| | 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 departures from a standstill letting the engine and, in particular, the clutch reach operating temperature.- Carry out departures from a standstill with the engine speed not below 1000 rpm releasing the clutch pedal gradually simulating the vehicle driving in traffic at a speed of around 10-20 km/h for a few seconds.- Carry out departures at different engine speeds, hot and cold, at different gradients.- Let the vehicle reach a constant speed (about 1000 rpm in 4th gear) and, with the clutch pedal released, accelerate quickly by fully depressing the accelerator pedal.- Check whether there is irregular advance (jerking). | Move on to Step 1 | Presence of irregular advance (jerking) | Check that the engine supports are properly secured |
| 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 4 | 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 |
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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 3 | Clutch pedal clearance or hardening | Replace the pedal Op. 3330B26 CLUTCH PEDAL - R+R |
| 3 | 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 4 | 1. The centering pins are missing2. The flexible couplings have become loose. | 1. Correct the problem by inserting the centering pins2. Restore the correct closure |
| 4 | 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 5 | 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 |
| 5 | 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 6 | 1.Obvious deterioration of the clutch disc and/or plate broken2. Disc distorted3. Plate with vitrified seal4. Oil or grease on the disc5. Break at the base of the clutch disc friction material support segments6. Flexible coupling system seriously damaged. | 1. Replace the assembly2. Replace the clutch plate3. Replace the clutch plate4. Remove the oil or grease.5. Replace the clutch plate6. Replace the mechanism |
| 5 | 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 6 | 1.Obvious deterioration of the clutch disc and/or plate broken2. Disc distorted3. Plate with vitrified seal4. Oil or grease on the disc5. Break at the base of the clutch disc friction material support segments6. Flexible coupling system seriously damaged. | 1. Replace the assembly2. Replace the clutch plate3. Replace the clutch plate4. Remove the oil or grease.5. Replace the clutch plate6. Replace the mechanism |
| 6 | 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 7 | Main shaft damaged, hub worn, excess grease on the bushes. | Replace the hub and/or main shaft |
| 7 | 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;- signs of overheating;- presence of grease/oil on the surfaces. | 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. |