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SERVICE BULLETINNUMBER ST-03-2/82 |
CATEGORY: TECHNICAL
ATTENTION: ALL DEALERS/SERVICE MANAGERS
SUBJECT: REPAIR OF FRONT FRAME EXTENSION
In the event that the front frame extension of a De Lorean
is damaged in an accident the following repair procedure
has been established:
1. Empty the fuel tank.
2. Remove fuel pump inspection cover located under spare
tire and rollover valve inspection cover located in
rear left quarter of luggage compartment beneath fuel
filler cap.
3. Disconnect fuel lines from fuel pump, fuel filler hose
and vent hose from fuel tank.
4. Disconnect electrical connections to fuel pump and fuel
gauge.
5. Using appropriate equipment, evacuate the air-conditioning
system.
6. Raise the vehicle on a hoist.
7. Drain the coolant system.
8. Remove air ducting shroud between air dam and radiator.
9. Disconnect air-conditioning lines and coolant hoses from
radiator.
10. Disconnect wiring harness from coolant fans.
11. Remove right and left side radiator mounting brackets and
remove radiator, condenser and fan as a unit.
12. Remove fuel tank closing plate and fuel tank.
13. Undo lower steering rack u-joint, steering rack brackets
and tie rod ends and remove steering rack.
Continued...
Issued 2/8/82
ST-03-2/82
Page 2
14. Using a hole saw cut a 10 inch diameter hole in spare wheel
well. THIS WILL PROVIDE ACCESS TO TOP OF RIGHT OF FRAME
EXTENSION.
NOTE: Save the piece removed as it will be necessary to
replace it at a later time.
15. Using an air chisel, high rotary grinder or metal saw,
remove damaged frame impact extension.
NOTE: Do not use an oxyaccetylene torch.
Do not cut into parent metal.
16. Grind all surfaces to be welded flush with parent metal
allowing approximately 3/4 inch to 1 inch of clean metal
at points to be welded.
17. Attach alignment jig J-33229 loosely to front cross member
(See Figure 1).
ST-03-2/82
Page 3
18. Attach new front frame extension (Part No. 105289) to
alignment jig J-33229 (See Fig. 1). Tighten all fasteners
on alignment jig while simultaneously checking positioning
of frame extension to cross member.
19. Tack weld at all major contact points and remove jig.
Continue welding until all contact areas are joined. Allow
to cool.
20. Clean all bare metal surfaces and coat with corrosion
protective kit Part No. 109264/5. Allow to dry.
21. Reinstall all parts in reverse order. Replace section
removed from spare wheel well using a suitable fiberglass
repair kit.
NOTE: Prior to installing anti-roll bar clamps and
radiator mounting brackets, ensure that the
frame extension stiffeners are installed as
follows:
a. Using the bolts to hold the side of the radiator
bracket to the impact extension, install two (2)
strengthening brackets (Part Nos. 111140/111141)
to the impact extension loosely (See Fig. 2).
ST-03-2/82
Page 4
b. Install clamp spacer (Part No. 106960) and anti-roll
bar bracket (Part No. 108998) and spacers (Part
No. 111205) using bolt (Part No. 111204) coated with
Loctite 242. Torque to 35 NM (26 ft. lb.) (See Fig. 2).
c. Ensure radiator is positioned as far as possible to
the right of the vehicle before tightening the
radiator support bracket, side bolts and top bolts.
d. Tighten lower radiator mounting bolts.
21. Refill cooling system and pressure test.
22. Recharge air-conditioning system.
23. Check and, if necessary, adjust wheel alignment.
Please inform all personnel concerned.
Doyle J. Potter
National Service/Training
Parts Manager
DJP:mtc