| | Results of the tests |
| 0 | PRELIMINARY CHECKS | All OK | Problems encountered | Operation |
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| - Carry out a driving cycle simulating a hilly / urban route with frequent gear changes and 4-5 departures from a standstill to heat up the clutch/engine assemblies.Assess the manoeuvrability of the gearbox by carrying out the following with the vehicle stationary and the engine idling:- engagements of reverse gear with manoeuvre times increasing from 1 to 4 seconds;- engagement of forward gears: carry out the manoeuvres by fully depressing the clutch pedal to the end of travel position.- Eliminate any obstacles to the correct clutch pedal travel (positioning of mats, interference of cables, etc.) | Move on to Step 1 | The problem only occurs when certain speeds are engaged | Continue as instructed, See table C002 GEAR ENGAGEMENT OR RELEASE DIFFICULT |
| 1 | CLUTCH LEVER TRAVEL CHECK | All OK | Problems encountered | Operation |
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| Check, inside the engine compartment, that when the clutch pedal is pressed the clutch control lever on the gearbox completes the correct travel | Move on to Step 9 | Clutch lever on gearbox travel incomplete | Move on to Step 2 |
| 2 | VISUAL INSPECTION FOR LEAKS OR SEEPAGE | All OK | Problems encountered | Operation |
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| - Visually inspect the operating cylinder and pipes.- Check that there is no seepage, leaks or damage. | Move on to Step 3 | Leaks, damage or seepage from pipes and/or hydraulic connectors | Repair the defective or damaged components |
| 3 | CHECK FOR AIR IN THE HYDRAULIC CLUTCH CIRCUIT | All OK | Problems encountered | Operation |
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| Using the operating cylinder bleed screw, check that there is no air in the circuit | Move on to Step 4 | Air in the circuit | Bleed the air |
| 4 | CLUTCH CONTROL CYLINDER CHECK (ON VEHICLE) | All OK | Problems encountered | Operation |
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| - 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. | Move on to Step 5 | Clutch control cylinder malfunction | Remove the clutch control cylinder and move on to Step 6 |
| 5 | ENGINE AND GEARBOX CASING ALIGNMENT CHECK | All OK | Problems encountered | Operation |
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| Check for the centering pins on the engine block checking whether the flexible couplings have become loose if the centering pins are not present. | Move on to Step 6 | 1. The centering pins are missing.2. The flexible couplings have become loose. | 1. Correct the problem by inserting the centering pins2. Ensure the flexible couplings are correctly closed. |
| 6 | CHECK | All OK | Problems encountered | Operation |
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| 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. | Move on to Step 7 | Clutch control cylinder malfunction | Replace the clutch control cylinder |
| 7 | CLUTCH PEDAL TRAVEL CHECK | All OK | Problems encountered | Operation |
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| With the system disconnected, check that the travel is correct when the pedal is pressed and released | Move on to Step 8 | 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 Op. 1820B48 SUPPLY HOSE TO OPERATING CYLINDER - R.R. |
| 8 | CLUTCH PEDAL CHECK | All OK | Problems encountered | Operation |
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| Clutch pedal disconnected from transmission, Op. 3330B26 CLUTCH PEDAL - R+R check that the travel is free and there is no sticking or hardening. | Move on to Step 9 | Clutch pedal clearance or hardening | Replace the pedal Op. 3330B26 CLUTCH PEDAL - R+R |
| 9 | PLATE LEVER AND BEARING CHECK (WITH GEARBOX REMOVED) | All OK | Problems encountered | Operation |
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| 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. | Move on to Step 10 | The presence of dirt or wear due to insufficient greasing does not allow the plate bearing to slide correctly | Replace the faulty or damaged components |
| 10 | CLUTCH ASSEMBLY CHECK | All OK | Problems encountered | Operation |
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| 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. | Move on to Step 11 | 1. Obvious deterioration of the clutch disc and/or plate broken.2. Oil or grease on the disc.3. Flexible coupling springs weak or broken.4. Break at the base of the clutch disc friction material support segments. | 1. Replace the assembly2. Remove the oil or grease from the disc3. Replace the mechanism4. Replace the clutch plate |
| 10 | CLUTCH ASSEMBLY CHECK | All OK | Problems encountered | Operation |
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| 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. | Move on to Step 11 | 1. Obvious deterioration of the clutch disc and/or plate broken.2. Oil or grease on the disc.3. Flexible coupling springs weak or broken.4. Break at the base of the clutch disc friction material support segments. | 1. Replace the assembly2. Remove the oil or grease from the disc3. Replace the mechanism4. Replace the clutch plate |
| 11 | CLUTCH SLIDING SPLINED HUB CHECK | All OK | Problems encountered | Operation |
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| 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. | Move on to Step 12 | 1. Main shaft damaged.2. Hub worn.3. Excess grease on the bushes. | 1. Replace the main shaft.2. Replace the hub.3. Remove the excess grease from the bushes |
| 12 | FLYWHEEL CONDITION CHECK | All OK | Problems encountered | Operation |
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| 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 | End of diagnosis | 1. Flywheel damaged2. Presence of dust in the flywheel friction seal | 1. Replace the flywheel2. Remove the dust from the flywheel friction seal |