-

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 IN CHAPTER: VEHICLE CONCERNED
STEERING ENGINE TYPE
I
Special
-
Super GT- 11 14 GTi 17 C 15 C 15
Operation DESCRIPTION GRAPHIC OPERATION LAYOUTS
Club ' Adm. TRS diesel diesel petrol
number 652 1124 1360 1124 1360 1580 1769 1769 1124
,061630 10915 15010 p
3
J E E

Tooling X X X X X X X

Characteristics and special features of the steering X X X X

(see MAN 108131)

(see MAN 108131) X X X

Removing and fitting a steering system (see MAN 108131)

(see MAN 108131) X X X X X

Removal and fitting of steering gear X

Reconditioning a steering system X '82- X X X X

Removal and fitting of an anti-theft device X X X X X X X

1892-T. bis I

MR. 630-311126b l
Steel: CC 35
For the dimensions which are not followed with,
any indication, the tolerance is: ? 0.25
All angles should be chamfered.
GTi
 VD 14 TRS-
2
440-00 C 15E
 i r n hochsten Punkt suchen

@ n d hojeste punkt.

>iuscar el punto rnas alto.

)c :.scertam the greatest stand-proud

a .+cercare il punto pi O alto

oek het hoogste punt op

o c u r a r o ponto rnais alto

~ o kden h6gsta punkten. '

a jachercher le point le plus haut

1 1E - RE 1 4 TRS-GT GTi-17D-17RD
F
4,5 mdaN
T
5 mdaN
Operation
DESCRIPTION
number

- Tools.

- Steering characteristics and special points.

- Steering removal and fitting.

- Removal/Fitting of an anti-theft device - W

 VD Di
2 REMOVAL A N D FITTING OF STEERING GEAR
442- 1

REMOVAL FITTING

Raise the vehicle and place it o n stands Fig. VI:

Remove the wheels.

I Adjust the steer~ngat a d ~ s t a n c eA = 7 2 . 5 m m

t o obtain the "STRAIGHT LINE" position.

Fig. I and 11:

Remove the nuts from the L.H. and R.H. ball-joint Fit the steering gear seeing that the steering column is
stem ( 1 ). properly engaged.

-
Remove ball-joints using extractor 1892 T bis.

Fig. IV:

Fit the two screws ( 3 ) with new NYLSTOP nuts, and

tighten to 3.5 mdaN.

Fig. Ill:

Fit screw ( 2 ) with a new NYLSTOP nut

Tighten to 1.5 mdaN.

Fig. Ill: Fig. I:

Remove attaching screw and nut (2) from the steering W i p e the ball-joint stems. D o not use solvent.
column.

Engage the ball-joint stems.

Fig. IV: Install new NYLSTOP nuts ( 1 ).
Tighten to 3.5 mdaN.
Remove the two fastening screws and nuts ( 3 )from the
steering gear box.
Refit the wheels and tighten them

Check and adjust the wheel alignment.

Fig. V:

Remove the steering gear (4).

.. . * <; -. -.- - 'id
' .
i i'.
 LIST OF OPERATIONS APPEARING IN CHAPTER: VEHICLE CONCERNED
BRAKING ENGINE TYPE
Specia! Super 11 14 GTi C 15 C 75
Club Adm. TRS diesel petrol
Operation DESCRIPTION GRAPHIC OPERATION LAYOUTS -
number 652 1124 1124 1360 1580 1769 1124
r/06/63( 10915 109 K 150 D 180 A 161 A 109 K

Toohng X X X X X X X

Character~sticsand special features of the braking system X X X X

(see MAN 108131) X

(see MAN 108131) X X

Working on the front brakes: removing and fitting the front brake pads X X X X
(see MAN 108131)

Working on the rear brakes: removing and fitting the brake shoes X X X X
(see MAN 108131)

Bleedmg the brakes (see MAN 108131) X X X

Adjusting the handbrake -Adjusting the braking system compensator X X X X

Bleeding the brakes.

Workmg on brakes - Replacing the rear brake linings X

(see Op. VD 422-3 a) X X

Adjusting the handbrake (see MAN 108131) X X

-
 DESCRIPTION

- Tools.

- Characteristics and special features of the braking system.

@ 1
- Adjusting the handbrake.
- Adjusting the braking system compensator.
- Bleeding the brakes.

- Working on brakes.
- Replacing the brake linings.
) E MINI

0.07 mm MAXl

El - E2 = 0.02 mm MAXl

1 8 1 mm MAXl 229,6 mm MAXl 181 mm MAXl

FE MINI
U 7 N . F . R . 1 2 6 - 4 0 - S - S.A.E. J 1 7 0 3

C 15 E
17 RD 14 TRS
GTi

A
 HANDBRAKE ADJUSTMENT
VD Di
2 BRAKING SYSTEM COMPENSATOR ADJUSTMENT
453-0
BLEEDING OF BRAKING CIRCUITS

HANDBRAKE ADJUSTMENT

-Actuate the hydraulic brake t w o or three times by depressing the pedal.

- Place the handbrake lever at the third notch of its travel.
Fig. I : Loosen lock-nut (2) and turn nut (1) until the rear brakes start t o apply (C 15 E - C 15 D).
Fig. I1 : Unscrew the sheath stops (--) until the rear brakes start to apply (VISA 17 D - 17 RD - 14 TRS - GTi).
-Balance the tension of the R.H. and L.H. cables.
-Check that the rear wheels are locked for a handbrake lever travel of 5 notches.
-Tighten the sheath stop lock nuts ( - ) or lock nuts (2).

BRAKING SYSTEM COMPENSATOR ADJUSTMENT

Forcibly depress t h e brake pedal t o close the compensator.

= 1 t o 1.5 m m (VISA 17 D - 17 RD - 14 TRS - GTi)
Fig. 111 : Adjust cable clamp (5) so as t o obtain a clearance J
=4to5rnm(C15D-C15E)
between the support face of the cable clamp and lever (4).

BLEEDING OF BRAKING CIRCUITS

- Bleed each wheel cylinder beginning at the front of the vehicle

Bleed: R.H. front side and L.H. front side.
R.H. rear side and L.H. rear side.

- Put a transparent tube on each bleed screw, the end of the tube being immersed in a clean receptable.
- Depress the brake pedal.
- Open the bieed screw.
- Hold the pedal right down.

- Close the bleed screw.

-Slowly release the pedal as far as abutment.
- Repeat the operation until all air bubbles disappear.
-Apply the same procedure for the other wheels.
 VD Di
2 WORK O N BRAKES
453-1

REMOVAL A N D FllTlNG OF REAR BRAKE SHOES

DBA fitting

REMOVAL

Loosen the rear wheel nuts Fig. I. Fig. IV:

Raisethevehicle using crossmember 1509-T, engaging
i t in securing lugs "a".
Remove rear cap (4)

Any other raising point is to be excluded.

Pin the crossmember at "b".

Position wheel jacks under jack support point. Fig. V:
Remove the wheels.
Insert a r o d through the orifice and actuate lever (5)
at "c".
Disengage handbrake cable.
Remove return springs (6) and (7).
Remove Fig. 11:
- cap ( I ) .
- nut ( 2 ) w ~ t h o u unlocking
t it,
- washer (3).

Remove the d r u m assemblv.

Remove Fig. VI:

- caps ( 8 ) .
Fig. Ill: - support springs (9).
In the event of difficulty with extraction:
- brake shoes ( 1 0).
Position a d r u m hole opposite the automatic wear
- seal ( 1 1 ) .
take up device sector; actuate the sector (*) w i t h
a screwdriver so as t o free the brake shoes.
Remove wheel cylinder, if necessary
I . . ..
 VD Di
WORK O N BRAKES 5
453- 1

Fig. IV and V:
There should ha no ail nor grease m;arks on
the drums and shoe ITnfrrgs,
Insert a rod through the orifice at "a" and actuate
lever ( 7 ) at "b" so as to make handbrake cable
hooking possible.
Fit hole "a" plug.

Fit the wheel cylinder, if need be.

Fit, Fig. VI:

Fit, Fig. I: - a new seal (8),

- brake shoes ( 1 ) equipped w i t h the automatic wear - the drum assembly,
take u p device. - the plain washer (9).
- t h e new nut (10). Tighten to 19 mdaN. Lock
it with a round ended tool,
- the sealing plug ( 1 1 ).

Fit, Fig II: Bleed the rear brakes, i f n e e d b e

- support springs ( 2 ) ,
- caps ( 3 ) .and lock them Adjust the handbrake.

Fit the wheels.

Fig. Ill:
Actuate lever (4)wnt~la min. l i n ~ n g
dia is obtained (+).
Fit return springs ( 5 ) and ( 6 ) .
 LIST OF OPERATIONS APPEARING IN CHAPTER: VEHICLE CONCERNED
ELECTRICAL EQUIPMENT AND RADIO
I
Specia Supe 11 14 17 C 15 C 15
Club Adm. TRS diesc diese
Operation
number
DESCRIPTION GRAPHIC OPERATION LAYOUTS - - petro
652 1124 1124 1360 176! 176: 1124
V06163 1091E 109 K G -
l61 161 ! 109 1

VD 510-000 Arrangement of the electrlcal lnstallat~on(General outlmes) (see MAN 108131) -718, X -718

VD 510-000 a Arrangement of the electrlcal lnstallatlon (General outltnes) 7/84 - 7/84 - X X X X

VD Di 510-00 Arrangement of the electrtcal rnstallatton -711

VD 510-00 Arrangement of the electrlcal lnstallatlon 7184 - 7184- X 184- X X

VD1 510-00 b. Arrangement of the electrlcal lnstallatlon (see MAN 108131) -7/&

VD2 510-00 p Arrangement of the electrlcal lnstallatlon (see MAN 108131) X -7188

VD 520-1 Removlng and f~tttngan tnstrument panel -m 'da 0 7/84 - 7184- X 184- X X

VD Di 520-3 Recondttlonlng a JAEGER Instrument cluster L(%

f .L
("K -63 -71m X -718, -7lE

L(x
f
0
f a
VD 520-3 a Recond~ttoncnga VEGLIA Instrument cluster p% X
7184- 7184- '84 - X X

VD 520-3 b Qecondttlontng a JAEGER Instrument cluster L(% **K

VD 522-1 Yemovlng a swttch 7/84 - 7/84. - X 84- X X

VD 532-00 Characterlstlcs and checks of a charglng clrcutt X X X

7184- '184- X

VD1 532-0 :haractertsttcs and checks of the electrlcal components (see MAN 108131) -718

VD2 532-0 :haracterlstcs and checks of the electrlcal components (see MAN 108131) X -7184
/--
/

VD 533-00 :haracterlstlcs of a starter motor X X X X X X

VD Di 540-0 4djust1ngheadlamps X X X X X X X

VD 961-0 :hecklng a rear wlndows heatlng element (see MAN 108131) X X X X X

 ARRANGEMENT OF THE ELECTRICAL INSTALLATION
(General outlines)

PRESENTATION:

The electrical system operations are composed of:

- a fuse table,
- a lamp table,
- a parts position list,
- a feed diagram (identification I),
- function diagrams (identification marks. II,III)
- a wiring diagram.
- an earthing points list (see page 6).

UTILISATION:

The wiring diagram indicates the layout of the leads in the harnesses and the connecting blocks, as well as the approximate
location of the components on the vehicle.

The feed diagram shows:

- the feed circuit for function diagrams,
- the symbol table for various function diagrams.

The function diagrams present the various circuits in a functional way.

The arrows, po~ntingto the upper line of frame on a function diagram, correspond to the ones, which show the same function,
on the feed diagram (order is unchanged).

Feed and function diagrams:

Certain equipment fulfills several functions and it may be shown exploded and located along several lines and diagrams.
Switches are shown at rest, with vehicle stationary, with the anti-theft switch open and the doors closed.
Single contact switches move from right to left: switches, relay contacts (the position of the coil for a relay, generally to the
left of the contact switch, is not compulsory).
Where the inverter or selector switch is complex, the contact movements are shown in the manner to be considered the most
comprehensible. The electronic parts are not shown in detail. The equipment symbols (in the function and feed diagrams), are
those shown on the "symbol key" (see page 5).
 VD
ELECTRICAL INSTALLATION, GENERAL OUTLINES
2 510-000 a

Parts lists:

For any electric operation, refer to the general lists of parts (large numeral figures) and harnesses (capital letters)
pages 3 and 4.
The same position part list indicating:
- 1st column: the reference of the part (large Arabic numeral);
- 2nd column: the position of this part on the wiring diagram (small letter);

- 3rd column: the supply or function diagram to be considered (Roman numeral);

- 4th column: the position of this part on the supply or function diagram (small Arabic numeral).
it is used for both wiring diagram and supply or function diagram.

Colour codes:
N = Black Or = Orange BI = Blue B = White
M = Brown J = Yellow M v = Mauve (violet) Ic = Transparent
R = Red V = Green G = Grey

0 When alone, above letters indicate the colour:

- of a wire (one letter topped by an horizontal dash).
- of an end fitting.
- or of the marking on a wire.

Examples. - B : white wire; B = white mark (end fitting or marking).

VG : green wire with grey mark (end fitting or marking).

0 When in a rectangle, a letter (with figures) identifies the channel and connection block used.

Examples. - 1- : 2nd channel of the blue connector with 8 channels

I 0B5 I : 5th channel of the white connector with 10 channels.
: 3rd channel of the brown connector

Note: m3 = Earthing point No. 3.

KEY TO DIAGRAM SYMBOLES

1. Socket connection. 9. Manual switch. 17. Motor.

2. Wiring connector. 10. Switch (fixed positions). 18. Dial.
3. Connecting block. 11. Mechanical switch. 19. Resistor.
4. Screened conductor(s). 12. Pressure switch. 20. Rheostat.
5. Fuse. 13. Temperature switch. 21. Coil (relays, etc).
6. Diode (rectifier). 14. Lighting. 22. Earthing point.
7. Accumulator. 15. Warning lamp. 23. Electronic unit.
8. Condenser. 16. Sound equipment. 24. Delay unit.
 ARRANGEMENTS OF THE ELECTRICAL INSTALLATION VD
GENERAL OUTLINES 3
510-000 a

PARTS LIST

Cigar lighter L.H. main beams

Distributor R.H. main beams
Alternator L.H. front direction indicator
Horn R.H. front direction indicator
Battery L.H. rear direction indicator
Monitoring unit R.H.rear direction indicator
lgnition coil L.H. main and dipped beams
lgnition unit (module) R.H. main and dipped beams
Electronic unit for oil level L.H. rear loudspeaker
Pre-heater control unit R.H. rear loudspeaker
Sparking plugs Rear foglamp switch
Heater plugs Switch for L.H. front window winder
TDC sensor Switch for R.H. front window winder
lgnition pick up No. 1 Switch for heated rear window
lgnition pick up No. 2 Check button for brake fluid level warning lamp
lgnition vacuum sensor Switch for rear window wipelwash
Speed sensor Switch for rear screen intermittent wiper
Computer Switch for air cooling fan
Flasher unit Switch for hazard warning signal
Tailgate switches on keyboard Injectors
Tailgate contact switch Fuel gauge
Contact switch for door locking device Map reading lamp
Contact switch for reversing lamps Windscreen wiper motor
Stoplamp contact switch Rear window wiper motor
Handbrake contact switch L.H. front window winder motor
Contact switch on throttle spindle R.H. front window winder motor
Choke contact switch Motor for R.H. front door locking device
Anti-theft device contact switch Motor for L.H. rear door locking device
Door pillar contact switch (L.H. front door) Motor for R.H. rear door locking device
Door pillar contact switch (R.H. front door) Engine electric cooling fan, R.H.
Contact switch for brake fluid level Engine electric cooling fan, L.H.
Contact switch for min-water level Clock
Liclhtincl switch Oil pressure switch
selector switch for window wiper, flasher, horn L.H. headlamp
Selector switch for lighting. flasher, horn R.H. headlamp
Switch for lighting, windscreen wiper, flasher, horn L.H. front brake pads
Selector switch for screen wipelwash R.H. front brake pads
Auxiliary-air regulator Windscreen washer pump
Condenser coil "+" terminal Rear screen washer pump
Tachometer Petrol pump
Horn compressor Centre interior lamp
Starter motor Diagnostic socket
Flowmeter Radio terminals
Electric cut out control on pump Injection relay
Lighting for heater control Electric fan relay
Ashtray lighting Dipped beams relay
Boot lighting Horn compressor relay
Lighting for L.H. number plate Front window winder relay
Lighting for R.H. number plate Windscreen wiper relay
Lighting for anti-theft switch Rear screen wiper relay
Floor lighting, passenger side Relays for accessories
Idle cut-off Relay for electric fan 2nd speed
L.H. side lamp Relay reversing the electric fan speeds
R.H. side lamp Electric fan 2nd speed resistance
L.H. tail lamp Rheostat for illumination
R.H. tail lamp L.H. side repeater
L.H. rear lamp (cluster) R.H. side repeater
R.H. rear lamp (cluster) Probe for oil level
L.H. stop lamp flater temperature sensor
R.H. stop lamp flater temperature sensor (injection)
L.H. rear fog lamp 3il pressure sensor
R.H. rear fog lamp 3il temperature sensor
L.H. reversing lamp Electric fan thermal switch on coolant circuit
R.H. reversing lamp flater temperature switch
Fuses reversing lamp 4ir conditioning cooling fan
L.H. dipped beams leated rear window
R.H. dipped beams =re-heating warning lamp
 VD
4 ELECTRICAL INSTALLATION, GENERAL OUTLINES
5 10-000 a

HARNESS PARTS LISTS

Iront (no mark on feed and function diagrams)

ilectric fan

C -.H. front door

I liagnostic

I oot lighting

I rom L.H. rear lamp to R.H. rear lamp

4 (ear screen washer time-delay

I ailgate, R.H.

;auge

l 'assenger's door

Vindow winder locking device

I jngine

Rear door

Interior lamp, gauge

Rear

Tailgate. L.H.

Instrument panel

Brake wear

Rear window wiper

Rear window wiper switch

Injection

Ignition
1 VISA 17 RD 1
 VlSA CLUB

VlSA CLUB (7184 +) . . 1 + 12

VlSA 11RE (7184 + ) . . 13-24
VlSA 14 TRS
25 + 36

--
)(7184 -)
VlSA GT
VlSA GTi. . . . . . . . . . . 37 + 48
VlSA 17 RD (7184 + l . . 49 60
C 15 D . . . . . . . . . . . . . 61 72
C 15 E . . . . . . . . . . . . . 73.84
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 VISA, VISA Club
I VISA 71
V15A14

FEMSA : ALT 1 2 N 4 3
lI lI
DUCELLIER : 5 1 4 0 0 5 F BOSH : 0 1 2 0 4 8 9 2 5 9
MOTOROLA : 9AR5096 G MOTOROLA : 9AR2728 F MELCO : A 0 0 2 T 27091
PARIS-RHONE : A 1 3 N 9 5

4 5 0 mini 650 mini

3 3 mini
I 4 7 mini

I
FEMSA DUCELLIER : 5 1 1023A
MOTOROLA : SRC 7 0 5 6 MOTOROLA : SRC 70 5
BOSCH : 1 1 9 7 3 1 1 0 0 8

PARIS-RHONE : Y H 19251
U (volts)
 VlSA VISA 11, VISA 14 VISA GTi VlSA 17
VlSA Club VlSA GT, C 15 E C 15D

BOSCH
DUCELLIER 532 012 B
FEMSA 9 000 334 101
ISKRA AZE 03 08
MAGNETI-MARELLI 632 205 35
MELCO
M 001 T 50 172
PARIS-RHONE

400 mini 565 mini 1256 mini

A
G 53-6

B a
L 53-13 b
-li'l ,----- --- - - - - - -.---

lll

L-- -- . -1l
Il

V 53-8

b A1 + A2 A1

VlSA
VlSA Club 22 maxi. 31 mini.

VlSA 11, VlSA 14

VlSA GT, C 15 E 16.5 maxi. 25,4 mini.
60 A maxi. 16 A maxi.
VlSA GTi 4 mini. 5.4 mini.

VlSA 17
C 15 D 4 mini. 6,5 mini.