E002 CLUTCH SLIPPING - Fiat - GRANDE PUNTO - eLearn

199000764 - E002 CLUTCH SLIPPING

0	PRELIMINARY CHECKS	All OK	Problems encountered	Operation
		Results of the tests
	- 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.	Move on to Step 1
1	CLUTCH LEVER TRAVEL CHECK	All OK	Problems encountered	Operation
	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 7	1. Clutch lever on gearbox travel incomplete.2. Clutch pedal free play insufficient	1. Move on to Step 22. Move on to Step 2
2	CLUTCH PEDAL CHECK	All OK	Problems encountered	Operation
	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 3	Clutch pedal clearance or hardening	Replace the pedal Op. 3330B26 CLUTCH PEDAL - R+R
3	OPERATING CYLINDER PUSH ROD SLIDING CHECK	All OK	Problems encountered	Operation
	Check the clutch operating cylinder push rod travel and return in the rest position	Move on to Step 7	Clutch control cylinder push rod travel incomplete	Release the clutch control cylinder from the lever and check that the latter is freeIf it is free, move on to Step 4, otherwise move on to Step 7
4	CLUTCH CONTROL CYLINDER CHECK (ON VEHICLE)	All OK	Problems encountered	Operation
	- 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 7	Clutch control cylinder malfunction	Remove the clutch control cylinder and move on to Step 5
5	CLUTCH CONTROL CYLINDER CHECK (WITH GEARBOX REMOVED)	All OK	Problems encountered	Operation
	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 6	Clutch control cylinder malfunction	Replace the clutch control cylinder
6	CLUTCH PEDAL TRAVEL CHECK	All OK	Problems encountered	Operation
	With the system disconnected, check that the travel is correct when the pedal is pressed and released	Move on to Step 7	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
7	PLATE LEVER AND BEARING CHECK (WITH GEARBOX REMOVED)	All OK	Problems encountered	Operation
	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.	Move on to Step 8	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 components2. Ensure that the bearing is correctly centered
8	CLUTCH ASSEMBLY CHECK	All OK	Problems encountered	Operation
	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 9	1. Obvious deterioration of the clutch disc and/or plate broken2. Clutch plate with vitrified seal3. Oil or grease on the disc4. Diaphgram spring broken.	1. Replace the assembly2. Replace the clutch plate3. Remove the oil or grease on the disc4. Replace the mechanism
8	CLUTCH ASSEMBLY CHECK	All OK	Problems encountered	Operation
	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 9	1. Obvious deterioration of the clutch disc and/or plate broken2. Clutch plate with vitrified seal3. Oil or grease on the disc4. Diaphgram spring broken.	1. Replace the assembly2. Replace the clutch plate3. Remove the oil or grease on the disc4. Replace the mechanism
9	CLUTCH SLIDING SPLINED HUB CHECK	All OK	Problems encountered	Operation
	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 10	Main shaft damaged, hub worn, excess grease on the bushes.	Replace the hub and/or main shaft
10	FLYWHEEL CONDITION CHECK	All OK	Problems encountered	Operation
	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.