22 · Diagnostics

Clutch not releasing correctly

Make: Fiat
Model: Doblò Factory Service Manual
Year: 2000–2010
Section: Clutch › Clutch not releasing correctly

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Fault diagnosisClutch not releasing correctly

CLUTCH NOT RELEASING CORRECTLY

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	With the engine idling, check whether the fault is present when all gears are engaged. Eliminate any obstacles to the correct travel of the clutch pedal (positions of mats, fouling of cables, etc.). Tester/Receptionist	Continue to Step 1	The fault occurs only when some gears are engaged	Continue, following the instructions in section C of the Tables
1	CLUTCH PEDAL POSITION CHECK	All OK	Problems met	Operation
	Visually check the alignment of the clutch pedal in relation to the brake pedal Tester/Receptionist	Continue to Step 2	Alignment not correct	Adjust the clutch cable linkage Op. 1820A14
2	CHECK CLUTCH LEVER TRAVEL	All OK	Problems met	Operation
	Check, inside the engine compartment, that when the clutch pedal is pressed, the clutch control lever on the gearbox performs the correct travel Tester/Receptionist or Mechanic	Continue to Step 5	Incomplete clutch lever travel on gearbox	Continue to Step 3
3	CLUTCH PEDAL CHECK	All OK	Problems met	Operation
	After disconnecting the clutch pedal from the transmission (see Assembly 1820), check that it travels freely without tight spots or stiffness	Continue to Step 4	Play or stiffness of clutch pedal	Replace the pedal Op. 3330B26
4	CONTROL CHECK	All OK	Problems met	Operation
	With the linkage released from the clutch pedal, check that there is no hardening or sticking by sliding the cable and that the cable is free and intact	Continue to Step 5	Linkage damaged	Replace the linkage Op. 1820A20
5	CHECK ON PRESSURE PLATE AND BEARING (WITH GEARBOX REMOVED)	All OK	Problems met	Operation
	After removing the gearbox, check that the lever is not stiff (because of dirt or insufficient lubrication) and that the clutch release bearing runs freely in its seating and shows no signs of damage	Continue to Step 6	The presence of dirt or wear caused by insufficient lubrication does not allow the clutch release bearing to slide correctly	Replace faulty or damaged components Op. 1820A24
6	CHECK ON CLUTCH ASSEMBLY	All OK	Problems met	Operation
	Visual check on the condition of the clutch assembly, which should not show breaks (pressure plate) and/or obvious damage (disc). Measurements using the gauge as per manual	Continue to Step 7	Obvious damage of clutch disc and/or breakage of pressure plate	Replace the assembly Op. 1820A20
7	CHECK ON CLUTCH SPLINED HUB	All OK	Problems met	Operation
	Check, in order: That there is no excess grease on the clutch plate hub bushes and the gearbox main shaft; Condition of hub and main shaft	Continue to Step 8	Main shaft damage, hub worn, excessive grease on bushes	Replace the hub and/or main shaft Op. 1810A20or OVERHAULING GEARBOXES Assembly 2110B
8	CHECK ON FLYWHEEL CONDITION	All OK	Problems met	Operation
	Check the condition of the flywheel. In particular, check: Condition of surface; Wear; Chips; Signs of overheating	Continue to Step 9	Flywheel damaged	Replace the flywheel Op. 1024B22
9	CHECK ON CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present		Fault persists	Search for the fault starting from another symptom'

0	PRELIMINARY CHECKS	All OK	Problems met	Operation
		Results of the tests
	With the engine idling, check whether the fault is present when all gears are engaged. Eliminate any obstacles to the correct travel of the clutch pedal (positions of mats, fouling of cables, etc.).	Continue to Step 1	The fault occurs only when some gears are engaged.	See table C02 GEAR ENGAGEMENT OR RELEASE DIFFICULT
1	CHECK CLUTCH LEVER TRAVEL	All OK	Problems met	Operation
	Check, inside the engine compartment, that when the clutch pedal is pressed, the clutch control lever on the gearbox performs the correct travel	Continue to Step 8	Incomplete clutch lever travel on gearbox	Continue to Step 2
2	VISUAL CHECK FOR LEAKS	All OK	Problems met	Operation
	Carry out a visual inspection of the operating cylinder and pipes Check that there are no leaks or damage	Continue to Step 3	Leaks or damage on pipes and/or hydraulic connections	Renew damaged or faulty components.
3	CHECK FOR PRESENCE OF AIR IN CLUTCH HYDRAULIC SYSTEM	All OK	Problems met	Operation
	Adjust the bleed screw on the operating cylinder to check that the system is free of air	Continue to Step 4	Presence of air in the hydraulic system	Bleed the air Op. 0010T67 Continue to Step 4
4	CHECK ON CLUTCH OPERATING CYLINDER (ON CAR)	All OK	Problems met	Operation
	Release the cylinder from the clutch control lever, keeping it connected to the hydraulic system. Press the pedal to induce the thrust pressure and check the pushrod travel. Using a punch, push the pushrod back in, checking that it travels freely	Continue to Step 5	Malfunction of clutch operating cylinder	Remove the clutch operating cylinder Op. 1820B30 Continue to Step 5
5	CHECK CLUTCH OPERATING CYLINDER (WITH GEARBOX REMOVED)	All OK	Problems met	Operation
	With the part on the bench, apply pressure (with compressed air) and check the pushrod travel (the test mirrors what was done on the car) The purpose of this test is to ensure that the fault is in the cylinder and not the pipes or pump	Continue to Step 6	Malfunction of clutch operating cylinder	Replace the clutch operating cylinder Op. 1820B30
6	CHECK ON CLUTCH PEDAL TRAVEL	All OK	Problems met	Operation
	With the system disconnected, check that when the pedal is pressed and released, the travel is correct	Continue to Step 7	Malfunction of hydraulic pump	Replace the pump Op. 1820B20
			Hose from clutch reservoir to pump worn or deformed	Replace the pipe Op. 1820B40
			Supply hose to clutch operating cylinder worn or deformed	Replace the pipe Op. 1820B48
7	CLUTCH PEDAL CHECK	All OK	Problems met	Operation
	Having disconnected the clutch pedal from the transmission (see Op. 1820B20), check that it travels freely without tight spots or stiffness	Continue to Step 8	Play or stiffness of clutch pedal	Replace the pedal Op. 3330B26
8	CHECK ON PRESSURE PLATE AND BEARING (WITH GEARBOX REMOVED)	All OK	Problems met	Operation
	After removing the gearbox, check that the lever is not stiff (because of dirt or insufficient lubrication) and that the clutch release bearing runs freely in its seating and shows no signs of damage	Continue to Step 9	The presence of dirt or wear caused by insufficient lubrication does not allow the clutch release bearing to slide correctly	Replace faulty or damaged components
9	CHECK ON CLUTCH ASSEMBLY	All OK	Problems met	Operation
	Visual check on the condition of the clutch assembly, which should not show breaks (pressure plate) and/or obvious damage (disc). Measurements with the gauge as per the manual.	Continue to Step 10	Obvious damage of clutch disc and/or breakage of pressure plate	Replace the assembly Op. 1810A24
10	CHECK ON CLUTCH SPLINED HUB	All OK	Problems met	Operation
	Check, in order: that there is no excess grease on the clutch plate hub bushes and the gearbox main shaft that the hub and main shaft are undamaged	Continue to Step 11	Main shaft damage, hub worn, excessive grease on bushes	Replace the hub and/or main shaft
11	CHECK ON FLYWHEEL CONDITION	All OK	Problems met	Operation
	Check the condition of the flywheel. In particular, check: condition of surface wear chips signs of overheating	Continue to Step 12	Flywheel damaged	Replace the flywheel Op. 1024B10
12	CHECK ON CORRECT OPERATION	All OK	Problems met	Operation
	Check that the fault is no longer present		Fault persists	Search for the fault starting from another symptom'

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Parts & tools for this job Staging For 2000 Fiat Doblò

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