2.1. Clutch and related parts - exploded view (model with mechanical clutch release system shown). 1. Bolt securing the casing to the flywheel (8), 2. Pressure plate assembly, 3. Slave plate, 4. Release bearing retaining clamp, 5. Release bearing, 6. Spring pin, 7. Clutch fork axle, 8. Clutch release fork, 9. Seal, 10. Return spring, 11. Bushings
2. The clutch release system is actuated on some models by hydraulic pressure, and on some models by mechanical means. The hydraulic clutch release system includes a clutch pedal, a master cylinder with a reservoir, a hydraulic pipe, a slave cylinder that operates the clutch release lever, and a clutch release bearing.
3. When the clutch pedal is pressed, hydraulic or mechanical pressure acts on the outer end of the clutch release lever. When the lever is turned, the fork presses on the release bearing. The bearing presses on the petals of the pressure plate, which in turn moves away from the clutch disc.
4. Before replacing parts, some preliminary checks should be performed to diagnose system faults.
a) First of all, check the fluid level in the clutch master cylinder reservoir (hydraulic system only). If the fluid level is too low, top up to the correct level and check for leaks in the clutch hydraulic system. If the master cylinder reservoir is empty, bleed the system as described in Section 8 and check the clutch operation again.
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b) To check the "clutch release time", set the engine to normal idle speed with the transmission in neutral (clutch pedal not pressed - engaged). Disengage the clutch (pedal pressed) and after a few seconds engage reverse gear. No friction noise should be heard. Clutch noise usually means a faulty pressure plate or clutch disc.
c) To check that the clutch is fully disengaged, start the engine (with the handbrake applied) and hold the clutch pedal approximately 12 mm from the floor. Move the selector lever between first and reverse gears several times. If the shifting does not occur smoothly, there is a malfunction. On vehicles with a hydraulic clutch system, check the stroke of the clutch slave cylinder pusher. When the clutch pedal is fully depressed, the clutch slave cylinder pusher should protrude significantly. Otherwise, check the fluid level in the clutch master cylinder reservoir and bleed the system (see section 8).
d) Inspect the clutch pedal bushing at the top of the pedal for wear or binding.
d) On cars with a mechanical clutch system, difficulty in operating the clutch pedal in most cases is caused by a faulty clutch cable. Check the cable at its entry housing for wear, rust, and traces of corrosion. If the cable appears normal, lubricate it with penetrating lubricant. If the pedal operation improves, the cable is worn and must be replaced.
e) Under the vehicle, check that the clutch release lever is securely fastened to the ball joint.