Lancia Delta Integrale 1986 Repair Service Manual

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🏷️ Basic Information Identification Make: Lancia Model: Delta Integrale Year: 1986 Codes Chassis Code: Type 831 👋 Introduction Market Position Positioning: The Lancia Delta Integrale, even from its 1986 inception (preceding the more famous Evoluzione models), was a homologation special designed for rallying. Its market position was that of a high-performance, compact all-wheel-drive sports hatchback, setting it apart from contemporary competitors. Competitive Analysis Competitors: While not a direct competitor, its performance ethos and AWD capabilities put it in a unique category. Competitors in spirit and performance might include rally-bred homologation specials from other manufacturers or high-performance European hatchbacks of the era. Key Features Aerodynamics: Distinctive box-flared wheel arches, front spoiler, and aggressive styling cues hinting at its motorsport pedigree. Powertrain: 2.0L turbocharged 16-valve engine, permanent four-wheel-drive with a Torsen center differential (in later models, but the 1986 car had a viscous coupling). Suspension: Stiffened and performance-tuned suspension geometry optimized for grip and handling. 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Suspension: Yes Brakes: Yes Electrical System: Yes Bodywork: Yes Interior: Yes Cooling System: Yes Fuel System: Yes Exhaust System: Yes Steering: Yes HVAC: Yes Page Count Estimated Pages: Extensive, likely exceeding 800 pages (typical for factory service manuals of this era and complexity) Manual Type Type: Repair Service Manual / Workshop Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Covers engine, fuel injection, ignition, cooling, exhaust, and lubrication systems for the 2.0L 16V turbocharged engine. Drivetrain: Includes detailed information on the 5-speed manual transmission, transfer case, and viscous coupling center differential for the permanent four-wheel-drive system. Chassis: Comprehensive coverage of front and rear suspension (MacPherson struts front, independent multi-link rear), steering system, and braking system (including ABS if equipped). Electrical: Extensive diagrams and troubleshooting guides for the entire electrical system, including lighting,...

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Description

🏷️ Basic Information

Identification

Make:

Lancia

Model:

Delta Integrale

Year:

Codes

Chassis Code:

Type 831

👋 Introduction

Market Position

Positioning:

The Lancia Delta Integrale, even from its 1986 inception (preceding the more famous Evoluzione models), was a homologation special designed for rallying. Its market position was that of a high-performance, compact all-wheel-drive sports hatchback, setting it apart from contemporary competitors.

Competitive Analysis

Competitors:

While not a direct competitor, its performance ethos and AWD capabilities put it in a unique category. Competitors in spirit and performance might include rally-bred homologation specials from other manufacturers or high-performance European hatchbacks of the era.

Key Features

Aerodynamics:

Distinctive box-flared wheel arches, front spoiler, and aggressive styling cues hinting at its motorsport pedigree.

Powertrain:

2.0L turbocharged 16-valve engine, permanent four-wheel-drive with a Torsen center differential (in later models, but the 1986 car had a viscous coupling).

Suspension:

Stiffened and performance-tuned suspension geometry optimized for grip and handling.

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Suspension:

Brakes:

Electrical System:

Bodywork:

Interior:

Cooling System:

Fuel System:

Exhaust System:

Steering:

HVAC:

Page Count

Estimated Pages:

Extensive, likely exceeding 800 pages (typical for factory service manuals of this era and complexity)

Manual Type

Type:

Repair Service Manual / Workshop Manual

Language

Language:

English

Format

Digital Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Covers engine, fuel injection, ignition, cooling, exhaust, and lubrication systems for the 2.0L 16V turbocharged engine.

Drivetrain:

Includes detailed information on the 5-speed manual transmission, transfer case, and viscous coupling center differential for the permanent four-wheel-drive system.

Chassis:

Comprehensive coverage of front and rear suspension (MacPherson struts front, independent multi-link rear), steering system, and braking system (including ABS if equipped).

Electrical:

Extensive diagrams and troubleshooting guides for the entire electrical system, including lighting, instruments, ignition, starter, alternator, and ECU.

Body & Interior:

Covers body panel removal and installation, door mechanisms, window operation, interior trim, seats, and HVAC system components.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.

Engine Repair:

Cylinder head removal and installation, piston and connecting rod service, crankshaft and bearing inspection, timing belt replacement, turbocharger overhaul.

Transmission Overhaul:

Complete disassembly, inspection, and reassembly of the gearbox and transfer case.

Brake System Service:

Pad and rotor replacement, caliper overhaul, brake fluid bleeding, ABS component troubleshooting.

Electrical Troubleshooting:

Diagnosing and repairing issues with wiring harnesses, sensors, actuators, relays, and ECUs using circuit diagrams.

Suspension And Steering:

Replacement of shock absorbers, springs, control arms, bushings, tie rods, and steering rack service.

Body Repair:

Panel alignment, rust repair techniques, glass replacement, and bumper repair.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to in-depth engine and transmission rebuilds, including detailed diagnostic procedures and specifications.

📊 Manual Specifications

File Format

Format:

Searchable:

Likely, depending on the PDF creation process.

Print Quality

Quality:

Full Printable

Zoom Capability:

Binding Type

Type:

Digital Download (no physical binding)

Paper Type

Type:

N/A (Digital)

Software Requirements

Reader:

Adobe PDF Reader

Unzipping:

WinZip or equivalent

Compatibility

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Code:

831 DOHC

Configuration:

Inline-4, turbocharged, DOHC, 16 valves

Displacement:

1995 cc (2.0 Liters)

Bore X Stroke:

83.0 mm x 92.0 mm

Compression Ratio:

8.1:1 (typical for early models)

Performance

Horsepower:

185 PS (182 bhp; 136 kW) at 5500 rpm (varies slightly by market/specific version)

Torque:

294 Nm (217 lb-ft) at 3000 rpm (varies slightly by market/specific version)

Fuel System

Fuel Delivery:

Bosch L-Jetronic fuel injection

Fuel Type:

Unleaded Gasoline (Premium)

Ignition System

Type:

Electronic Ignition (Magneti Marelli or similar)

Turbocharger

Model:

Garrett T3 (typical)

🔧 Transmission

Standard

Type:

5-speed Manual

Optional

Type:

N/A for 1986 model

Features

Drive System:

Permanent Four-Wheel-Drive

Center Differential:

Viscous Coupling Unit (VCU)

Rear Differential:

Open Differential

Fluid Specifications

Gearbox Oil:

API GL-4, SAE 75W-90 or 80W-90 (check manual for exact spec)

Transfer Case Oil:

API GL-4, SAE 75W-90 or 80W-90 (check manual for exact spec)

📐 Dimensions

Exterior

Length:

4040 mm (159.1 in)

Width:

1700 mm (66.9 in) (excluding flared arches)

Height:

1365 mm (53.7 in)

Wheelbase:

2475 mm (97.4 in)

Track Width Front:

1420 mm (55.9 in) (approx.)

Track Width Rear:

1410 mm (55.5 in) (approx.)

Weights

Curb Weight:

1210 kg (2668 lbs) (approx.)

Gross Weight:

1600 kg (3527 lbs) (approx.)

🛡️ Safety Features

Ratings

Crash Test Results:

Limited publicly available data for this specific 1986 model year in modern standardized tests. However, build quality was robust.

Active Features

Optional on some early models, standard on later variants.

Braking System:

Front ventilated discs, rear solid discs. Larger diameter discs and performance calipers common.

Passive Features

Seatbelts:

Front three-point inertia reel seatbelts.

Construction:

Reinforced body structure for increased rigidity and crash protection, typical of rally homologation specials.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio and cassette player, often with 4 speakers. Aftermarket upgrades common.

Driver Assistance

Optional, as noted in safety.

Connectivity

Type:

N/A (pre-digital era)

🔧 Maintenance

Service Intervals

Oil Change:

Every 7,500-10,000 km (4,500-6,000 miles) or 6-12 months, whichever comes first. More frequent in harsh use.

Air Filter Replacement:

Every 20,000-30,000 km (12,000-18,000 miles) or annually.

Fuel Filter Replacement:

Every 30,000-40,000 km (18,000-24,000 miles).

Spark Plug Replacement:

Every 30,000-40,000 km (18,000-24,000 miles), depending on plug type.

Timing Belt Replacement:

Crucial! Every 50,000-60,000 km (30,000-36,000 miles) or 4-5 years. Failure is catastrophic.

Fluid Specifications

Engine Oil:

SAE 10W-40 or 15W-40, API SG/SH (or equivalent) - check manual for exact turbo rating.

Coolant:

Ethylene Glycol based, typically 50/50 mix with distilled water. Lancia recommended coolant or equivalent.

Brake Fluid:

DOT 3 or DOT 4 (check manual for specific type).

Known Issues

Rust:

Common in wheel arches, sills, rear quarter panels, and tailgate.

Turbocharger:

Can be prone to oil starvation if maintenance is neglected, leading to premature failure.

Clutch:

Can wear out relatively quickly under spirited driving.

Suspension:

Bushings and ball joints can wear, affecting handling.

Electrical Gremlins:

Age-related issues with wiring looms, relays, and sensors are not uncommon.

Engine Gaskets:

Valve cover gaskets and oil sump gaskets can leak.

📚 Vehicle History

Brand Heritage

Heritage:

Lancia has a rich motorsport history, particularly in rallying, with legendary models like the Stratos and the Fulvia. The Delta Integrale built upon this legacy.

Model Evolution

Evolution Summary:

The 1986 Delta Integrale was the first iteration, based on the Lancia Delta 'Super' model. It introduced the permanent 4WD system and a more powerful turbocharged engine. It was subsequently followed by the HF 4WD, then the Integrale 8v, 16v, Evoluzione I, and Evoluzione II, each progressively more extreme and successful in rallying.

Production

Production Years:

1986-1994 (for the Delta Integrale line, with various sub-models)

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Rally Success:

While the 1986 model was the genesis, the Delta Integrale platform went on to dominate World Rally Championship (WRC) from 1987 to 1992, winning six consecutive manufacturers' titles.

Ratings

Performance Reviews:

Consistently praised by automotive journalists of the era for its exceptional grip, handling, and rally-bred performance characteristics.