangingsettingsor
adjustments,byadditionofunapprovedparts,orthefittingof
unsuitablereplacementparts— canresultindeviationfromthe
agreedspecification.Suchdeviationscanhavelegalconsequences
andyouarethereforeadvisednottomakealterationsandtoensure
thatreplacementpartsaretotheoriginalspecification.
SPECIFICATIONCHANGES
1
1
1
1
1
1
TheCompanyreservestherighttochangethespecificationofthe
carfromtimetotimewithoutnotice.
ThisisrequiredinordertoachievetheCompany'sobjectivefor
constantimprovement.Beforecarryingoutanyrepairrefertolatest
issueoftheServiceBulletins,whicharedesignedtoadviseany _.
changesinspecificationorrepairtechnique.

I
p,
n^
L J
RT^I
'-
i
p;
r
^
_
f
W
:
f
n^
CONTENTS
GENERALDATA
FUELTANK .
ENGINE'
FUELEMISSIONANDEXHAUSTSYSTEM
CLUTCH
MANUALTRANSMISSION
AUTOMATICTRANSMISSION....
STEERING
;
FRONTSUSPENSION
REARSUSPENSION
BRAKES,WHEELSANDTYRES....
ELECTRICALSYSTEMANDINSTRUMENTS.
jjjHEATING ANDAIRCONDITIONING.
BODY....
SUB-DIVIDED INTOTHE FOLLOWING:^
•GLASSREINFORCED PLASTIC (G.R.P.)
.,- • STAINLESSSTEEL ^
•INTERIOR /-''*,
CHASSIS . . . S . ....
SECTION
A
B
C
D
E
F
G
H
J
K
L
M
N
P
. R
a
.;;:„:-,
f^l

r
•
r
GeneralData
•
r
r
r
r
CONTENTS
VEHICLESPECIFICATIONDATA
ENGINETUNINGDATA
TORQUE
DIMENSIONS - GENERAL
RECOMMENDEDLUBRICANTS,FLUIDSAND
CAPACITIES
DMCMAINTENANCE
PRE-DELIVERYINSPECTION
LABELIDENTIFICATION
A:01:01
A:02:01
A:03:01
A:04:01
A:05:01
A:06:01
A:07:01
A:08:01

I
r
I
•
•
•
i
r
r
i
GeneralData A:01:01
ENGINE
Numberofcylinders.
Boreofcylinders.
Strokeofcrankshaft.
Enginecapacity
Compressionratio.
Maximumpoweroutput
Maximumtorque.
COOLINGSYSTEM
Type
Startstoopenat. .
Fullyopenat
Circulation....
Fans
VEHICLESPECIFICATIONDATA
V6
91mm(3.58in.)
73mm(2.87in.)
2849cc(173.86cu.in.
8.8:1
FUELSYSTEM
MakeType.
Pump....
FuelFilter
LinePressure
Injectorsopenat
Restpressure
Controlpressure
Minimumoutput
IGNITIONSYSTEM
Type
RotationofDistributor
Firingorder....
Ignition Timing
SparkAdvance— Vacuum
-FUELINJECTION
'
130B.H.P. I.S.O. at5,550R.P.M.on
91OctaneFuel(unleaded)
208 Nm (153ft.lbs.)at2750R.P.M.
Positivepressureclosedsystem
85°-89°C(185°-192°F)
100°C(212°F)
Impellortypepump,thermostaticallycontrolled
Electricallyoperated twin, thermostaticaliv
controlled
BoschK Jetroniccontinuousinjection
Electric— immersedinfueltank
Paper with nylongauze
4.8to5.0bar (70 to72 Ib./sq. in.)
3.5to4.1bar(51to59lb.sq. in.)
2.95bar(42.77 Ib./sq. in.)
4.9bar(71.05 Ib./sq. in.)
120 litres/hour. 32U.S.gallonshour
Bosch(Electroniccontactless)
Clockwise— viewedfromtopofrotorarm
1-6-3-5-2-4
13°± 2°B.T.D.C.at750± 50R.P.M.
5in.hg.= 3°
10 in.hg.= 12°
15in.hg.= 20°

A:01:02
IGNITIONSYSTEM(Contd.)
SparkAdvance— Mechanical
GeneralData
1000R.P.M.
2000R.P.M.
3000R.P.M.
4000R.P.M.
=0°
= 10°
=14°
=20°
mm
i
i
ELECTRICALDATA
System12v A C Delco FreedomII
3anery 12v 75AHMaintenancefree
Aiternator Ducellier80Ampoutputor
Motorola90Ampoutput
AUTOMATICTRANSMISSION. . TYPE4141
Ratios:1st2.40
2nd1.48
-3rd 1.00
Reverse 1-92
MANUALTRANSMISSIONTYPE369
Ratios:1st3.36
2nd'V 2.06
3rd1.38
4th1.06
5th0.82
Reverse3.18
WHEELSANDTYRES ;,~j/> ["-' "•'
Wheelstype >il; • • • • ' '• Cast->r1§^%iloy"•' ••£<
Size: Front...... ? 14"x 6W (35/7 mm,x 152mm)
Rear15"x 8" (381 -p| 203mm)
Spare15"x 4"(381mmx 102mm)
TyrestypeGoodyearNCTsteelbeltedradial
Size: Front195/60HR14
Rear235/60HT15
SpareT125/70D 15
torn
W\v
fJ':\
r"ii;i''|

m^p
f
GeneralData
V.
STEERING
Type. .
Turningcircle....
Wheelturns(locktolock)
A:01:03
RackandPinionwithadjustablecollapsible
column
13.20meters(43ft.)
2.4
rmq
STEERINGGEOMETRY
Tow-ln
CasterAngle
CamberAngle
KingPinInclination. .
3mm(0.12)perwheel
3 % ° to4°Positive
0°to Vi° Negative(NonAdjustable)
6°+
1/2°
- 0°(NonAdjustable)
BRAKES
Type
DiscDiameter:Front
Rear
Powerassisted— Discsfrontandrear
254mm(10in.)
275mm (10% in.)
SUSPENSION
Front....
Rear
Unequallengthupperandlowercontrol arms,
coilsprings,telescopicshockabsorbersand
stabilizerbar.
Diagonaltrailingradiusarmswithupperand
lowerlinks,coilspringswithtelescopicshock
absorbers.
I'Ml?
f^
HEATINGAND A/C
CHASSIS/BODY
Orificetubetypeelectricallyoperated clutch
recycling.
Epoxycoatedsteel backbone chassis,reinforced
glassfibreunderbody,grade304stainlesssteel
bodypanels.
L
!
i

GeneralData A:02:01
ENGINETUNINGDATA
,[:••• -j
Idle Speed775R.P.M.± 50R.P.M.
CO. readingat950 R.P.M 1%± 0.3%
Valveclearance(cold):
Inlet 0.10-0.15 mm (0.004" -0.006")
Exhaust0.25-0.30mm(0.010"-0.012")
ValveTimingLHRH
Inlet opensB.T.D.C. 9° 7°
closesA.B.D.C.45°43°
ExhaustopensB.B.D.C.45°43°
closesA.T.D.C.9°7°
SPARKPLUGS
TypeBoschHR6 DS
Gap0.6-0.7mm(0.024"-0.028")
Torque 17-20 Nm (13- 15 ft./lbs.)
F'~]
i"-^'\
P"1
\' i?l
fi^j

GeneralData A:03:01
DESCRIPTION
CHASSIS:
FuelTankCoverPlate
FuelTankFront
-
HornBracketAttachment
RadiatorMountingBracketTO
Frame
HorntoBracket
RadiatorStayBrackettoFrame
l
' REARSUSPENSION:
TrailingArmBushAttachment
LowerLinkBothEnds
Upper Link BothEnds
TrailingArmHubtoCarrier
r— OuterDriveShafttoHub
TravellingArmtoPivotBush
ShafttoInnerandOuterDrive
| Shafts
i
ParkingBrakeCableBracketto
HubCarrier
Caliper— HubCarrier
FlexBrakePipeAttachment
Wheels
TORQUE
16lb.ft.- 22 Nm
8lb.ft.- 11Nm
8lb.ft.- 11Nm
16lb.ft.- 22Nm
REMARKS
8lb.ft- 11Nm
3lb.ft.- 5 Nm
16 lb ft.- 22Nm
INNER-OUTERINNER-OUTER !
60 lb. ft.-42 lb.ft. 80Nm-64Nm
60 lb. ft.-42 lb.ft. 80Nm-64Nm |
75lb.ft.- 55NmI
l
270lb.ft.- 370Nm
42lb.ft.- 64Nm
30 lb. ft.- 40Nm
51/? lb.ft.- 7 Nm
40lb.ft.- 55Nm
12lb.ft.- 16Nm
60lb.ft.- 80Nm
•
f

A:03:02 GeneralData
DESCRIPTION
TRANSMISSIONAND
FINALDRIVE:
DrainandFillPlugs
Mounts8 mm
10mm
TRANSMISSIONSHIFT
LINKAGE:
AutoandManualRelayPivot
Bolts
FRONTSUSPENSION:
CalipertoMountingBracket
DustShield
FrontDisctoHub
i
iStubAxletoSteeringKnuckle
HubBearingtoStubShaft
UpperControlArmPivotBolt
LowerControlArmPivotBolt
ShockAbsorber(Upper)
ShockAbsorber(Lower)
StabilizerBar— Lower
ControlArm
StabilizerBarPivot(onChassis)
I
FlexBrakePipeAttachment
UpperBallJointtoSteering
Knuckle
LowerBallJointtoSteering
Knuckle
BodytoChassis
FixingBolts
TORQUE
15lb.ft.- 20Nm
18lb.ft.- 25Nm
2636
16lb.ft.- 22Nm
55lb.ft.- 75Nm
20lb.ft.- 28Nm
20lb.ft.- 28Nm
165 lb. ft.- 220Nm
145lb.ft.- 190Nm
60lb.ft.- 80Nm
60lb.ft.- 80Nm
20lb.ft.- 28Nm
60lb.ft.- 80Nm
INNER-OUTERINNER-OUTER
44lb. ft.-68lb. ft. 60Nm-90Nm
26lb.ft.- 36 Nm
12 1b. ft.- 16 Nm:0.
35lb.ft.- 50 Nm
35lb.ft.- 50Nm
23lb.ft.- 35Nm
23lb.ft.- 35Nm
REMARKS
i
Assemblewith Loctite 501\
|
I
1
;;';;• >0-'
1
>'•'•'">
pm

\^
p^
i
ffyF*S
r
GeneralData A:03:03
DESCRIPTION
ENGINE:
EngineMounts
A/CCompressorBrackettoEngine
HeatShieldstoExhaustCrossover
ExhaustCrossoverPipetoManifold
U'BoltCatalysttoMuffler
MufflerSupportBracketonEngine
MufflerRubberMounts
BRAKELINES:
"T" ConnectionstoFrame
FlexPipetoFrame
LineUnionthroughFrame
RADIATOR:
FanCowltoRadiator
STEERINGUNITS:
LowerColumntoUniversalJointto
RackPinionandUpperColumn
TieRodtoSteeringKnuckle
TieRodtoLockNut
SteeringRackAssemblytoFrame
TORQUE
18lb.ft.- 25Nm
12lb.ft.- 16Nm
8lb.ft.- 11Nm
30lb.ft.- 40Nm
11lb.ft.- 15Nm
16lb.ft.- 22Nm
22lb.ft.- 30Nm
8lb.ft.- 11Nm
8lb.ft.- 11Nm
16lb.ft.- 22Nm
12lb.ft.- 16Nm
12lb.ft.- 16Nm
5lb.ft.- 7 Nm
8lb.ft.- 11Nm
16lb.ft.- 22Nm
26 lb; ft.- 36Nm
48lb.ft.- 65Nm
18lb.ft.- 24Nm
REMARKS
!
/fify
f*3^

A:03:04 GeneralData
J
TORQUEFIGURES
ENGINE
CylinderHeadTightening
NewCylinderHeadGasket.Torquetightento45lb.ft.— 61 Nm. Slackenoff,pre-tightento
15lb.ft.- 20NmandthenAngulartighten 115°.
Re-tighten CylinderHead.Slackenoff, pre-tighten to15lb.ft.— 20NmandthenAngulartighten 115c
TighteningmainbearingCapNuts:Pre-tightento20lb.ft.— 27NmandthenAngulartighten75°.
DESCRIPTION
BigEndCapNuts
FlywheelFixing Bolts
ConverterDrivingPlateBolts
SumpFixingBolts
Crankshaft PulleyFixing
OilPumpSprocketBolts
ChainTensionerBladeBolts
TimingCoverFixingBolts
CamshaftSprocketFixingBolts
CamshaftPulleyFixing Bolts
CamshaftSprocketAccessPlug
InletManifoldFixingBolts
TaperSeatSparkPlug(NoWasher)
TORQUE REMARKS
34lb.ft.- 46Nm
I !
42lb.ft.- 58Nm| WithLoctite601 •
I
49lb.ft.- 66Nm
11V4 lb.ft.- 16Nm
135lb.ft.- 183Nm
4lb.ft.- 6 Nm
11lb.ft.- 15Nm
11lb.ft.- 15Nm
55lb. ft. - 75Nm
74 Ib.'ftv- 100Nm
22 lb.ft. -430Nm
9lb.ft.- 14Nm ".
14lb.ft.- 18,Nm
WithLoctite601
WithLoctite601
BottomboltswithLoctite601
1
f'**"]
,^ff^
<r~'
l

GeneralData A.-03.-05
MANUALTRANSMISSION
1
DESCRIPTION
HalfCasingBolts8 mm
Diameter10mm
RearCoverFixingBolts8 mm
Diameter10mm
ClutchHousingFixing Bolts
ReverseGearSelectorBolts
i
I CrownWheelFixing Bolts
SecondaryShaftSpeedoWorm
i
i
| BearingPlateBolts
i
i
PrimaryShaftNut
TORQUE
22% lb.ft.- 31 Nm
37lb.ft.- 50Nm
18lb.ft.- 25Nm
37 lb. ft.- 50Nm
37lb.ft.- 50Nm
26lb.ft.- 35Nm
100lb.ft.- 130Nm
REMARKS
105lb.ft.- 135Nmj
37lb.ft.- 50Nm
105lb.ft.- 135Nm I
I
AUTOMATICTRANSMISSION
jffr^
DESCRIPTION
OutputShaft(PlanetWheelCarrier)Nut
HalfCasingAssy.Bolts8 mmDia.
HalfCasingAssy.Bolts10mmDia.
FinalDrivePinionNut
F2BrakeBolts
StatorSupportFixingBolts
ConverterCasingtoFinalDriveCasing
FixingBolts
HydraulicDistributorFixingBolts
CrownWheelFixing Bolts
TORQUE
145 lb. ft.- 195Nm
22% lb.ft.- 31Nm
32lb.ft,- 44Nm
170 1b. ft.- 230Nm
11lb.ft.- 15Nm
24lb.ft.- 33Nm
32lb.ft.- 44Nm
7%lb.ft.- 10Nm
100lb.ft.- 130Nm
REMARKS
i

GeneralData A:04:01
DIMENSIONS - GENERAL
A— OverallLength
B— WheelBase
C— Height(DoorOpen)
D— Height(DoorClosed)
E- Width
F— Track— Front
G— Track— Rear
H— GroundClearance— Front
J— GroundClearance— Rear
M :
• if^mJhes
is ;166:oo
95.00 .
77.20
< 44.90
73.10
62.60
62.80
5.60
6.10
Millimetres
4213
2410
1962:
1140
1856
1590
1594
142
155
^•;n
A']
p. j
r';V'>,
F^j

GeneralData A:05:01
RECOMMENDEDLUBRICANTS,FLUIDSANDCAPACITIES
UNIT
ENGINE
ANDFILTER
U.S.
GALLONS
1.72
1.78
CAPACITY
U.K.
PINTS
11.4
11.8
I
1
LITRES
6.5
6.75
GRADE
15W 40
20W 40ABOVE- 10°C H4°Fi
20W 50
15 W 40
•10W 30BELOW- 10°C 14°F'
5W 20
*T'HE USEOF 10 W 30 MUL~: GRADEOILIS \C ADVISABLEUNLESS
THE
TEMPERATUREWARRANTS
HOWEVER IF A 10W 30 MULTI-GRAOE OILS USED TOASSISTSTARTINGINCOLD WEA~HE=
TMAYREMAIN IN THE SUMP ASLONG AS*Ht'EMPERATURE DOES NOT RISEABOVE- -C°C
MANUALGEARBOX
(INCLUDESFINALDRIVE) 0.97 5.5 3.7TOMEETSPEC
MIL - L 2105COR
!API- GL5
*SAE 75WBELOW- 10CCH4°F1
SAE80WABOVE- i0°C14°F1
•WHERE SAE ^5W OIL IS NCT AVAILABLE SAEBOWOIL MAY BE USE!
FINALDRIVEAUTOMATIC 0.42 2.6 1 5 SAE80W
\
MIL- L 2105C
APIGL5
AUTOMATICTRANSMISSION
(CONVERTER) 1.5710.5
5.0 ATFTYPEDEXTRON 11
ELFRENAULT MATIC D2OR
MOBILATE220
BRAKECIRCUIT 0.764 DOT4
I
COOLINGSYSTEM 2.919.3711.0ETHYLENGLYCOLBASED
j (CONTAININGNOBORAX).
MINIMUM5050MIXTUREWITH
WATER
!TOBEUSEDALLYEARROUND
ANDREPLACEDANNUALLY
CLUTCHCIRCUIT
WINDSHIELDWASHER
RESERVOIR
AIRCONDITIONING
REFRIGERANTOIL
FUELTANK
WHEELBEARINGS
STEERINGRACK
.66
9
I
i
2.50
POUNDS
13.5
0.3U.S.
PINT
11.5IMP.
GALLONS
.26
0.378
DOT4
5.5
1.40
GRAMMES
51.6
0.15
SUNISO5GSORTEXACO
CARPELLA'E'OREQUIVALENT
R-12 - FREONORARCTON
91OCTANE(UNLEADED)
SEALEDFORLIFE
APISERVICEGL-5
(SAE- EP90)