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SERVICE BULLETINNUMBER SC-01-1/82 |
CATEGORY: SAFETY CAMPAIGN
ATTENTION: ALL DMC DEALERS/SERVICE MANAGERS
SUBJECT: SAFETY CAMPAIGN NO. RA-0002
THROTTLE CABLE ASSEMBLY
DMC is initiating the above referenced campaign because it has
been determined that a safety problem exists due to potential
cable icing and/or binding.
Enclosed please find:
1. A copy of the notification letter sent to all
De Lorean owners, dated January 21, 1982.
2. Repair and reimbursement instructions.
Parts Supply
A supply of parts, determined by the number of cars DMC shipped
to you, is being shipped free of charge for arrival starting
January 25, 1982.
V.I.N. Listing
A listing of vehicles assigned to your dealership for repair
and follow up showing V.I.N. numbers, owners' names, and
addresses will be mailed to you.
William A. Charles
Director, Service/Parts
WAC:ak
Attachments
Issued 1/20/82
IMPORTANT SAFETY RECALL NOTICE TO ALL DE LOREAN OWNERS: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. De Lorean Motor Company has determined that a defect which relates to motor vehicle safety exists in the throttle linkage of 1981 De Lorean vehicles. In very cold weather, moisture may enter the throttle cable housing and freeze inside it, possibly resulting in throttle sticking. In addition, if there is insufficient slack in the throttle cable in the engine compartment, the cable may bind, preventing the throttle from closing completely to the idle position. If moisture inside the cable housing freezes, you will notice that the throttle tends to return to the idle position more slowly than usual or remains fixed in position. This condition may occur either when the car has been left overnight or while the car is being driven in freezing weather. If you notice that the throttle returns to the idle position too slowly, or if it operates and returns normally but fails to close entirely to the idle position, stop the car or proceed with extreme caution to the nearest De Lorean dealer. If the throttle remains fixed on any position, stop the car (if necessary, turn off the ignition key but to not remove it while the car is still in motion) and notify the nearest De Lorean dealer. Failure to heed these warnings can result in vehicle crash or loss of control. De Lorean Motor Company will correct the defect without charge by repair of the throttle linkage at any authorized De Lorean dealer. The estimated repair labor time is less than one hour. Dealers will receive necessary parts and instructions by January 27, 1982. If you are not satisfied with the service you receive, or if you no longer own your De Lorean, please notify us immediately. Call 800-854-3088 (in California, call 800-432-2282), toll-free. If you believe that DMC or your dealer has failed or is unable to perform this work without charge or within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Adminis- tration, Washington, D. C. 20590, or you may call the toll free Auto Safety Hotline at 800-424-9393 (Washington, D.C. area residents call 426-0123). Sincerely, RA-0002 DE LOREAN MOTOR COMPANY 1/21/82 IMPORTANT - SEE OTHER SIDE
IMPORTANT - SAFETY RECALL NOTICE SUPPLEMENT READ CAREFULLY TO ALL DE LOREAN OWNERS: In mid-November, you received a notice from De Lorean Motor Company (DMC) concerning a safety defect in the front suspension of 1981 De Lorean vehicles. DMC had determined that the nuts fastening the stabilizer bar to the lower link and the lower ball joints to the lower link might become loose, possibly resulting in detachment of the stabilizer bar or lower ball joints. Many of you have had your cars repaired by now. In pre-installation inspections, however, DMC has recently discovered that some of the replacement nuts used on the ball joints (not on the stabilizer bar) in this safety recall campaign have been cracked. DMC has decided to replace all of this type of nut with new nuts to insure that no problems occur. There is no evidence that the nuts will crack in use. Even if the nuts were cracked at the time of installation, or if they crack in use, there is no evidence that they will detach from the ball joints or that there will be any loss of vehicle control. De Lorean Motor Company will replace these nuts, augment supporting brackets on the stabilizer bar and inspect it without charge at any authorized De Lorean dealer. The estimated repair time is less than one hour. Contact your dealer immediately to arrange an appointment. Dealers will receive the necessary parts and instructions by January 27, 1982. If you are not satisfied with the service you receive, or if you no longer own your De Lorean, please notify us immediately. Call 800-854-3088 (in California, call 800-432-2282), toll-free. If you believe that DMC or your dealer has failed or is unable to perform this work without charge or within a reasonable time, you may submit a complaint to the Administrator, National Highway Traffic Safety Adminis- tration, Washington, D. C. 20590, or you may call the toll free Auto Safety Hotline at 800-424-9393 (Washington, D.C. area residents call 426-0123). Sincerely, RA-0001 #81V-138 DE LOREAN MOTOR COMPANY 1/21/82 IMPORTANT - SEE OTHER SIDE
Campaign - RA-0002
Procedure - Page 1
THROTTLE CABLE MODIFICATION
1. Allow the throttle cable to thaw.
2. Remove the air cleaner assembly and disconnect the throttle cable
from the threaded adjuster. At the accelerator pedal, pull the
cable through the cable housing leaving one inch of cable extend-
ing from the housing in the engine compartment.
3. Route the throttle cable and housing assembly over its mounting
bracket. There should only be enough slack in the cable assembly
to allow the cable housing to reach from the engine compartment
bulkhead grommet to the return spring stop post. Cable housing
length must be measured with the cable housing taut. Adjust the
cable assembly length at the bulkhead grommet if necessary.
NOTE: If this cable assembly will not reach the return spring
stop post and this length is less than 550 mm (23 inches)
replace cable assembly.
4. Protect the carpet under the pedal box assembly with shop towels.
5. Fit a suitable length of rubber hose onto the cable housing with
the other end fitted to a pump type oil can filled with a 55/45
mixture (ethylene-glycol/water) anti-freeze solution. Ensure
a tight fit at both ends of the rubber hose.
6. Pump the anti-freeze solution through the cable housing until it
exits at the accelerator pedal connection in a steady flow.
7. Pack the throttle cable threaded adjuster with Dow Corning Molykote
#33 (medium weight) and reinstall the cable housing into its
threaded adjuster (Figure 2).
8. Attach the cable plate and clip assembly (plate P/N 109267 &
clip P/N SP10881) with the existing valve cover bolt at position
shown in Figure 1. Ensure the cable clamp fits tightly to the
cable housing and exerts cable housing pressure toward the
threaded adjuster.
Campaign - RA-0002
Procedure - Page 2
9. Install the supplied seal (P/N 111183) on the throttle adjuster
as shown in Figure 2.
NOTE: Warming the seal may make fitting it to the threaded adjuster
easier.
10. Remove the outer throttle return spring. On cars equipped with
automatic transmissions as illustrated in Figure 2, it will be
necessary to remove "E" clip, bushing and plate.
Modify the outer return spring by taking the upper end of the
spring and passing it over the top and under the first coil.
(Figure 2)
Reinstall return spring and liberally lubricate the throttle
spool and return spring with WD-40.
11. Install the four (4) internal tooth spring clips supplied
(P/N SP10882) to groove in return spring stop post, as shown in
Figure 2.
12. Reinstall the throttle cable to the throttle spool and adjust.
Ensure the lower end of spring is placed under the spring clips
install in step 11.
13. With the throttle spool in full rest position the cable should be
taut but not influence throttle spool position.
14. To achieve the above condition loosen 8 mm cable retaining nut
located on the bottom of the throttle spool and pull on the
throttle cable end until taut. Retighten the nut.
NOTE: Fine adjustment can be achieved by adjusting cable
housing threaded adjuster.
Campaign - RA-0002
Procedure - Page 3
15. Check the full throttle position by depressing the accelerator
pedal to the floor. The throttle spool should touch the full
throttle boss. Ensure the smooth operation of the complete
throttle linkage mechanism from the pedal to the throttle plates.
16. Install the splash shield (P/N 111184) to the air inlet manifold
using existing bolt as shown in Figure 3. Ensure the installation
is firmly located and free from vibration.
17. Relocate the wiring harness away from edge of splash shield using
one of the harness retention clips as shown in Figure 3.
