gearbox Alfa Romeo MiTo 2008 Owner handbook (in English)

Engine compartment junction boxfig. 91
DEVICE PROTECTEDFUSE AMPERE
Ignition deviceF03 20
Passenger compartment fanF08 40
Additional heater (Turbo TwinAir and 1.3 JTD
M-2versions)F09 5
Two-tone hornF10 15
Main beam headlightsF14 15
Additional heater (PTC 1)F15 30
Air conditioning compressorF19 7.5
Heated rear windscreen, demisting system F20 30
Electric fuel pump in tankF21 15
Front fog lightsF30 15
Additional heater (PTC2)F81 60
Additional heater (PTC1)F82 50
Additional heater (PTC2)F82 40
FreeF83 –
HI-FI sound system (control units, Bassbox speaker) mechanical gearbox setup F84 20
Power socket on tunnelF85 15
Electric door mirror demisters / Demisters on windscreen jets / Relay switch coil for heated
windscreenF87 7.5
113

Luggage compartment fuse boxfig. 95
DEVICE PROTECTEDFUSE AMPERE
Electric roof opening systemF1 20
Luggage compartment power socket F3 15
Front seat heatingF6 15
IMPORTANT
28)Never replace a fuse with metal wires or anything else.
29)If it is necessary to wash the engine compartment, take care not to directly hit the fuse box and the window wiper motors with the water jet.
WARNING
112)If a fuse blows again, contact an Alfa Romeo Dealership.
113)Never replace a fuse with another with a higher amp rating; DANGER OF FIRE.
114)If a general protective fuse (MAXI-FUSE, MEGA-FUSE, MIDI-FUSE) blows, contact an Alfa Romeo Dealership.
115)Before replacing a fuse, make sure that the ignition device is at STOP, that the key, if mechanical, has been removed and that all devices are
switched off and/or disconnected.
116)Contact an Alfa Romeo Dealership if a safety system (airbags, brakes), transmission system (engine, gearbox) or steering system general
protection fuse blows.
115

CARTRIDGE REPLACEMENT
Only use Fix&Go original cartridges
which can be purchased at an Alfa Romeo
Dealership.
To remove the cartridge, disengage the
coupling of the black inflation tube,
rotate the cartridge anticlockwise and
then lift it. Insert the new cartridge,
rotate it clockwise to its end of travel,
insert the coupling of the black inflation
tube blocking it with the lever and then
rewind the transparent tube into its
compartment on the compressor.
IMPORTANT
32)Show the package and the label to the
personnel charged with handling the tyre
treated with the tyre repair kit.33)Fix&Go provides a temporary repair,
therefore the tyre must be examined and
repaired by a specialist as soon as possible.
The sealing fluid is effective at temperatures
between -40°C and +50°C. It is possible to
repair tyres which have been damaged on
tread up to a diameter of 4mm; however,
tyres damaged on their side cannot be
repaired. Before using Fix&Go kit, ensure
that the tyre isn't excessively damaged and
that the rim is in good condition, otherwise
do not use it and contact an Alfa Romeo
Dealership. Do not remove foreign bodies
from the tyre. Do not let the compressor
turned on for more than 20 consecutive
minutes - overheating hazard.
WARNING
123)The information required by the
applicable regulation is indicated on the
Fix&Go kit package label. Compliance with
the indications on the label is an essential
condition to ensure the safety and the
effectiveness of the Fix&Go kit. Carefully
read the label before use, avoid improper
use. Fix&Go is subject to expiration and
must be replaced periodically. The kit should
be used by adults and cannot be used by
children.
JUMP STARTING
STARTING THE ENGINE
If theicon stays on with steady light
on the instrument panel display,
immediately contact an Alfa Romeo
Dealership.
JUMP STARTING
124)
34) 35)
If the battery is flat, start the engine
using an auxiliary battery with the same
capacity or a little higher than the flat
one.
Proceed as follows to start the vehicle
fig. 111:
connect the positive terminals (+ mark
near the terminal) of the two batteries
using a suitable lead;
with a second lead, connect the
negative terminal(–)oftheauxiliary
battery to an earth point
on the engine
or the gearbox of the car to be started;
start the engine; when the engine has
been started, remove the leads reversing
the order above.
If after a few attempts the engine does
not start, contact the Alfa Romeo
Dealership.
110A0K0521C
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IN AN EMERGENCY

JUMP STARTING(versions with Start&Stop system)
125)
When jump starting, never connect the
negative lead (–) of the auxiliary battery
to the negative pole 1 fig. 111 of the car
battery, but rather to an engine/gearbox
earth point.
BUMP STARTING
Never, under any circumstances, jump
start the engine by pushing, towing or
coasting downhill.
IMPORTANT
34)Never connect the negative terminals of
the two batteries directly! If the auxiliary
battery is installed on another car, prevent
accidental contact between metallic parts of
the two cars.35)Never use a fast battery-charger to
start the engine as this could damage the
electronic systems of your vehicle,
particularly the ignition and engine fuel
supply control units.
WARNING
124)This starting procedure must be
performed by expert personnel because
incorrect actions could cause electrical
discharge of considerable intensity.
Furthermore, battery fluid is poisonous and
corrosive: avoid contact with skin and eyes.
Keep naked flames and lighted cigarettes
away from the battery and do not cause
sparks.
125)Before opening the bonnet, make sure
that the engine is off and that the ignition
key is in the STOP position. Please follow the
instructions on the decal near the front
crossmember. We recommend that you
remove the key from the ignition if other
people remain in the vehicle. The vehicle
should always be left after the key has been
removed or turned to the STOP position.
During refuelling, make sure that the engine
is off (and that the ignition key is in the STOP
position).
FUEL CUT-OFFSYSTEM
Operation
This intervenes in the case of an impact
causing:
the fuel supply cut-off with the engine
consequently switching off;
the automatic unlocking of the doors;
the switching on of the interior lights.
The intervention of the system is
indicated by a message shown on the
display.
Carefully check the vehicle for fuel leaks,
for instance in the engine compartment,
under the vehicle or near the tank area.
126)
After a collision, turn the ignition key to
STOP to prevent the battery from
running down.
To restore the correct operation of the
car, proceed as follows:
turn the ignition key to the MAR
position;
activate the right direction indicator;
deactivate the right direction
indicator;
activate the left direction indicator;
deactivate the left direction indicator;
activate the right direction indicator;
deactivate the right direction
indicator;
activate the left direction indicator;
deactivate the left direction indicator;
111A0J0392C
123

“VELOCE” versions: remove cap 1 by
pressing on the upper part, take tow hook
2 from its housing in the tool support and
screw it in fully on the threaded pin.
WARNING
127)For versions with key without remote
control, before towing, turn the ignition key
to MAR and then to STOP without removing
it. The steering column will automatically
lock when the key is removed and the wheels
cannot be steered. Also check that the
gearbox is in neutral (on versions equipped
with automatic transmission, check that the
gear lever is in N position). For versions with
electronic key, move the ignition device to
MAR and then to STOP, without opening the
door.128)The brake servo and the
electromechanical power steering will not
work while the vehicle is being towed. You
will therefore need to apply more force on
the brake pedal and steering wheel. Do not
use flexible ropes when towing, and avoid
jerky movements. During towing, make sure
that the trailer hitch does not damage any
components it is touching. When towing the
car, you must comply with all specific traffic
regulations and adopt an appropriate
driving behaviour. Do not start the engine
while towing the car. Before tightening the
ring, clean the threaded housing thoroughly.
Make sure that the ring is fully screwed into
the housing before towing the car.
129)The front and rear tow hooks should be
used only for emergencies on the road. You
are allowed to tow the vehicle for short
distances using an appropriate device in
accordance with the highway code (a rigid
bar), to move the vehicle on the road in
readiness for towing or transport via a
breakdown vehicle. Tow hooks MUST NOT be
used to tow vehicles off the road or where
there are obstacles and/or for towing
operations using cables or other non-rigid
devices. In compliance with the above
conditions, towing must take place with the
two vehicles (one towing, the other towed)
aligned as much as possible along the same
centre line.
118A0J0039C
126
IN AN EMERGENCY

PERIODIC CHECKS
Every 1,000 km or before long trips
check and, if necessary, top up:
engine coolant, brake fluid and
windscreen washer fluid level;
tyre inflation pressure and condition;
operation of lighting system
(headlights, direction indicators, hazard
warning lights, etc.);
operation of screen wash/wipe system
and positioning/wear of windscreen/
rearscreen wiper blades
Every 3,000 km check and top up if
required: engine oil level.
IMPORTANT To find out the correct oil
quantity, always check using the dipstick.
Carry out the check with the vehicle
parked on level ground.
DEMANDING USE OF THE CAR
If the vehicle is used mainly under one of
the following conditions:
towing a trailer or caravan;
dusty roads;
short, repeated journeys (less than
7-8 km) at sub-zero outside
temperatures;
engine often idling or driving long
distances at low speeds or long periods
of inactivity;
the following checks must be carried out
more often than indicated in the
Scheduled Servicing Plan:
check front disc brake pad condition
and wear;
check cleanliness of bonnet and
luggage compartment locks, cleanliness
and lubrication of linkage;
visually inspect condition of: engine,
gearbox, transmission, pipes and hoses
(exhaust - fuel system - brakes) and
rubber elements (boots - sleeves - bushes
- etc.);
check battery charge and battery fluid
level (electrolyte);
visually inspect conditions of the
accessory drive belts;
check and, if necessary, change engine
oil and replace oil filter;
check and, if necessary, replace pollen
filter;
check and, if necessary, replace air
cleaner.
136
SERVICING AND MAINTENANCE

REFUELLING
Turbo TwinAir 1.4-litre Petrol
Prescribed fuels and original
lubricants
litres kg litres kg
Fuel tank 45 – 45 –Unleaded petrol not less than
95 RON (EN
228 specification) including a reserve of 5 - 7 – 5 - 7 –
Engine cooling system (with
climate control)5.4 5.3 5.2 4.6Mixture of distilled water and
PARAFLU fluid
UP
50%(*)
Engine sump 2.8 2.5 2.7 2.3SELENIA DIGITEK P.E. (Turbo
TwinAir versions)
SELENIA StAR P.E. (1.4 Petrol
versions) Engine sump and filter 3.3 2.8 2.9 2.5
Gearbox casing/differential 1.65 1.5 1.6 1.4TUTELA TRANSMISSION
GEARFORCE
Hydraulic brake circuit with ABS
(Anti-lock braking system)0.53 0.5 0.53 0.5 TUTELA TOP 4/S
Windscreen/rear
window/headlight washer fluid
reservoir
(**)2.2 (4.5) 1.9 (4.0) 2.8 (4.6) 2.5 (4.1)Mixture of water and TUTELA
PROFESSIONAL SC 35
(*) When the vehicle is used in particularly harsh weather conditions, we recommend using a 60-40 mixture of PARAFLUUPand demineralised water.
(**) Values in brackets refer to versions with headlight washer
169

1.4 Turbo Petrol/LPG 120 HP 1.4 Turbo MultiAir
Prescribed fuels and original
lubricants
litres kg litres kg
Fuel tank 45 – 45 –Unleaded petrol not less than
95 RON
(EN228 specification)/LPG
(1.4 Turbo Petrol/LPG 120 HP
versions)
Unleaded petrol not less than
95 RON
(EN228 specification)
(1.4 Turbo MultiAir versions) LPG tank (1.4 Turbo Petrol/LPG
120 HP versions)
(*)39 – – –
including a reserve of 5 - 7 – 5 - 7 –
Engine cooling system (with
climate control)6.3 5.0 6.0 5.3Mixture of distilled water and
PARAFLU fluid
UP
50%(**)
Engine sump 2.75 2.4 3.1 2.6SELENIA MULTIPOWER GAS
5W-40 (1.4 Turbo Petrol/LPG
120 HP versions)
SELENIA DIGITEK P.E.
(1.4 Turbo MultiAir versions) Engine sump and filter 3.3 2.9 3.5 3.0
Gearbox casing/differential 2.0 1.7 2.0 1.7TUTELA TRANSMISSION
GEARFORCE
Hydraulic brake circuit with ABS
(Anti-lock braking system)0.53 0.5 0.53 0.5 TUTELA TOP 4/S
Windscreen/rear
window/headlight washer fluid
reservoir
(***)2.2 (4.5) 1.9 (4.0) 2.2 (4.5) 1.9 (4.0)Mixture of water and TUTELA
PROFESSIONAL SC 35
(*) Maximum refuelling capacity including reserve
(**) When the vehicle is used in particularly harsh weather conditions, we recommend using a 60-40 mixture of PARAFLUUPand demineralised water.
(***) Values in brackets refer to versions with headlight washer
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TECHNICAL SPECIFICATIONS

1.3 JTDM-2Prescribed fuels and original lubricants
litres kg
Fuel tank 45 –
Diesel for motor vehicles
(EN590 Specification)
including a reserve of 5 - 7 –
Engine cooling system (with climate control) 7.2 6.4Mixture of distilled water and PARAFLU
fluid
UP
50%(*)
Engine sump 3.7 3.0
SELENIA WR FORWARD
Engine sump and filter 3.9 3.25
Gearbox casing/differential 1.8 1.5 TUTELA TRANSMISSION GEARFORCE
Hydraulic brake circuit with ABS (Anti-lock
braking system)0.53 0.5 TUTELA TOP 4/S
Windscreen/rear window/headlight washer
fluid reservoir
(**)3.0 (6.0) 2.8 (5.6)Mixture of water and TUTELA
PROFESSIONAL SC 35
(*) When the vehicle is used in particularly harsh weather conditions, we recommend using a 60-40 mixture of PARAFLUUPand demineralised water.
(**) Values in brackets refer to versions with headlight washer
,
171

Use Features SpecificationOriginal fluids and
lubricantsApplications
Lubricants and greases
for drive transmissionSAE 75W grade
synthetic lubricant.9.55550-MZ6 or
MS.90030–M1TUTELA TRANSMISSION
GEARFORCE
Contractual Technical
Reference No. F002.F10Mechanical differentials
and gearboxes
Molybdenum disulphide
grease, for use at high
temperatures. N.L.G.I.
consistency 1-2FIAT 9.55580 – GRASS IITUTELA ALL STAR
Contractual Technical
Reference No. F702.G07Wheel side constant
velocity joints
Grease for constant
velocity joints with low
friction coefficient.
N.L.G.I. consistency 0-1FIAT 9.55580 – GRASS IITUTELA STAR 700
Contractual Technical
Reference No. F701.C07Differential side constant
velocity joints
Lubricant for
electro-hydraulic
actuator (versions with
Alfa TCT)Fully synthetic oil with
dedicated additive9.55550-SA1 or
MS.90030-H1TUTELA CS SPEED
Contractual Technical
Reference No. F005.F98Lubricant for
electro-hydraulic
actuator
Brake fluidSynthetic fluid for brake
and clutch systems.
Exceeds specifications
FMVSS no. 116 DOT 4,
ISO 4925 SAE J1704.9.55597 or MS.90039TUTELA TOP 4/S
Contractual Technical
Reference No. F001.A93Hydraulic brakes and
hydraulic clutch controls
Protective agent for
radiatorsRed protective with
antifreeze action, based
on inhibited monoethyl
glycol with organic
formula. Exceeds CUNA
NC 956-16, ASTM D
3306 specifications.9.55523 or MS.90032PARAFLU
UP(*)
Contractual Technical
Reference No.
F101.M01Percentage of use: 50%
distilled water 50%
PARAFLUUP(**)
(*)IMPORTANT Do not top up or mix with other fluids which have different specifications from those described.
(**)When the vehicle is used in particularly harsh weather conditions, we recommend using a mixture of 60%PARAFLUUPand 40% demineralised
water.
173