-

USE OF THE MANUAL

PRESENTATION.

The Repair Manual dealing with this type of vehicule consists of twovolumes.

The MECHANICAL COMPONENTS, PART 1 (8581) cover operations on the MECHANICAL COMPONENTS and
the BODYWORK which may be carried out by a general workshop.

The two volumes together are divided into 15 chapters separated by vinyl tab insefts numbered @ to @
@ : General @ : Rear axle
@ : Engine @ : Suspension -wheels -tyres
@ : Fuel system-Carburettor @ : Steering
@ : Ignition system 0 : Braking system
@ : Clutch @ : Electrical equipment and radio
@ : Gearbox-Drive shafts @ : Heater, ventilation and air-conditioning
@ : Source and reserve of pressure @ : Bodywork
@ : Front axle (Removable parts and panelling)

The BODYWORK volume (8583) covers only operations involving the BOOYWORK.
It is divided into three chapters in the same way as thevolume dealing with the MECHANICALCOMPONEMTS.

@ : General
@ :Welded parts
@ : Removable parts and panelling

Each volume comes in a beige binder with a "MULTO type mechanism to facilitate filing of updated pages
or removal of a part for an operation in the workshop.

COMPOSITION OF A CHAPTER

Each chapter includes:

-the list of operations in it,
-the operations in numerical order.
-where applicable, the execution drawings for the MR tools necessary for the operations covered in the chapter.

OPERATIONS.

The order of operations has been designed to obtain the best standard.of work in the shortest time.

The numbers of the operations are as follows:

a) vehicle reference number: VD
b) a number with three figures identifying the assembly or assembly part
C) a figure indicating the type of repair.
- the figures 0 0 0 indicate the type of vehicle
- the figures 0 0 indicate the type of assembly
- the figures 0 indicate checks and adjustments
- t h e figures 1.4.7 indicate removal and fitting
- t h e figures 2, 5. 8 indicate dismantling and re-assembly
- the figures 3, 6, 9 indicate reconditioning.
OPERATIONS (continued).
The various operations are presented differently:
a) Through photos, drawings and texts.
b)~hrough photos. drawings and symbols.
A GLOSSARY has been placed at the beginning of each volume for this purpose.
In the glossary (the one in the Mechanical Components volume is different from the one in the Bodywork volume), the mea-
ning for each symbol has been translated into nine languages.
.
It consists in a removable set of "plastic" sheets bound with one manceuvrable metal ring to facilitate the extraction of one
several sheets (and obtain photocopies from them. for instance).

TOOLING.

In the MECHANICAL COMPONENTS, PART 1 for each chapter, the summary lists and photos of the special tooling, requi- L

red for proper completion of the work, are given at the end of the operation description.

In the BODYWORK volume, the numbers and photos of the special tooling are given in the description as the work progresses

-Tooling referenced OUT followed by 6figures ending in the letter T is sold by the Replacement Parts Department.
- The tooling referencedwith 4figures followed by the letter T is sold by Societe FENWICK DepartementAMA
24, boulevard Biron. 93404 SAINT-OUEN - Telephone: 252.82.85.
-The tooling referenced MR must be made up by the repairer himself.

VOLUME UPDATING.
The number of the volume (8581or 8583) is given at the bottom right hand side of the recto side of the page.

There is a figure @ to, @ in a circle at the top of each page. recto and verso. indicating the chapter in which it is to be filed.
Additives are identified by black spots to the left of the volume number
The number of spots indicates the additive number.
For example: lspot 0 8581 supplement No. 1.
For example: 2 spots 00 8581 supplement No. 2.
Additive sheets should be ordered immediatelyon notification. through a DOCUMENTATIONBULLETIN, of their issue.
The systematic distribution of free updating. via the application form for subscription duly filled and sent, will no longer be effec-
ted.

TIGHTENING TORQUES.
The tightening torques are expressed in metre Decanewtons (mdaN) the official torque measuring unit.
0.981 mdaN = 1 mkg (former measuring unit)
In practice. lmdaN = lm.kg.

IMPORTANT NOTES:
For all technical information concerning these vehicles, please consult:
DEPARTEMENT TECHNIQUE APRES-VENTE. ASSISTANCE TECHNIQUE
163. avenue G. Clemenceau- 92022 NANTERRE CEDEX - Telephone: 725-97-10
For all technical information concerning operating incidents. ask for internal extension number 5077 or 5278.
For information concerning tools or repairs, ask for extension number 5211.
 LIST OF OPERATIONS APPEARING I N CHAPTER: VEHICLE CONCERNED
GEARBOX DRIVE-SHAFTS - ENGINE TYPE
P- P
--
Super 11 14 C 15 C 15
Operation
number DESCRIPTION GRAPHIC OPERATION LAYOUTS
1124
-
Adrn.
1124
-
TRS
1360
diesel
1769
petrol
1124
10915 3 E 161 A 109 K

- Tooling X

- Characteristics and special features of the gearboxes X X

(see MAN 108131)

(see MAN 108131) X X

- Characterstics and special features of the gearboxes

X

- Adjusting the gear-change control X

- Checking and adjusting the gearbox control (see MAN 108131) X X X X

- Removing and fitting the gearbox on the vehicle X

- Reconditioning a gearbox (see MAN 058881. Op. XB14.330-3) X X X X

(see MAN 058881. Op. XB16.330-3) X

(see MAN 108131)

-Working on the gearbox in situ X

-Working on the gearbox: removing and fitting a gearbox drive outlet shaft
or a seal - rernovlng and f~ttingthe gearbox rubber support blocks
(see MAN 108131)

- Characteristtcs and special features of the drive-shafts X X X

 LIST OF OPERATIONS APPEARING IN CHAPTER: VEHICLE CONCERNED
GEARBOX - DRIVE-SHAFTS ENGINE TYPE

Special Super 11 14 GTi

TRS
Operation GRAPHIC OPERATION LAYOUTS
Club + -
Adm.
DESCRIPTION 652 1124 1124 1360 1580
number 2 180 A
'06/630 10915
P

Characteristics and s ~ e c ~features

al of the drive-shafts (see MAN 108131) X

(see MAN 108131) X X

Removing and fitt~ngthe drive-shafts

(see MAN 108131) X X X

 v

L
-

. , -
p-

r
-
-
??
,

X'+
L
S\
F

- -- d
'

82-2085 I OUT 30 - 7101 T

 VD. Di
2
330
 .
Too?- Part flattened by forging

MATERIAL: laminated A 33-1 0 14 I I

 I

VD.Di
2 ADJUSTING THE GEAR-CHANGE LEVER ~~'ROENA
330-0

Set the gear-change lever in "NEUTRAL" position.

Adjusting the gear-change lever.

Lever "a" of the gear-change lever should be set vertically, if it is not, modify length "z" of reaction link-rod
(3) which should be comprised between 51 mm and 61 mm.

Longitudinal adjustment of the gear-change lever.

The centre of the handle should be at L= 195 mm approx. from the axis of the car radio housing; if it is not, modify
length "X" of the gear-change link-rod ( l ) which should be comprised between 295 mm and 305 mm.
When "X" decreases, "L" decreases.
When "X" increases, "L" increases.

When tightening the link-rod lock-nut, balance the link-rod travel on the ball-joints.

Lateral adjustment of the gear-change lever.

The gear-change lever should be set vertically, as seen from the front of the vehicle, if it is not, modify length "y"
of gear-change link rod (2) which should be comprised between 130 mm and 140 mm.

When "y" decreases: the lever tilts towards the left.

When "y" increases: the lever tilts towards the right

Adjusting the lst/2nd gear selection:

Loosen the screws ( 1 ) of the box, set the gear-change lever end-gear position, position the box so as to obtain a free-play
J = 1 to 2 mm between the lever guide block and the box.
Make sure that the reverse gear can be selected freely.
When carrying out a road test, make sure all the gears can be selected freely.
 I Kmlh I

i l55/7OSR 13 MXL
= 1,670 metre
 I BT 87 ] VISA 14 TRS

MlCHELlN
155170 SR 13 MXL

= 1.670 metre
TOTAL TRANSMISSION
TM MULTIGRADE
 VlSA l 7 D
VlSA 17 RD

MlCHELlN
145 SR l3 MX

MlCHELlN = 1,725 metre

155 SR 13 MX

= 1,760 rnktre
BE,
 MlCHELlN
145 SR l3 MX
MICHEIIN = 1.725metre
185/60 HR 13 MXY
= 1.675 mbtre
 VD. Di REMOVING A N D F l l T l N G
2 A GEARBOX
330-1

REMOVAL

Chock the veh~cle.wheels h a n g ~ n gfree. Unclip the clamp of the starter motor harness

Drain the d ~ f f e r e n t ~ h
aol u s ~ n g(keep the 011). Disconnect the reversing lamp harness

Uncou~lethe drive-shafts from.the differential (see Remove p r o t e c t ~ v eplate ( 1 5 ) of the englne flywheel:
Op. v b . 0 1 372-1 ) Fig. Ill.
- the three screws ( 1 6) and release starter motor ( 1 7).

First, uncouple the L.H.drive-shaft. Fit, without Sling the gearbox at "b" and "c".
fail, tools 7 1 0 1 - T.M. and 7 1 01 - T.N.to hold Use the s l ~ n gattachment.
the sun gears In posit~on. MR 630-41 /43, Fig. IV.
Uncouple the R.H. drive-shaft. Fit a jack under the englne to f a c ~ l ~ t a tthe
e gearbox
uncoupl~ng.

Protect the r a d ~ a t o r .
Remove, Fig. V:
Remove spare wheel carrler bar ( 1 ) (if necessary) - nut ( 1 8).
- support ( 1 g ) , the t w o screws at "d",
- alr f ~ l t e r( 2 ) assembly,
- extended-head screw (20).
- de-aerat~nghose ( 3 ) .
- the four screws (+)c o u p l ~ n gthe englne to the
- battery (4). ~ t tray s and ~ t ssupport Fig. I,
gearbox, Fig. VI.
- the w l n g mudflap

Uncouple the gearbox f r o m the englne, and lower ~t

under the v e h ~ c l e .
Remove the vacuum pump

Prepare the gearbox before fitting it

Uncouple:
- Supply hoses ( 5 ) and vacuum hoses ( 6 ) f r o m the W h e n handling the gearbox, keep the clutch thrust
MASTE R-VAC. b e a r ~ n gagalnst its g u ~ d e ,by clamping the fork at "e",
Fig. VI.
Check that the t w o centering bushes are f ~ t t e d slightly
;
grease the thrust b e a r ~ n gguide and the driving shaft.
Remove: Fig: II, double guide ( 7 ) :
- earth cable (8).
- tensioner roller (9).
- the pump ( 1 l )three securlng screws.
- belt ( 1 0).
- p u m p ( 1 1).
REMARK:

Use centerlng tools 1713 - T or 7 0 1 1 - T for:

a) checking the correct position of the clutch disc.
Uncouple: b) r e c o n d ~ t ~ o n i nthe
g clutch.
- I ~ n k - r o d s( 1 2). ( 1 3 ) and ( 1 4 ) c o n t r o l l ~ n gthe gears.
- speedometer cable "a": Fig. I,
- the clutch cable (by removing the balance-weight).
- keep the sprlng and the push-rod
 REMOVING AND FllTlNG VD. Di
5
A GEARBOX 330-1

Couple the gear-change link rods, speedometer cable

Sling the gearbox at "a" and "b" using lug (7). Fig. II.
M.R. 630-41 /43.

Connect the reversing lamp harness (13). Fig. II.

Bring the lower level of the differential housing above
the unit.
Fit. Fig. 11:
- the engine flywheel protective plate.
Offerupthe gearbox. rotate the engine, if necessary, to
- vacuum pump (16).
- belt (2).
engage the disc splines. - tensioner roller (15). tighten the belt,
- earth cable (9).
- double collar (14).
Carry out the coupling, fit the upper screw (1).

Fit the screws coupling the engine to the gearbox. and

the screws securing the starter motor (1 2). Fig. Il. Couple supply hoses (6) and vacuum hoses (8). Fig. II:

Fit extended-head screw (3) of the gearbox.

(LOCTITE FRENETANCH on the threads). tightening Fit, Fig. II:
torque: 3.5 mdaN. - battery support (10).
- the tray,
- the battery.
Fix support (5) of the gearbox, tighten screws "c" - the air filter assembly.
to 1.8 mdaN. - the spare wheel support bar.

Fit nut (4). tightening torque: 3.6 mdaN, Fig. Ill.

Couple R.H. and L.H. drive-shafts to the differential
(See Op. VD. Di 3 72-7 ).
Remove the sling attachment, M.R. 630-41/43.

Fit the wing mudflap.

Couple the clutch control cable (1 l ) , by fitting the
balancing-weight (fit the push rod and the spring).
Fig. II.
Lower the vehicle to the ground

Check the travel operation and setting. Top up the gearbox oil level.
 VD WORKING ON THE GEARBOX IN SlTU
2
330-4

REMOVING AND FllTlNG PRIMARY AND SECONDARY SHAFTS

REMOVAL

Chock the vehicle with the front wheels hanging free. Remove the primary shaft nut, Fig. IV
(12 face bush, 28 mm A/fi

Drain the gearbox.

Remove the L.H. front wheel and protective plate ( I ) ,

Fig. I.
Remove 5th gear synchronizer (7) with its fork (6).
Keep ball (5). Fig. V.
Remove: Refit the 5th gear synchronizer, without its fork, unlock
- the spare wheel and its carrier bar. nut (8) without removing it.
- the air filter, the battery and its tray. Remove the 5th gear synchronizer, pinion (g), the busb
and the thrust washer.

Slightly raise the gearbox and remove both support (2)

and its axle, Fig. II.

Remove, Fig. IV and VI:

- screws (4) securing the bearing,
- circlip ( 1 1 ) using a little screwdriver,
Remove the gearbox cover - stop plate (10) of the selector fork shaft.
- stop screw (12) of the reverse gear gudgeon pin,
Drift out pin (3) (dia. = 5 mm) to free the 5th gear selec- - the housing securing screws.
tor fork, Fig. Ill.

When loosening the nuts, it is necessary to jam the gear-

box :
To do this, engage 4th gear using the gear change control
and engage the 5th gear by pushing the corresponding
selector fork.
 WORKING O N THE GEARBOX I N SlTU

Rotate the housing by a quarter of a turn to remove it Orientale the 5th gear control shaft (4) to release
Keep magnetic plate ( I ) , Fig. 11. it from its housing, Fig. IV and V.

Set the gearbox to the reverse gear position by means Tilt the forks to release them from the interlocking
of the gear change lever. device ( 5 ) and remove both the shafts and their
forks, Fig. VI and VII.

Remove reverse gear shaft and pinion (2). Fig. 11.

Remove oil seal (6) using a right-angled screwdri-
ver. Fig. VII.

Rotate fork shaft (3) by a quarter of a turn to free the

balls and move it back by several centimetres to
release it from its housing, Fig. Ill.
 VD WORKING ON THE GEARBOX IN SlTU
6
330-4
Lubricate the oil seal and fit it using tool 7107-T.Q.
Fig. I.
When replacing parts on the primary shaft, it is neces-
sary to adjust the bearing load.
The primary shaft should be fully equipped before
being fitted in the casing, the case being in position:
hold the unit using the nut and sleeve 7107-T.R. Sligh-
tly tighten, Fig. II.
Fit sleeve 7107-T.S. on the primary shaft, the outer
race already in position.
Measure distance abm between the sleeve surface
being in contact with the bearing and the casing joint
face. Fig. Ill.
Since both the base of sleeve 7107-T.S and the base
of the depth gauge measure 10 mm, the reading
should be reduced by 20 mm to obtain distance sbm.
Measure distance {cab) between the face of the
shim being in contact with the thrust guide and the
sealing surface of the casing, Fig. IV. Reduce the
reading of the depth gauge by 10 mm to obtain dis-
tance ccan.
The stress exerted upon the bearings should be
0.05 mm. Therefore, the thickness of the shim
will be e = (a - b) +
0.05 mm.
The thickness of the shim chosen should be as
close as possible to thickness {ten.
FITTING
Before fitting the shafts, make sure that oil deflec-
tor (2) is correctly positioned on the casing and set
the fork (1) to the reverse position, Fig. V.
(using the gear change lever).
Slightly lubricate the primary shaft bearing surfa-
ces, fit the forks on the synchronizers, without
setting control shafts (3) in their final position,
Fig. V!.
Fit the shim and the bearing outer race into the
casing.
 VD
WORKING ON THE GEARBOX IN SlTU 9
330-4

Fit the shafts and the selector fork, Fig. I. Make sure that magnetic plate (5) and the t w o cente-
ring bushes are fitted on the casings, Fig. IV.

Smear the sealing surface with sealing compound

Fit selector fork ( 1 ) in its synchronizer groove and on Fit the casing and tighten the screws.
the interlocking device (2). Fig. I and II.

Fit set screw (9) of the reverse gear shaft (copper

sead, Fig. V.

Fit stop plate (7) of the fork shaft.

Fit 5th gear control shaft (3) in the casing and on
interlocking device (2), Fig. Ill.
Place circlip (8) and the screws with their thrust was-
hers on the bearing at cca),, and nb11.

Fit on the primary shaft: Fig. VI:

Fit fork shaft (4) in the casing and orientate it towards -thrust washer (13).
the fork balls, Fig. IV. -bush (1 2) (previously lubricated),
- 5th gear pinion ( 1 1).
-5th gear synchronizer (101, without its fork and
engage the speed.

Engage the 4th gear using the gear-change lever

Fit reverse gear pinion (6) with its shaft, Fig. IV (the pin
being in its housing).
Tighten the secondary shaft nut to 5m.daN.
 VD WORKING ON THE GEARBOX IN SlTU
10
330-4

Remove 5th gear synchronizer (3). Raise the gearbox and fit the support shaft in the
gearbox casing, the threads being previously coa-
ted with LOCTITE FRENETANCH.
Fit fork (2) on 5th gear synchronizer (3) and offer up the
Tightening torque: 3.5 m.daN.
unit.
Fit the unit with ball (1) in its housing and engage the
speed, Fig. I.

Fit the engine mounting (5). Fig. IV

Nut tightening torque: 3.5 m.daN.
Screw tightening torque: 1.8 m.daN
Tighten the primary shaft nut to 5 m.daN.

Adjust the clutch control, (if necessary).

Lock the nuts using a non cutting-tool, Fig. II. Fill up the gearbox with oil (1.4 litre).

Check that the gears engage correctly.

Set the 5th gear synchronizer to neutral position and fit

stop pin (4). Fig. Ill. Fit the air filter, the battery and its tray,
the spare wheel carrier bar, Fig. V.

Fit protector (6), the wheel and lower the vehicle to

the ground, Fig. VI.
Smear the sealing surface with sealing compound and
fit the gearbox cover.
 VD.Di FllTlNG AND REMOVING
2 THE DRIVE-SHAFTS
372-1

REMOVING AND FllTlNG THE L.H. DRIVE-SHAFT

REMOVAL

FITTING

Remove the hubcap

Insert the drive-shaft into the hub, and then into the
Loosen and remove nut ( 1 ) Fig. I, raise and chock the differential sun gear.
front of the vehicle.

Using a lever, position the swivel lower ball-joint

Remove nut (2) and the screw securing the swivel lower pivot.
ball-joint, Fig. II.
Fit the screw an new nut ( 2 ) .Fig. II.
Tightening torque: 3.5 mdaN.
Drain the differential housing (keep the oil).
Lower the vehicle t o the ground
Using a lever, release the ball-joint by acting (*) on the
anti-roll bar, Fig. Ill.
Fit new nut ( 1 ) Fig. I
Tightening it to: 2.5 mdaN, then lock it.
Release drive-shaft (3) from the differential, and from
the hub, Fig. IV.

Top up the oil level.

Remove the differential outlet seal, replace it by a new
one, u s e t o o l 7 1 0 1 -T.G., smear lips at "a"with grease.
Fig. V and VI. Fit the hubcap
VD. Di
3
372-1
 REMOVING AND FllTlNG VD.Di
THE DRIVE-SHAFTS 5
372-1

After having removed the L.H. drive-shaft, position tools Remove the differential outlet seal. Replace it with
7101 T - M and 7101 T -'N. Fig. I so as to prevent a new one, use tool 7101 - T.O.,grease the seal lips,
the sun gears from rotating inside the differential Fig. Ill.
housing.

When fitting the drive-shaft, Fig. I, use bush (2) to

protect the seal during the drlve-shaft (3) splines
passage.

(Bush (2) is supplied by the Replacement Parts Depart-

ment with the seals).

Loosen the two nuts ( l ) , rotate the screw heads by Fit the two screws in the bearing and slightly grease
half a turn to release the bearing from the seat, Fig. II. the bearing outer race before inserting the drive-shaft.

Remove the drive-shaft. Tighten the nuts (l) to 1 mdaN.

 LIST OF OPERATIONS APPEARING IN CHAPTER: VEHICLE CONCERNED
FRONT AXLE ENGINE TYPE
Speciai Super 11 14 GTi 17 C 15
Club Adm. TRS diesel petrol
Operation DESCRIPTION GRAPHIC OPERATION LAYOUTS
652 1124 1124 1360 1580 1769 1124
number
/06/63C 10915 109 K 150 D 180 A 161 A

Tool~ng X

Character~st~cs
and speclal features of the front axle X X X X

(see MAN 108131) X

(see MAN 108131) X X

Checklng and adjust~ngthe front axle (see MAN 108131) X

0 checking the alignment

0 adjusting the alignment

Checking and adjusting the front axle (see MAN 108131 except for the X X X X
adjustment readings)

0 checking the alignment

0 adjusting the alignment

Reconditioning a lower arm X

Removing and fitting a front hub (see MAN 108131) X X X X

Reconditiontng a front hub (see MAN 108131) X

Reconditioning a swivel X X
OUT 380 61 3 T
It- I
 +1
P = 3 mm- c = 00 55nk3O

---------
I
-
 LIST OF OPERATIONS APPEARING IN CHAPTER: VEHICLE CONCERNED
REAR AXLE ENGINE TYPE
l -
,pecial 14 17 C 15
TRS liesel liesel
Operation DESCRIPTION GRAPHIC OPERATION LAYOUTS
-
Club
652
+

1360 1769 l769

number 36/630 E 61 A 61 A

X X
'D 420 Tooling

X X X
'D 420-00 Characterist~csand spec~alfeatures of the rear axle

'D1 420-00 (see MAN 108131) X

ID2 420-00 (see MAN 108131)

ID1 420-0 Check~ngand adjusting the rear axle (see MAN 108131)
X

checking the alignment

adjusting the alignment

X X
ID2 420-0 . Check~ngand adjusting the rear axle (see MAN 108131 except for the
adjustment readings)

checking the alignment

adjusting the alignment

X
JD 422-1 - Removing and fitting a rear axle

X
r/D DI 422-1 - Removing and fitting a rear half-axle

(see MAN 108131) X

r/D1 422-1

(see MAN 108131)

X
VD2 422-1

X X X
VD 422-3 - Reconditioning a rear axle

X
VD 422-3 a
 LIST OF OPERATIONS APPEARING IN CHAPTER: VEHICLE CONCERNED
REAR AXLE ENGINE TYPE
Specia 11 14 17 C 15 C 15
Operation
number
l DESCRIPTION

--
GRAPHIC OPERATION LAYOUTS
Club
652
/06/631
Adm.
1124
109 K
TRS
1360
150 D
diesel
1769
161 A
diesel
1769
161 P
petrol
1124
109 K

- Removing and fining a rear hub X X

(see MAN 108131. Op. VD 451-4)
X X

(see OP. VD Di 453-1)

X
- Reconditionmg a rear hub (see MAN 108131)
X X X

-
I OUT 20 4028T 1

[ OUT 28 1509T 1
OUT 380 909 - TI
OUT 30 7106 - TI
OUT 50 4068,- T [
D0- GTI
VD
420 -00
3
 VD
2 REMOVING AND FllTlNG A REAR WHEELARM ~~R&NA
422-1

REMOVAL FITTING

(ON THE SlDE TO BE FITED)

Slacken off nuts (1) to release the handbrake cables, and
separate each cable from its compensator at (cam (on the Offer up the complete arm (12) horizontally and
side to be removed). Extract the cables from the floor, wedge it into casing (8). Fig. IV and VI.
Fig. I.

Refit arm shaft (5), the washer and tighten nut (3)
(ON THE SlDE TO BE REMOVED) to 13 mdaN. Fig. II and Ill.

Install compression device 4068-T, fitted with clamping

claws 4082-T, Fig. II.
Position the vehicle with the wheels hanging freee.
Refit, Fig. 11, Ill and V:
- screws (10) to the anti-roll bar bearing:
Tighten to 3.5 m.daN
- release stop (4).
- clip (7) into the flexible hose groove.
- screw up the connection and tighten it.

Remove both the wheel and its embellisher.

Release the spring to remove tool 4068-T and
claws.
Compress spring (2) by screwing at nbn and free tapered
ball-joint (6) from its housing, Fig. Ill.
Refit:
- the wheel, its embellisher,
Remove, Fig. II, IV and V:
Tighten the screws.
- release stop (4).
- screws (10) from the anti-roll bar bearing.
Loosen connection (9) of brake flexible hose, and blank Hook up the handbrake cable onto the
with a plug at acn. compensator.

Remove, Fig. II and Ill: Adjust the handbrake control, on the compensator.
- clip (7) from the flexible hose, Bleed the brakes.
- nut (3) from the arm shaft, Lower the vehicle to the ground.
- shaft (5) holding it in position.

To disengage the arm raise the whole assembly so that

the upper part of casing (8) is not in your way, Fig. IV.
 VD Di
2 REMOVING A N D F l l T l N G A REAR HALF-AXLE
422- 1

REMOVAL

Remove: Fig, I Remove: Fig. Ill

- the screw securing rear seat-belt (1 ). - collars "b" of the handbrake cable,
- plastic cover (2). - screws (5).
- loosen nuts (3). without removing them. - plates (6) of the anti-roll bar.

Unhook the compensator spring at "c"

(for a L .H. half-axle).

Fig. I1
Remove: Fig, IV
Raise the rear of the vehicle, using the crossmember-
1509 - T: insert it in the securing lugs (4). - hub ( 7 ) seal plug.
- nut (8) without unlocking it.
Do not use any other lifting points. Pin the - washer (9).
crossmem ber at "a". - drum unit (10).
Position the stands under the side reinforcing parts. - handbrake cable.

Any other resting point is forbidden.

A (See Op. VD.Di 453- l):
Free the sheath stop of the brake plate.
Remove the wheel
Fig. V:
Loosen screw ( 1 1).
Remove sleeve nut ( 12).
Remove washer ( 13).
Release shock-absorber yoke (14).

Fig. I and VI:

Remove nuts (1 5) of the articulating arm.

Remove nuts (3). Tilt the unit downwards and release it,
as well as the side support.
 VD Di
REMOVING A N D FllTlNG A REAR HALF-AXLE 5
422- 1

FITTING

Fig. I, Il and Ill: Fig. V:

Insert the half-axle in ~ t smountlngs, as well as s ~ d e Replace seal ( 9 ) .

support ( l ).

m F t
Fit the flat washers, NYLSTOP nuts ( n e w ones) (2). - drum unlt ( 1 0 ) .
Tighten to: 4 to 5 mdaN. - washer ( 1 1 ),
- nut ( 1 2) (new one) Tighten to 21.5 mdaN.

Fit: (Lock the nut w ~ t ha non-cutting tool)

- p l a s t ~ ccover (3).
- seat-belt. ~ plug ( 1 3).
F I seal
Tighten screw (4) t o 3 mdaN
F I the
~ wheel
F I NYLSTOP
~ nuts ( 5 ) (new ones) without tightening
them.

Fig. IV: Fig. VI :

Couple yoke (6) t o the arm component F I plates

~ ( 1 4) securlng the anti-roll bar

Fit:
- washer (7). Fit screws ( 1 5). Tighten to 4 mdaN.
- sleeve-nut (8), without tightening It.

Insert the handbrake sheath stop into its h o u s ~ n g .

Hook the cable (See Op. VD.Di 453- 7)

-
 VD Di
6 FllTlNG A N D REMOVING A REAR AXLE
422- 1

Fig. I and I I Fig. Ill:

Using tool 4028 - T clamp the suspension so as to Tighten:

o b t a ~ na 180 mm height measured with tool 2305 - T. - articulating nuts ( l ) to 7.5 mdaN,
- sleeve nut (2) of the shockabsorberyoketo3.5mdaN.
- stop screw (3) to 4 mdaN.

Unclamp the suspension

Adjust the wheel alignment ( ~necessary).

f

i
 X = B-A
e = X + 0,18mm

mini 0 , 1 4 mm
maxi 0.22 mm
 --

VD
CmOeNa REMOVlNG AND FITTING A REAR HUB 5
426-1

Remove. Fig. I Fit the hub

- the bearing inner race (1) using puller 2400-T and pad
7101-T.J.
- the thrust cup (2) of the hub seal.
Engage hub (3) gently tapping the inner race so as
to release the threads of the stub axle, Fig. IV.
Keep on fitting the hub using the hub nut.
Take off the nut.

Clean.

Clean and lubricate

(grease TOTAL MULTIS MS)
Check if the threads of the stub-axle is in good condition. Fit the. hub washer and (new) nut.

Prevent the stub axle from rotating,

FITTING Fig. V
Tightening torque: 27.5 mdaN

Refii the thrust cup (2) of the hub seal (using tool
7106-T). Fig. II and Ill.

Lock the nut with a non-cutting tool

Prevent the stub axle from rotating.

Fit, Fig. VI
- hub (3) cap (6)
- the drum
Refit the hub inner race
- drum screw (4)
Drive in the race using the hub nut then a bush.
- stop (5) to the arm
Clean and lubricate (grease TOTAL MULTIS MS).
- the wheel and its attachments
- the embellisher

Lower the vehicle to its wheels

Tighten the wheels.

 VD
2 REMOVING AND FITTING A REAR HUB
426- 1

REMOVAL

Chock the vehicle Fig. I. Unlock the hub nut

Remove, Fig. I Prevent the stub axle from rotating using a 19 m m

- the wheel embellisher ALLEN KEY or an hexagon socket spanner, 14 m m
- the screws, or nuts Fig. Ill NF. Fig. IV.
- the wheel

Remove, Fig. IV
Remove, Fig. I1 - hub nut (5) (40 m m NF)
- stop (2) - washer (6)
- screw ( 1 ) securing the drum - the hub, Fig. V
- drum (3) (Use puller 2400-T and pad 7101-T.J.)
- hubcap (4)
 LIST OF OPERATIONS APPEARING I N CHAPTER: VEHICLE CONCERNED
SUSPENSION WHEELS - TYRES - ENGINE TYPE
Special Super 11 14 17 C 15 C 15
Club Adm. diesel diesel petrol
Operation
number DESCRIPTION GRAPHIC OPERATION LAYOUTS - TRS
652 1124 1124 1360 1769 1769 1124
1106163( 10915 109 K 150 D a
Tooltng X X

Characteristics and special features of the front suspension X X X X

Characteristics and special features of the suspension (see MAN 108131) X

(see MAN 108131) X X

Characteristics and spec~alfeatures of the rear suspension X X X X

Removing and fitting a rear suspenslon unit X X

Removing and fitting a front suspenslon unit X X

(see MAN 108131) X X X X X

Removing and fitting a rear suspension unit . X X

(see MAN 108131) X X X

Reconditioning a front suspension unit (see MAN 108131) X

(see MAN 108131) X X X X

Reconditioning a rear suspension unlt (see MAN 108131) X

(see MAN 108131) X X X X

P
 LIST OF OPERATIONS APPEARING IN CHAPTER: VEHICLE CONCERNED
-
SUSPENSION WHEELS TYRES - ENGINE TYPE
I
Special, Super
--
11 14 17 C 15
-
C 15
diesel petrol
Operation DESCRIPTION GRAPHIC OPERATION LAYOUTS -Club Adm. TRS diesel -
number 652 1124 1124 1360 1769 1769 1124
106/63C 10915 E 161 A 161 A 9

Removing and fitting the anti-sway bars X X X X X X X

Characteristics of the wheels and tyres X X X X

(other VISA types: MAN 108131, general characterist~cs)

 OlJT 20 - 4076-T

I OUT 38 - 0909-T 11

I OUT 20 - 4028-T

OUT 28 - 1509-T
76-656
-
 14 TRS
I
 VD
GTi 5
430-00

- -
 REMOVING AND FITTING
A REAR SUSPENSION UNIT
REMOVAL
Chock the vehicle with the wheels hanging free.
Remove
- the rod protector
- nut (1) from shock absorber rod Fig. I
NOTE
pp-p
To avoid damaging the shock absorber piston ring,
hold the rod, using an ALLEN key to unscrew nut (1)
- CUP (2)
- flexible spacer (3)
- release stop (4) from arm Fig. II
Screw up nut (1) by a few turns on the shock absorber
rod.
Place tool 4068-T fitted with claws 4082-T, Fig. Ill.
Check that the claws are properly positioned on the
thrust cups.
Compress the suspension spring to disengage the ball-
joint stem from the arm.
The extremity of the ball-joint stem can be tapped with
a bronze rod if necessary.
Decompress the suspension spring
Remove tool 4068-T
Remove nut (1) from shock absorber rod Fig. I.
Withdraw the suspension unit
NOTE
If two suspension units are to be removed, it is
essential not to mingle half-spring spacer plates
(12) since they match the springs.
FITTING
Prepare the suspension unit, Fig. IV.
Put both half-spring spacer plates (12) into position
over the shock absorber body. Hold them with an
elastic ring.
Fit:
- lower cup (5)
- plain washer (7)
- rod protector (8)
- washer (9) securing the protector
- flexible spacer (10) and its inner tube.
Pull the shock absorber rod out as much as possi-
ble.
Engage suspension spring (6) taking care that it be
positioned on the lower cup.
Insert the suspension unit into its housing
Direct mark A downwards, Fig. V.
Fit to the shock absorber rod, Fig. IV
- rod centering bush (1 1)
- flexible spacer (3)
- washer (2)
- the new NYLSTOP nut ( l ) ; screw it up by hand
Install tool 4068-T fitted with clamping claws 4082-
T, Fig. Ill
Compress the spring until the ball-joint stem fits
into its recess.
Refit release stop (4). Fig. II
Decompress the s p h g making sure that the ball-
joint stem is correctly fitted in the arm.
Remove tool 4068-T with 4082-T
Tighten nut (1) without turning the rod.
Tightening torque: 2 mdaN.
Fit the rod protector
Lower the vehicle to the ground.
 VD.Di FRONT SUSPENSION ASSEMBLY
2 REMOVAL A N D F l l T l N G
434- 1a

REMOVAL FITTING

On the side to b e removed. Preparation of the suspension unlt: Fig. VI.

(See operation VD 434 - 3a)
Fig. V:
Positioning of cables 4076 - T. Fig. I, V and VI.
Fig. V:
Engage the suspension unlt (8)in its upper mountings
Insert one of the cables at "d". Fit newwashers and nuts (+)
but d o not tighten home.
Rotate the wheel outwards In order t o insert the other
cable at "e"
Engage the third lead of each cable (8)and ( 1 0 ) at "a",
into the slotted holes of the lower cup. Fig. IV:
Engage the shock absorber body (3) in swivel (4) fully
home.
Make sure that pin "b" has entered slot "C" of swivel.
Turn the male hexagon spanner by 1/12 turn t o
release it.

Remove the swivel to subframe wire attachment.

Loosen the 3 nuts shghtly (+):
Fig. V.

Disconnect earth lead (6)

Place the vehicle o n stands located at jacking points: Fig. Illand IV:
Fig. 11. Fit screw ( 1 ) and a n e w NYLSTOP n u t (5).
Remove the wheel. D o u p nut (5)without tightening it fully home
Remove screw ( 1 ): Fig. IV.
Place male hexagon spanner (A) into the swivel slot (4) Fit the wheel.
and turn it by 1 / l 2 turn t o open the upper section ofthe
swivel. Lower the vehicle t o the ground

Connect the swivel t o the subframewith a wire In order Check that the shock absorber body is o n its stop
t o prevent transmlsslon ( 2 ) from swlnging out. at "c"; if not, slackent off nut (5) and the shock
absorber will place itself automatically in position.
Withdraw the shock absorber body (3)from swivel (4).

Remove the upper mounting nuts (r))

Tighten:
- nut (5) t o 7.5 mdanN.
- the 3 nuts (*)to 1 mdaN,
- the wheel screws.

Pull out the suspension unit: Fig. VI. Remove the two cables (8) and ( 1 0).
 VD.Di REAR SUSPENSION ASSEMBLY
2
434-1b REMOVAL A N D F l l T l N G

REMOVAL FITTING

Slacken off the wheel nuts

Lift up the rear of the vehicle using crossmember
-
1 5 0 9 T engaging it in the fixing points ( 1 ) : Fig. I.
Do not use other lifting point.
Engage th SUSK nit in its upper and lower
mountings (on the lowermounting: fit a flat washer (7)
either side of the suspension unit): Fig. V.
Screw on nut (5) but do not tighten home: Fig. Ill.
Tighten the top nuts (8) to a torque of 1 mdaN: Fig. IV.

Pin the crossmember in place at "a", Fig. I.

Position the stand.^ underthe jacksupports and remove

the wheel:
Remove, Fig. 11: Refit the wheel and put the vehicle on a garage lift
- the screws (I)),
- lining ( 3 ) ,
- cover (2).
Using t o o l 4 0 2 8 - T t i g h t e n up the suspension to obtain
a length at "L" of 1 8 0 mm: Fig V and VI.

Remove, Fig. Ill:

- locking screw (4).
Tighten:
- shock absorber end yoke (5),
- the shock absorber yoke nut (5) t o 3.5 mdaN,
- the three upper mounting nuts (7): Fig. IV.
- the locking screw (4) t o 4 mdaN: Fig. Ill.

Free the shock absorbet yoke (6) and remove the

suspensron unlt: Fig. Ill. Check if the wheel nuts are correctly tightened.
 I. REMOVING AND FllTlNG THE FRONT,ANTI-SWAY BAR
OF A DIESEL VEHICLE,
(SALOON and COMMERCIAL)

REMOVAL FITTING

Raise the vehicle with the wheels hanging free,
Fig. I.
Remove the anti-sway bar bearings (4). Fig. II.
Loosen the collar (5) securing rod (6) and pull it out.
Remove, Fig. II:
- screws (3) to uncouple the swivel ball-pins
- anti-sway bar nuts (2) and washers
- screws (1) coupling the suspension arms to the
units.
Uncouple gear controls at [can and ~ b i Fig.
i Ill.
Engage the anti-sway bar onto the suspension unit.
Couple up the gear controls at ccaii and abn, Fig. Ill.
Pin 'on the brake pipe fitted with its linings.
Ofter up the suspension arms to the anti-sway bar
(position the washers and spacers).
Rotate the arms by 114 turn to engage the ball pins
into the swivels.
(Place protective plates (8) in position, Fig. W.)
Fit screws (3) and new NYLSTOP nuts.
Tighten to 3.5 mdaN.

Separate the brake pipe from the unit. Couple up the suspension arms to the unit with
new NYLSTOP nuts.
Tighten to 3.5 mdaN.
Undo anti-sway bar (7) towards the left hand side.

Fit:
- the bearing nylon trims (using grease G7)
- bearings (41, tighten to 3.5 mdaN.,
- the washers and new NYLSTOP nuts'(2) securing
the anti-sway bar in the suspension arm; tighten
to 7.5 mdaN.

Place collar (5) 330 m m from the fastening, Fig. II

screw tightening: 3 mdaN.

Lower the vehicle to the ground

II. REMOVING AND FllTlNG THE FRONT ANTI-SWAY BAR

OF A PETROL VEHICLE
(SALOON and COMMERCIAL, except GTi),
(see OP. VD2 416-1, MANUAL 108131) (11)
 WORKING ON THE MECHANICAL COMPONENTS VD 5
OF THE HYDRAULIC SUSPENSION 434-4

Ill. REMOVING AND FITTING THE REAR ANTI-SWAY BAR OF SALOON VEHICLES
(see Op. VD Di 422-1, CHAPTER. @ )

IV. REMOVING AND FITTING THE REAR ANTI-SWAY BAR OF COMMERCIAL VEHICLES

REMOVAL

Preparation: To gain access to the anti-sway bar bearing screws, compress the rear of the vehicle with hoisting
crossmember 81509-T and suspension compressor 4028-T.

Remove:
- RH and LH bearing screws (2)
- caliper screw (4).
Decompress the vehicle.

Fit, either on the LH or the RH side:

- spring compressor 4068-T fitted with clamping claws 4082-T

Compress the whole suspension unit. Place the vehicle on stands with the wheel hanging free (on spring compression
side).

Remove bar (1) by pushing one extremity into the suspension casing on the compressed side, in order to release the
other extremity.

To refit the anti-bar, reverse above procedure

Fit:
- LH and RH bearings (3); tighten the screws t o 9 mdaN,
- caliper (4) and the screw. Tighten the nut.

Remove the compression tools from the suspension unit and the vehicle.

Lower the vehicle to the ground.

 VD WORKING ON THE MECHANICAL COMPONENTS
6 OF THE HYDRAULIC SUSPENSION
434-4

V. REMOVING AND FllTlNG THE FRONT ANTI-SWAY BAR OF A GTi VEHICLE

REMOVAL

Raise the vehicle with the wheels hanging free.

Removing exhaust shield (I), Fig. I:

- Unclip pin (2)
- Unwedge shield ( I ) from the gear-shift lever bracket; take it out from between the suspension unit and the drive shafts.

Unclip gearshift control (12) Fig. IV.

Free brake pipes (4) from pins (3) and draw it apart from the unit crossmember

Removing the exhaust line, Fig. II and Ill:

Remove:
- nuts (8). washers (9) and springs (71,
- nut (IO),
- both rubber rings (1 1)

Removing the anti-sway bar, Fig. I and IV:

Remove:
- screws (6) and the bearing caps
- NYLON bearings.
- ball-joint nuts (5); prevent them from rotating.

Extract the anti-roll bar from the R.H. side, with its extremities wan facing backwards, Fig. IV.
 WORKING ON THE MECHANICAL COMPONENTS VD 9
OF THE HYDRAULIC SUSPENSION 434-4

F i i n g the anti-sway bar. Fig. I and 11:

Engage the bar from the R.H. side of the vehicle, with its extremities directed towards the rear. Fitting position to be
observed: swell at ccan, on the L.H. side.

Smear the NYLON bearings at aba with KLUBER GREASE, R.P. ref. 79 01 973 007 before fitting them

BEARING IDENTIFICATION
There is a R.H. bearing, and a L.H. bearing (2) with an inner groove to fit bar swell at "a" exactly.

Position ball-joint nuts (10). Prevent them from rotating; tighten to 4.5 mdaN.
Fit bearing cap screws (3) and (6); tighten to 3.5 mdaN.

Refit exhaust line (17). Fig. Ill:

Position the silencer fully to the left. Lubricate exhaust pipe at "d" and screws at "c" with grease GRIPCOlT-A-F.

Refit friction washers (11). springs (12). cups (13) with nuts (14). and attachments (15); hook up rings (16).

Clip-fasten:
- brake pipe (9) into clips (8),
- gear change control on the R.H. side

Fit exhaust nut (5):

Wedge nut tongue in the gear shift lever bracket. Fasten pin (4) onto the rack housing.

Lower the vehicle to the ground.