- Carry out a driving cycle simulating a hilly/urban route with frequent gear chages to heat up the clutch/engine assemblies. Evaluate the problem in the following usage conditions:

- with the vehicle speed constant in 3rd-4th speed and the engine speed about 4-5 revs max torque, accelerate the engine rapidly with the accelerator pedal fully depressed.

- carry out departures from a standstill on a flat surface re-engaging the clutch and accelerating gradually from an initial engine speed of 1000-1500 rpm.

Carry out a departure from stationary in 4th gear releasing the clutch pedal gradually and checking for the fault: the vehicle does not move and the engine does not cut out.

1. Clutch lever on gearbox travel incomplete.

2. Clutch pedal free play insufficient

1. Move on to Step 2

2. Move on to Step 2

Clutch pedal disconnected from transmission

Op. 3330B26 CLUTCH PEDAL - R+R

check that the travel is free and there is no sticking or hardening.

Replace the pedal

Op. 3330B26 CLUTCH PEDAL - R+R

Release the clutch control cylinder from the lever and check that the latter is free

If it is free, move on to Step 4, otherwise move on to Step 7

- Release the cylinder from the clutch control lever, keeping it connected to the hydraulic system.

- Press the pedal producing the thrust pressure and check the push rod travel.

- Using a drift, retract the push rod checking that it travels freely

With the part at the bench, apply pressure (using compressed air) and check the push rod travel (the test mirrors what was done in the vehicle).

N.B.: This test is designed to ensure that the problem is due to the cylinder and not to the pipes or the pump.

1. Hydraulic pump malfunction.

2. Flexible pipe from clutch reservoir to pump worn or distorted.

3. Flexible supply pipe to clutch control cylinder worn or distorted

1. Replace the pump

Op. 1820B20 MASTER CYLINDER (PUMP) - R + R

2. Replace the pipe

Op. 1820B40 HOSE FROM CLUTCH RESERVOIR TO MASTER CYLINDER (PUMP) - R + R

3. Replace the pipe

After the gearbox has been removed, check that there is no hardening of the lever (as a result of dirt or insufficient greasing) and that the plate bearing slides freely in its housing and shows no signs of damage.

The thrust bearing offset reference on the diaphragm spring may indicate that the centering is not correct.

1. The presence of dirt or wear due to insufficient greasing does not allow the thrust bearing to slide correctly.

2. Thrust bearing not correctly centered.

1. Replace the faulty or damaged components

2. Ensure that the bearing is correctly centered

For the 1.2 8v, 1.4 8v, 1.3 JTD;

Visually inspect the state of the clutch assembly, making sure there are no breaks and/or signs of overheating on the plate, obvious deterioration of the driven disc or grease/oil on the friction surfaces.

Measurements using the gauge as in the manual.

1. Obvious deterioration of the clutch disc and/or plate broken

2. Clutch plate with vitrified seal

3. Oil or grease on the disc

4. Diaphgram spring broken.

1. Replace the assembly

2. Replace the clutch plate

3. Remove the oil or grease on the disc

4. Replace the mechanism

For the 1.9 JTD;

Visually inspect the state of the clutch assembly, making sure there are no breaks and/or signs of overheating on the plate, obvious deterioration of the driven disc or grease/oil on the friction surfaces.

Measurements using the gauge as in the manual.

1. Obvious deterioration of the clutch disc and/or plate broken

2. Clutch plate with vitrified seal

3. Oil or grease on the disc

4. Diaphgram spring broken.

1. Replace the assembly

2. Replace the clutch plate

3. Remove the oil or grease on the disc

4. Replace the mechanism

Check the following, in order:

- for excess grease on the clutch plate hub bushes and the gearbox main shaft;

- the condition of the main shaft hub.

Check the condition of the flywheel. In particular, check:

- the state of the surface;

- wear;

- cuts;

- presence of grease/oil on the disc surfaces;

- signs of overheating.

1. Flywheel damaged

2. Presence of dust in the flywheel friction seal.

1. Replace the flywheel

2. Remove the dust from the flywheel friction seal.