1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf¶
19 excerpts.
Remove cylinder head¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 38 · Applies to: 450, 451 · AR: AR01.30-P-5800SN
5 Remove cylinder head AR01.30-P-5800SN ~ Remove timing case cover AR01.40.P-8000SM 7 Take bearing bolts (1) out of cylinder head W Installation: Replace tensioning rail (3), (2); remove tensioning rail (3) ~ Puller "450589033300 8 Remove chain sprocket on camshaft ( 4) W Installation: Replace chain sprocket on camshaft ( 4 ). 9 Remove timing chain for valve assembly (5) W Installation: Replace timing chain for valve assembly (5). 10 Remove bolts (6) and chain tensioner (7) W ln$tallatlon: Replace chain tensioner (7). ~ "BA05.10-P-1001-01G 11 Detach slide rail (8) W Installation: Replace slide rail (8). 12 Detach chain sprocket on camshaft drive (9) W Installation: Replace chain sprocket on camshaft drive (9). 13 Install in the reverse order 8 Timing chain drive Number Designation Engine Engine 160.910 160.920 BA05.10•P•1001-01G Bolt, chain tensioner to crankcase Nm 12 12 450 589 03 33 00 Puller Commercially available tools Number Designation WH58.30·Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
Remove, install hydraulic valve clearance compensating elements¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 39 · Applies to: 450, 451 · AR: AR05.00-P-2500SM
21.8.07 in up to WME01MCO12H106037 ENGINE 160.920 in MODEL 450.4 /3 as of WME4503001J000001 ENGINE 660.940 in MODEL 450.4 /3 1 Valve clearance compensating element 2 Cylinder head P05.00-2040-01 ~ ·~ Remove/install 1 Remove the cam follower AR05.00-P-2500SM 2 Remove valve clearance compensating W Installation: Wet valve clearance element (1) from mounting holes in cylinder compensating element (1) with engine oil and head (2) insert into mounting holes in the cylinder head (2). 3 Install in the reverse order
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 46 · Applies to: 450, 451 · AR: AR07.03-P-6522SM
31.10.02 '" up to WME01MCO12H106037 ENGINE 160.920 In MODELS 450.3 /4 from WME4503001J000001 1 Intake manifold 2 Bolts 3 Fuel ra/1 P07.03-2078-03 pJj~ Removing/installing 1 Remove 1ntake manifold (1) AR09.20·P-131 OSM 2 Unscrew bolts (2) in the air intake pipe (1) 1B "BA07.52-P-1001-01 D 3 Pull out the fuel distftllutor (3) with injectors I W The injectors are just place on the intake evenly from the intake manifold (1) manifold (1) axially, not locked. Replace the fuel distributor (3): i Adapt the Injection valves AR07.03-P-6522SM Fl Install in the reverse order ~Fuel rail Number Designation Engine Engine 160.910 160.920 BA07.62-P-1001-010 Bolt of fuel rail to intake manifold Nm 8 8
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 55 · Applies to: 450, 451 · AR: AR05.20-P-6292SM, AR05.20-P-6292SN
21.8.07 m up to WME01MCO12H106037 ENGINE 160.920 in MODEL 450.4 /3 as of WME4503001J000001 ENGINE 660.940 in MODEL 450.4 /3 Shown on engine 160.910 1 Roller drag lever 2 Cylinder head P05.00--2041-01 [g][gf Remove/install 1 Remove camshaft Engine 160.910/920 AR05.20-P-6292SM Engine 660.940 AR05.20-P-6292SN 2 Remove roller-type cam follower (1) W Observe correct installation position. Check roller-type cam follower (1) for wear, replace if necessary. 3 Install in the reverse order
up to WME01MC012H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 81 · Applies to: 450, 451 · AR: AP15.10-P-1580SM
21.8.07 up to WME01MC012H106037 ENGINE 160.920 in MODEL 450.3 /4 as of WME4503001J000001 Shown on engine 160.9 1 Endoscope 2 lnspectlOfl fight R4 Sparl< plvgs Pfr1 .00-2655-06 \lo! 1W Remove/install l&oanger! Risk of death caused by vehicle slip.ping or Align vehicle between oolumns of vehicle lifl ASOO.OO-Z-0010-01 A toppling off the lifting platform. and posttion four support plates at vehlele lift support poinls specified by vehicle manufacturer. 1 Lift vehicle using the vehicle lift until the rear wtieels can be turned freely 12 Remove spar1< plugs (R4) ~ AP Replace spark plugs AP15.10-P-1580SM 13 Lead a suitable hose through the spark plug threaded hole in the respedive cylinder and turn engine at the center boll of crankshaft belt pulley in the direction of engine ·rotation until the piston slands at tile bottom dead center of the cylinder to be checked \4 Attach inspection light (2) to endoscope {1) Endoscope (cold light) and lead Inspection light (2) through the h!Y!:llgotis.aftersales.gaimlerch!)'.sler.com spark plug threaded hole In the cylinder to be cllecked \t,!J Checking 5 Checl< cylinder wa.11, piston crOWTI and valv8$ W In the case of visible cylinder wear the cylinder barrel rs roughened and the honing marks are no longer visible·. The cylinder head must be removed in cases of doubt. Refer to: i Remove/install cylinder head AROt .30-P-5800S N II) Notes for evaluation of a cylinder barrel AHOl .40-P-0001.Q3SM 6 Inspect other cylinders in the same way 7 tnstall in the rewrse order
II] Test poly V-belt tension with measuring¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 85 · Applies to: 450, 451 · AR: AR13.21-P-1202SM, AR13.22-P-1202SM, AR61.30-P-1001SM
device (V-belt tension) (4): Poly-V-belt of refrigerant compressor (6) Retension limit: 300 N ~ •450589002100 If necessary: t -subject to separate repair order Tension poly-V-belt of refrigerant compressor (6), see: t ~AR Remove/Install poly V-belt of compressor AR13.21-P-1202SM 8 Check poly-V-belt tension at generator (5) W Test poly V-belt tension with measuring device (V-belt tension) (4): Poly-V-belt of generator (5) retension limit 280 N lfil • 450589002100 If necessary: t -subject to separate repair order Tension poly-V-belt of generator (5), See t ~ AR Remove/install poly V-belt AR13.22-P-1202SM [gJ ' Install ~ AR Install generator cover On model 450.3 up to 14.11.99 AR15.40-P-5032-02SM On model 450.3 as of 15.11.99 and 450.4 AR15.40-P-5032-02SN 10 Install poly-V-belt cover (3) W Lock trim panel with spreading clip (2) into the hole (arrow) and fasten with pin (1) 11 Install rear underfloor trim panel ~ AR AR61.30-P-1001SM 450 589 00 21 00 Gauge (V-belt tension)
Install radio dimming diode¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 90 · Applies to: 450, 451 · AR: PE00.19-P-1100MC
10.11.03
1
Cable
2
Connector
3
R&dlo dimming diode
A
wlre end
8
wlreend
P82.60-4373-
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 101 · Applies to: 450, 451 · AR: AR01.00-P-3050SM
26.11.02 In up to WME01MCO12H106037 ENGINE 160.920 in MODELS 450.3 /4 from WME4503001J000001 ENGINE 660.940 in MODELS 450.3 /4 (except, 450.418) Shown on engine 160.910 1 Connector 2 Coolant thermostat 3 Hose 4 Hose 5 Hose P20.10-2061-02 llol liil Removing/Installing 1 Release rear drive module AR01.00-P-3050SM ~ Drain coolant AR20.00.P-1142SM ~ Unplug connector (1) I W CheclC loclCing tabs. 4 Detach hose (3), hose (4), hose (5) at W Installation: Moisten hose (3), hose (4), coolant lhe,mostat (2) hose (5). 5 Unscrew bolls from coolant lhe,mostat (2) I!!! Engine 160 'BA20.10-P-1005•01J ~Englne660 •BA20.10-P-100S.01K 6 Remove coolant tbe,mostat (2) 7 Install in reverse order ~ Coolant pump, coolant thermostat Number Designation Engine Engine 160.910 160.920 BA20.10-P•1005--01J Boll !or thermostat housing on the cylinder Initial tightening Nm 12 12 head Retightening Nm 9.5 9.5 8 Coolant pump, coolant thermostat Number Designation Engine 660.940 BA20.10.P-1005•01 K Bolt for the,mostat housing on tile cylinder head Nm 12
8E,,;ine660¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 105 · Applies to: 450, 451 · AR: AR13.21-P-3200SM
'BA01 40,P-1003--0IN
8
Engine 160
'BA22.1o.p.1005-01 M
8Engine660
'BA22_ 10-P-1005-01N
!Ill Relainer
"450589296300
:_;i
lnslalllng
15
Remove engine blod< (4) bradtet
IW Suppart using a suitable lifter.
16
Screw in bolls for liming case oover(3)
I~ Engine 160
'BA01.4G-P-1002-01 M
8
Engine660
'BA01.4Q.P,1003--01N
17
Install rear engine mounting
IW At right rear.
AR2210-P•1160SM
[II Suppart u$1ng a suitable lifter.
18.1
Attach paly-V-belt tensiOnmg delnCe for
Only on vehicles wiU, A~ conditioning Plus
AR13.21-P-3200SM
compressor
(wiUl o
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 112 · Applies to: 450, 451 · AR: AR01.30-P-5800SN, AR01.45-P-7500SM
5.7.04 m up to WME01MCO12H106037 ENGINE 160.920 in MODEL 450.3 14 as of WME4503001J000001 P01 .40-2110-07 Oil filter cover 2 Bolts 3 Bolts P01 .40-2l1 1-01 ii,_glllJ Removlng/lnstalllng 1 lnst~ I retainer for engine block AR01 ,00-P-0201SM 12 Remove cylinder llead AR01.30-P-5800SN 13 Remove oil pan AR01.45-P-7500SM 14 Unscrew oil ·filter cover (1) Li.I Installation : Clean sealing surfaces. Replace gasket and filler element, 5 Remove poly-V-bett AR13.22-P-12 02SM 16 Unscrew bolts (2) and remove the generator I~ 'BA15.40-P-1005-0IG bracket 7 Unsaew bolts (3) of the timing case cover I~ "BA01.40-P-1002-01 M 8 Take off timing case cover I W The timing case cover is posijioned In the lower area of the crank.ease by means of dowel pins. Leve, off the timing case cover axlally to the crankshaft on the casting lug (a/Tow) on the crankshaft. ill Installation: Clean sealing surfaces and coat with sealant. 9 Install in ceverse order 8 Crankcase, timing case cover, end cover Number Designation Engine 160.910 Engine 160.920 8A01.40-P-1002-01M Bolt for Urning case cover on crankcase lnitial torq~ Nm 12 12 Continued torque Nm 9.5 9.5
Crankshaft radial seal¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 155 · Applies to: 450, 451 · AR: AR03.30-P-1700SM
1 Crankshaft radial seal 2 Timing case cover Modification notes 10.11.05 Note on dry installation of a radial shaft seating ring • added I~ ' Removing 1 Remove belt pulley 2 Lever the crankshaft radial sealing ring (1) out of the timing case cover (2) using a suitable tool rgJ ' Install 3 Clean sealing surface on the timing case cover(2) 4 Install crankshaft radial sealing ring (1) in the timing case cover (2) 5 Install the belt pulley 28.11.05 P03.20-2107-01 Step4 AR03.30-P-1700SM I l2J Do not drive in the tool too deeply otherwise the timing chain will be damaged. Do not apply tool too near to timing case cover (2) otherwise the sealing ring seat will be damaged. W The sealing surface on the timing case cover (2) must be free of grease, clean and undamaged. W The crankshaft radial sealing ring (1) must be installed dry to avoid leakage. III The timing case cover (2) and the Cfankshaft radial sealing ring (1) must make one surface. The liming case cover (2) does not have a stop for the crankshaft radial sealing ring (1 ). AR03.30-P-1700SM
Ftt rubber spacer disk to end piece 120 mm W Exhaust line opening must not face in¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 162 · Applies to: 450, 451 · AR: AR20.00-P-1142SM, AR61.30-P-1001SM
59 Ftt rubber spacer disk to end piece 120 mm W Exhaust line opening must not face in (5) direction of travel. 60.1 Install diagonal strut (8) Wonly model 450.4. 8 •BA61.25-P-1001-01 C 61 Pour in coolant ~AR Drain/fill In coolant AR20.00-P-1142SM ~2 Connect ground cable to battery ~AR Disconnect/connect battery's ground cable AR5-4.10-P-0003SM 163 Install underbody paneling ~AR Remove/install undert>ody paneling AR61.30-P-1001SM 64 Seeure all loose lines wi1h cable straps 65 Coat heater unit components with a.nlicorrosion wax 66 Start engine., set vehicle heating to "warm• and select blower stage , or 2 67 Select "Defrosr posttion 68 Perfom, an operation check on the stationary heater 69 Glue warning sign (24) onto El-pillar in area of striker and wof1<s label duplicate (25) in area of door hinges Concluding work 70 Fill in the warran·ty certificate W For the customer, the manufacturer and thewof1<shop. 71 Fill in the installation confirmation and place in the vehicle 72.1 Add specfal equipment to the vehicle data Wonly at workshops without OMS Autoline card and to the online vehicle data card 8.0 dealer system. [II Stationary heater, code 112. 73 Perform test run of stationary heater: in the W Stationary heater diagnostic tool event of malfunction connect stationary Order number00021664VOOOOOOOOO heater diagnostic tool and troubleshoot. ~AR Finally, delete the fa.ult memory Connect diagnostic tool to auxiliary heater AR83.7Cf.P-0017SM (water heater) ~ Diagonal strut to underbody Number Oeslgnatlon Model 450.4 BA61.25-P-1001-01C Bolt, diagonal strut to unde_rbody Nm 70 Twist drill set Workshop equipment ! Drill (electric/pneumatic)
P05.20-2297-09¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 247 · Applies to: 450, 451 · AR: AR05.20-P-6020MCC
21.8.07 P05.20-2297-09 1 Expansion clip 4 Center bolt 6 camshaft adjuster 2 Cover 5 nmlng case cover 7 Camshaft sprocket 3 Crankshaft bell pulley ~ Remove/Install 1 Remove cy·linder head cover AR01.2()..P-5014MCC 2 Detach right rear wheel AR4010-P-1100MCC 3 Remove expansion clips (1) and remove cover (2) 1~, Checking 4 Copy marking (arrow A) to the crankshaft I W If necessary, tum engine at the center belt pulley (3) onto the front side using a bolt (4) of crankshaft belt pulley (3) in the suitable colored pencil direction of engine rotation. 5 Rotate engine in direction of engine rotation until scribe marl< (arrow A) on pulley/ vibration damper (3) corresponds with scribe mark (arrow B) on timing case (5) 6 Lower vehicie with lifting platform 7 Ched< whether the marking (arrow C) on W Set basic position of camshafts if camshaft adjuster (6) and marking (arrow D) necessary, see: J on camshaft sprocket (7) stand opposite each other at the height of the upper edge of the timing case cover (5) S.et basic posihon of the camshafts AR05.20-P-6020MCC 8 Install in the reverse order
Replace poly-V belt (5) or poly-V belt of¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 282 · Applies to: 450, 451 · AR: AR13.21-P-1202MCC
. Replace poly-V belt (5) or poly-V belt of refrigerant compressor (4) - subject to a separate repair order. ~ AR Remove/install poly-V belt Engine 132.9 except in model model AR 13.22-P-1202MCC 451.380/480 Engine 660.9 AR13 22-P-1202MCD ~ AR Remove/install poly-V belt of starter- alternator Engine 132.9 in model 451 .380/480 AR13 22-P-0005MCC On vehicles with code (101) Air conditioning Plus ~ AR Remove/install poty-V belt for compressor Engine 132.9 AR13.21-P-1202MCC Engine 660.9 AR13 21-P-1202MCD ~ ' Install ~ Position cover (3), insert expansion clips (1) and press in pins (2) 5 Lower vehicle with lifting platform
Spam plugs¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 283 · Applies to: 450, 451 · AR: AR15.12-P-2003MCC
30.11.06 R4 Spam plugs P15.10-2222-11 ,ld~ Remove/install 1 Remove ignition coils ~AR Remove/install ignition coils AR15.12-P-2003MCC 2 Unscrew spark plugs (R4) ~ 'BA15.10-P-1001-01 B 3 Install in the reverse order ~ Spark plugs Number Designation Engine 132.9 BA15.10-P-1001-01B Spark plugs Initial torque Nm 18 Continued torque Nm 18
P05.20-2297-09¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 297 · Applies to: 450, 451 · AR: AR05.20-P-6020MCC
21.8.07 P05.20-2297-09 1 Expansion clip 4 Center bolt 6 camshaft adjuster 2 Cover 5 nmlng case cover 7 Camshaft sprocket 3 Crankshaft bell pulley ~ Remove/Install 1 Remove cy·linder head cover AR01.2()..P-5014MCC 2 Detach right rear wheel AR4010-P-1100MCC 3 Remove expansion clips (1) and remove cover (2) 1~, Checking 4 Copy marking (arrow A) to the crankshaft I W If necessary, tum engine at the center belt pulley (3) onto the front side using a bolt (4) of crankshaft belt pulley (3) in the suitable colored pencil direction of engine rotation. 5 Rotate engine in direction of engine rotation until scribe marl< (arrow A) on pulley/ vibration damper (3) corresponds with scribe mark (arrow B) on timing case (5) 6 Lower vehicie with lifting platform 7 Ched< whether the marking (arrow C) on W Set basic position of camshafts if camshaft adjuster (6) and marking (arrow D) necessary, see: J on camshaft sprocket (7) stand opposite each other at the height of the upper edge of the timing case cover (5) S.et basic posihon of the camshafts AR05.20-P-6020MCC 8 Install in the reverse order
Replace poly-V belt (5) or poly-V belt of¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 309 · Applies to: 450, 451 · AR: AR13.21-P-1202MCC
. Replace poly-V belt (5) or poly-V belt of refrigerant compressor (4) - subject to a separate repair order. ~ AR Remove/install poly-V belt Engine 132.9 except in model model AR 13.22-P-1202MCC 451.380/480 Engine 660.9 AR13 22-P-1202MCD ~ AR Remove/install poly-V belt of starter- alternator Engine 132.9 in model 451 .380/480 AR13 22-P-0005MCC On vehicles with code (101) Air conditioning Plus ~ AR Remove/install poty-V belt for compressor Engine 132.9 AR13.21-P-1202MCC Engine 660.9 AR13 21-P-1202MCD ~ ' Install ~ Position cover (3), insert expansion clips (1) and press in pins (2) 5 Lower vehicle with lifting platform
Spam plugs¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 310 · Applies to: 450, 451 · AR: AR15.12-P-2003MCC
30.11.06 R4 Spam plugs P15.10-2222-11 ,ld~ Remove/install 1 Remove ignition coils ~AR Remove/install ignition coils AR15.12-P-2003MCC 2 Unscrew spark plugs (R4) ~ 'BA15.10-P-1001-01 B 3 Install in the reverse order ~ Spark plugs Number Designation Engine 132.9 BA15.10-P-1001-01B Spark plugs Initial torque Nm 18 Continued torque Nm 18
The following components are connected to the SAM control unit¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 317 · Applies to: 450, 451 · AR: PE00.19-P-2150MCC, PE54.22-P-2000MCC, GF54.30-P-6000MCC, GF42.45-P-5120MCC, GF80.50-P-6000MCC (+5 more)
via UN 8: • Rain sensormght sensor • Tachograph Overall network (GVN), location of components t-rPE Wiring diagram of CAN bus l.:t'PE Wiring diagram for data link connector/ diagnostic socket Instrument cluster. component description Yaw rate and lateral acceleration sensor, component description Interior protection, component description Rain/light sensor, component description Battery sensor component description Component description for the alternator Alarm signal horn, component description Restraint systems control unit. component description Component description for COi control unit ME-SFI (ME) control unit, component descrip_tion 1componentdescnpllon for the"""" control unit Component description for glow output stage Component description for the automated manual tfansmission control unit Component description for the heater/air conditioning operating unit ESP control unij, oomponent description Steering ang~ sensor, component description Electric steering control unit, component description Starter-alternator control unit, component description Data link connector component desaiption GF00 19-P-0001-01MCC PE00.19-P-2150MCC PE54.22-P-2000MCC A1 GF54.30-P-6000MCC 8 24115 GF42.45-P-5120MCC 832 GF80.50-P-6000MCC For vehicles with code (V01) Anti-theft alarm system (FFO) 838 GF54 21-P-6000MCC For vehicles with code (V54) Rain/light sensor 895 GF54 10-P-2100MCC On model 451.38/48 G2 GF15.40-P-2000MCC On vehicles with engine 660.9 H3/2 GF80.50-P-6020MCC For vehicles w'rth code (VO!) Anti-theft alarm system (FFO) N2/7 GF91 60-P-4048MCC N3/9 GF07 16-P-6000MCC On vehicles wtth engine 660.9 N3/10 GF07.61-P-6000MCC On vehicles with engine 132.9 N10/10 GF54 21-P-4157MCC N14/2 GF15 20-P-2105MCC On vehicles with engine 660.9 N15/6 GF2619..P-1010MCC On vehicles with transmission 717.4 N23 GF83.40-P-3001MCD For vehicles with code (101) Air oonditioning Plus N47-5 GF42.45-P-5118MCC N49 GF42.45-P-5107MCC N68 GF46.35-P-7 t 00MCC For vehicles with code (V26) Power steering, EPS (FFO) N129 GF54.21-P-4190MCC On model 451.38/48 X11/4 GF54.22-P-2200MCC