1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf¶
289 excerpts.
~R42.1 0-P-001 OSM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 1 · Applies to: 450, 451
bEL
4!o.41 3
!Bleed brake system
119.2.08
P42.10.2193-09
Shown on model 450.3
1
Right swvi<:e grill (except
2
Bmk• fluid reservoir
4
Wlteel brake cyt/nci.r
model 4511.418)
3
Bntke caliper
llol
Remove
I
I& Danger!
Rlsk of poisoning caused by SW8llowlng
Only pour brake fluid inlo suttable and
AS42 50-Z-0001-0lA
I
brake ffuld. Rio.k of injury caused by brake
appropriately marked containers. Wear
fluid coming Into contact with sl
Connect hose of the brake fluid receptacle to I W Only dose the brake bleeder valve when¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 2 · Applies to: 450, 451
6 Connect hose of the brake fluid receptacle to I W Only dose the brake bleeder valve when the brake bleeder valve of the right wheel the brake fluid escapes free of bubbles and brake cylinder (4) and open the brake without contaminants (light color of brake bleeder valve fluid). A second person is needed who assists the brake fluid changer by slowly pumping on the brake pedal. E3 0BA42.10-P-1001-08C 7 Carry out the bleeding process on the left W Observe correct sequence. wheel brake cylinder (4). on the right brake caliper (3) and on the left brake caliper (3) in the s.ame manner l!!l 0 BA42.1 0.P-1001.QBC 83 0BA42.1 0-P-1002-03C 8 Check brake pedal travel W In the event of a soft pedal feel or long pedal travel, bleed the secondary circuit of the brake system. Bleed secondary circuit 9 Connect STAR DIAGNOSIS ;ind bleed the W The Instructions for secondary circuit secondary cfrcuJt of the brake system bleeding are specified by STAR DIAGNOSIS. A second petson is nei!ded who assists the brake fluid changer by slowly pumping on the brake pedal. ~AD Connect STAR DIAGNOSIS and read out ADOO OO-P-2000--04SM fa.ult memory 10 Press dust cap onto brake bleeder valve 11 Lower vehicle with vehicle lift 12 Disconnect brake fluid changer 13 Checi< brake fluid level and (X)treet if f~AP necessary Brake system - inspect fluid level AP42 10-P-4210SM llll ' Install 14 Screw on cap of brake fluid reservoir (2) 15.1 Install right service grill (1) On model 450.3/4 except 450.418 15.2 Install windshield In case of model 450.418 AR6710-P-1000CR 16 Check brake system for leaks AR42.10-P-0100-01SM El Fronhxle floating caliper Number Designation Model 450.3/4 BA42, 10.P-f002-03C Brake bleeder valve to brake caliper Nm 7.5 ~ Brake cy_linder Number Designation Model 450.314 BA42.10.P-1001-08C Brake bleed valve to rear axle wheel Nm 6,5 brake cylinder
BB00.40-P-0331-00A¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 3 · Applies to: 450, 451
Brake fluids (DOT 4 plus) The item number "000 989 08 07'' is decisive for release. The supplementary codes printed on the container (11th and 12th digits of number) essentially have logistic functions. This does not affect the product release. For all vehicle models from Mercedes- Sheet 331-0 Benz and smart Product name Customer, town/country MB 331.0 brake fluid 000 989 08 07 Daimler AG, Stuttgart/Gennany
Remove/install brake drum¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 4 · Applies to: 450, 451
22.8.07 1 Bralcedrum 2 Screw 3 Hub A Centering surface P42.10-2179-04 la!~ Remove/install 1 Remove left or right rear wheel W Installation: Adjust brake after mounting AR40 10-P-1100SM the rear wheel. Refer to: t Adjust drum brake AR42.10-P-1010-11SM 2 Unscrew bolt (2) of brake drum (1) 3 Remove brake drum (1) from hub (3) W Check brake drum (1) for wear. 'BE4210-P-1001-12C [TI Installation: Clean brake drum (1) on braking surface and hub (3) until metallic bright. Apply a light coating of brake paste to the centering surface (A) of the hub (3). Brake paste 'BR00~Z- t060-06A 4 Install in the reverse order Test values for drum brake Number Designation Model 450.3/4 8E42.10-P-I00l-12C Brake drum diameter New mm 203,0 Wear limit for maintenance service mm 204,5 ~uxillary repair materials Number Designation Order number 8R00.45•Z•1060-ooA Brake paste O0007 414V0OOOOO000
B<>lts¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 5 · Applies to: 450, 451
19.6.02
1
B<>lts
'
Muter broke cflln,,.,
8
Ft'Ont brake hose
2
ABS hydraulic unir
6
Sntlc.e Une
9
Rear bn,.ke hose
3
Brake lino
6.1
Bnl<eliM
10
Pre.sure reducer
4
Elnkellne
7
Srak.e One
11
Brakolln•
11.1 Brake line
12
T-pllCO
13
Wheel bralle cyllncJ.r
Modification notes
.6.05
Do not undertal
Notes on repairs to brake system¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 6 · Applies to: 450, 451
!J)
Notes on repairs to brake system
All models
AHA2.00-P-0003-01A
w
Collecl brake nuld whfch runs out In a
suitable oontaloer
ill
When inslalling do not bend brake lilles. pay
attention to routing, leaktightness a·n<1
e1&a1anoe 10 the body,
1
Ren,ove underfloor paneling
AR61 30-P-1001SM
ti. 1
Remove diagonal strul
W Only Model 450.4.
E3
'BA61.2S-1'•1001-01C
<II
Check
13
Check brake Jines tor color codings
IW Brake lines should be replaced H. with
red colof coding, they have been released at
the c;ooespoodlng screwing po;nL
See: I
Mark brake Unes
AR42 10-P-0013-05SM
"YellOYI' lod<ing paint
'BROO.◄S-Z-1027-07A
"Red" safety paint
'BROO.AS-Z-t028-07A
Brake llnes from ABS hydraulic u.nlt (2) to
mnter brake cyllndef (5)
14
Unsetew bolts (1) on brad<et of ABS
1r:::i
'BA42.30-P· 1002-03B
hydraulic unit (2)
5
Unscrew threaded connection of bral
Remove brake line (7)¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 7 · Applies to: 450, 451
10 Remove brake line (7) W On vehicles up to 3.9.01 when "!placing a brake lioo (7) for the first time upstream or downstream of the pressure reducing valve (10) both brake lines are changed due to the different length. ITI Do not damage brackets. Brake lines on rear axle 11 Unscrew threaded connedion of brake line ® Installation: Do not damage 111e 111read (11) on the right or brake line (11.1) on the when attaching oll1erwise failure of 111e brake left at T-piece (12) and wheel brake cylinder system may oCC<Jr caused by the formation (13) on the right or left of shavings. II) Counterhold al the T,piece (12) using a suitable tool. [II Seal opening In wheel brake cylinder (13) using suitable plugs. E!J 'BA42.10-P-1008-04E El "BA42.10-P-1003-04E 12 Remove brake line (11) on the right or brake I W Do not damage brackets. line (11.1) on the left 13 lnsta11 fn the reverse order 14 Bleed brake system AR42. 10-P-0010SM 15 Carry out cransposition check f$"AO Connect STAR DIAGNOSIS and read out AOOO.OO•P-2000-04SM fault memory STAR DIAGNOSIS diagnosis system 'WH58.30-Z-1048-13A 16 Check brake system for leaks AR42.10-P-0100-01 SM !!!! Brake lines, brake hoses Number Designation Model 450.31' BA42. IO-P-1002-04E Brake pipe to brake hose Nm 15 BA42.10-P,1003-04E Brake line to rear wheel brake cylinder Nm 18 BA42.10-P-1004-04E Brake line to ABS hydraulic un~ Nm 14 BA42.1 O•P .. 1005--04E Brake pipe 10 master brake cylinder Nm 14 BA42.10-P-1006-04E Brake line to pressure reducer Nm 12 BA42.11),P-1008-04E Brake line to T-piece Nm 18 B Hydraulic unit Number Designation Model 450.314 BA42.30-P-1002-038 Bolt. intermediate bracket to floor panel Nm 20 B Diagonal strut to underbody Number Designation Type 450.4 BA61.25-P-1001-01C Bolt. diagonal strut to underbody Nm 70
Ring wrench socket¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 8 · Applies to: 450, 451
450 589 09 99 04 Ring wrench socket Commercially available tools Designation STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Repair materials Number Designation Order number BR00.45-Z-1028-07A "Red" safety paint Lackfabrik Bilder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 BR00.45-Z-1027-07 A "Yellow'' locking paint Lackfabrik Bader GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092
Remove/install brake shoes at rear axle¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 9 · Applies to: 450, 451
21.8.07 1 Spring 2 Ii] Pliers 3 Spring 4 Brake shOH 5 Dustboot 6 WIIHI bral<e cytlnw 7 WIIHlhub 8 Spring 9 Handbrake cable 10 BrakecotTlerplate 11 Mull/purpose vernier cal/per A Dimension Modlflcatlon notes 114.2.06 !5pec1a1 tool modified Is1ep2 ~~ Removennstall l&oanger1 Risk of poisoning caused by swaOowlng Only POUr bteke ftuld Into suttable and AS-42 50-Z-0001-01A brake nuld. Risk of Injury caused by brake app,opriately marf<ed containers. Wear ftuid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. I® Brake ftuld notes AH42.50-P-0001-01A I® Notes on repairs to broke system AH42 OO-P-0003--01 A t Remove left or f,ght brake drum AR42.10.P-1010SM 2 Support pliers (2) on brake anchor plate (10) I® Always replace damaged or and unhook spring (1) overstretched springs (1) in the set of springs, as otheiwise the braking effect may be impaired. [Il Installation: Measure the brake shoes (4) using the multipurpose vernier caliper (11) diagooally and set 10 the dimension (A) 202.6 mm, as measured o.n the upper s-ide of the linings. ~ •450589()03700 Universal vemier gauge set htt~~/llotis aftersales.daim!!!rchraler £om ~ Remove springs (3). remove retajning pin of ® Always replace a damaged or stretched springs (3) spring (3) in the set of springs, as othefWise the braking effect may be impaired. Ii] ·4505591863-00 14 Push back spring (8) on hand brake cable (9) W Rotate w'1eel hub (7) until a bott hole Is and unhook hand brake cable (9) on bteke in the lower position shoe (4) 5 Tift brake shoes (4) upward by 90' over wheel hub (7) le Remove brake shoes (4) upwards, pressing brake pistons (6) of wheel brake eyllnde< IW Do not damage the dust boots (5), together -
Clean brake carrier plate (10)¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 10 · Applies to: 450, 451
7 Clean brake carrier plate (10) W Installation: Smear the contact surfaces (arrows) of the brake carrier plate (10) at the brake shoes (4) with a thin coating of brake paste. Brake paste *BR00.45--Z-1060-06A 8 Check ease of movement and leakproofness W If there is the slighte.st sign of brake fluid of wheel brake cylinder (6) escape or sluggishness of the brake pistons in the wheel brake cylinder (6) this must be replaced, see: l Remove/install wheel brake cylinder (6) AR42.1 0-P-0167SM 9 Install in the reverse order 450 589 00 37 00 450 58918 63 00 Pliers Removal and installation tool Auxiliary repair materials Number Designation Order number BR00.45-Z-1060-06A Brake paste Q0007414V000000OO0
!Check brake system for le<1ks¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 12 · Applies to: 450, 451
111 !Check brake system for le<1ks ~ Front axle floating caliper !AR42.10-p-0100-01sM Number Designation Model 450.314 BM2.10•P•1003-03C Bolt, brake caliper lo swiveling bearing Nm 115 E3 Brake lines, brake hoses Number Designation Model 450.314 BM2.10-P-1001-04E Brake hose to front floating caliper Nm 18 BM2.10.f'-1002-04E Brake pipe to brake hose Nm 18 450 589 09 99 04 Ring wrencll socket Repair materials Number Designation Order number 8R00.4S-Z-1028-07A ·Red" safety paint Lackfabrik Bader GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 BR00.45-Z-1027-07A "Yellow" locking paint Lacllfabrik Bader GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax+49 711 383092
Removennstall front axle brake disk¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 13 · Applies to: 450, 451
Brake disk
2
lS'.J Measuring Cllllper
3
8"'kepad
1
8,ake disk
4
Screw
5
WhHlhub
A
Cftffterlng surface
Modifaeation notes
6.9.07
MeaSllrement of dlstance between the bral<e disl< and
rake carrier added
li<il
Removing
1
Remove front wheels
~
Check wear, condition of brake pads (3) and
brake disk (1) usir19vemietcaliper (2)
13·
Remove left or righ1 brake car.per on tho
front axle
14
Remove bolt (4) and N!movo brake disk (1)
11<.>1
Install
15.1
Measure clearance of brake disl<s (1) to the
respecllve brake earlier
5.2
Clean v.1lee1 hub (5), grease centering
surface (A) llgh11y with brake paste and
tighten brake disk (1) with boft (4)
SlepS.1
B
i Farron! wheels¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 14 · Applies to: 450, 451
17 i Farron! wheels Check values for front brake pad lAR40 I0,P, 1100SM Numbe< Designation Model 450.314 8E'42.l0,,P-1001-05E Btal<e pad New (willl pad backing plate) mm 15 lhi,ckness Wear llmtt {Without pad mm s;2 backing plate) for malntenanc. seMce Wear liml (with pad bo<:klng mm s7,, plate) for rruilntananee .. rv1 .. Response ol ..... r lnd1C81ll< mm •7,7 (with pad backing plate) Test values for front btake disks Number Designation Model 450,314 ae,2.10-P-1001..QSE Brake disk lhickness New mm 9 Wearllmlt mm 8 8E42.1G-P-1002-08E Minimum distance, mm 0.5 outside of bral<e disk to bfakeeanier U.2. IQ.P-100).()8E Minimum distanoe. mm 0,85 inside of brake disk to brake canief !3 Front ule fl0011ng eallper Num:ber ues19n.anon Model 450.314 8A42.10..P~t003-03C Bolt, brake eaffper ID swlv&ling bearing Nm 115 8 Brake discs, brake cover plate Number Designation Model 450.314 BA,c2.10-P, t001-060 Se~•locking bolt or Iron! braM disk to wheel Nm 6.5 llange Repair materials Number Oeslgnatlon Order number BR00,4S...Z•106Ml6A Brake paste 00007414VOOOOOOOOO
Remove/check/Install front axle brake pads¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 15 · Applies to: 450, 451
10.7.07 P<42.10..2197..Q9 Brakecall- 5 Lug 9 ~ Brake piston pusher tool 2 Scraw 3 Sprlnf1$ 6 Bnl<opads 7 Se/lows 10 Bnkoplston 11 Dusi bOot 4 Gulde bOlts 8 Cali- suppotf 12 Up Modification notes 1450.314 •s 42.10-P-1001 l~l,.,J Remove/Install &oaogeff Risk of poisoning caused by swallowing O,,iy Pour brake ftuld Into suitable and AS42 50-Z-0001-01A brake fluid. Risk of Injury caused by brake appropriately mar1<ed conlalne11'. Wear fluid coming into conlacl with skln and eyes. protective clothing and eye protectloo when handUng brake fluid. ~ Brake fluid notes AH42.50-P-000I-0 IA ® Notes on repah 10 brake sysiem AH42.00-P-0003-01A 1 Remove left or right t,ont wheel AR40 1().P,1100SM rz Checlc wear. condition of brake pads and the Brake pad thickness •BE42. 10-P• 1001-0SE brake disks (6) usi"9 • ""mier callpe, Brake disk thickness "BE42.10-P-1001-08E ~ •450589011900 3 Undo bolt (2) on top of the brakecallper(1) IW When undoing the bolt (2) counterhold the guide pin (4) using a suitable open end wrench, 8 'BM2. 10-P· 1001-03C ~ Fold down brake callper (1) IW Installation: When folding up the brake caliper (1) ensure that the springs (3) of the brake pads (6) ore clamped under the brake callper (1). 5 Check bellows (7) ror damage W Damaged bellows (7) should be replaced. tr the lower boot (7) is damaged, then the brake caliper ossembly (1) must be replaced. [II Installation: Tum boots (7) using fingers, to make sure that the boots (7) are correctly seated. The ..,,.I1ng lip (12) of the boots (7) must be Rf'J$1fM MrrArtlv ln th-A or~ M tM
Remove brake pads (6)¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 16 · Applies to: 450, 451
~ Remove brake pads (6) @) If the brake pads (6) have been removed do not pre$$ the brake pedal as otherwise the brake piston (10) will be p,essed out of the brake caliper (1 ). (TI Pay attention to installation position of plale(5), 17 Clean conlad surfaces (arrow) on the brake pads (6) and brake cali!)er $upj)Ort (8) 18 Check upper and tower guide pins (4) I® Check for ease of movement of the upper and lower guide plns (4). II the guide pin (4) catches or Is sluggish the brake caliper ( 1) must be replaced as otherwise the braking effect may be uneven. ~ Press b;ocl< the brake piston (10) with the W The fluid level In the brake fluid reservoir brake piston teselting device (9) rise$ when the brake piston (10) is pushed back. Ensure that lhe brake fluid reservoir does not overflow. II must be possible to mow the brake piston (10) easily. Check dust boot (11) tor signs of leaks, replace W necessary. ~ 10 Apply grease to the contact sulfaces (arrows) 1<2l Installation: Apply light and un~orm on the brake ca6per support (8) and the brakepads (6) 11 Install In the reverse oroer l&oanger1 Risk of accident when comml$$ionlng the vehicle due 10 a rack of braking &ffed when the service brake ls operated f0t the first time after repair work 12 PreM the brake pedal sewral times In succession until the brake pads (6) make conlad with the brake disk 13 Check brake system for Jeaks ..,,..,..,.,: van,es ror 11v.,, 1Jnuut ~ Number Deslgnation SE.,2.10.P-1001-0SE Brake pad New (with pad bacldng plate) thickness Wear limft (without pad backing plate) for ma.intenanu service Wea.r limn (with pad backing plate) ro, maintenance service Response of wear Indicator (with pad backing plate) Test val,_ f0< front brake disks N..,mber Designation 8E42. 10-P-100t..08E Brake disk thickness New Wea, limit ~ Front axle ffoating caliper I Number I Designation coating of grease. grease musl not come into contad w'~h the l'rlctlon surfaces or tile brake pads (6) and the brake disk as otherwise the braklng effed may be Impaired. Molykote 111 grease Before starting engine, actuate brake pedal several times until the pressure is bullt up ,and maintained in the brake syslem. [I) A firm resistance must be noticeable at the brake pedal. mm mm mm mm Model 450.3/4 15 ,s;2 s 7,7 - 7,7 Model 450.3/4 mm 9 mm 8 I Model 450.314 "450589023700 "BR00.45•Z·1070-06A A5'12 50-Z-0002.01A AR-12 10-P-0100-0ISM
Vernier caliper¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 17 · Applies to: 450, 451
450 589 01 19 00 450 589 02 37 00 Vernier caliper Brake piston resetting device Auxiliary repair materials Number Designation BR00.45- -10 0- Molykote 111 grease 0014759V 00000000
Remove/Install wheel brake cylinder¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 18 · Applies to: 450, 451
10.7.07 1 Wlleel broke cyflnc/er 2 Sta/<el/ne 3 Boll$ P42,.10-a2SS7-03 l..,Jll.,J Remove/lnslall !&Danger! Risk of poisoning eausea by swauowmg Ion1y pour brake fluid into suitable and AS'42.0U-£-000t-01A brake fluid. Risk of Injury caused by brake approPriately marked con1ainars, Wear fluid coming into contact with skin and eyes. p,olective clothing and eye protection when handling brake fluid. 12) Brake fluid notes AH42.50-P-0001-0t A (2) Notes on repairs 10 brake system AH42 00-P--0003-01A , Remove left or right wheel AR40 10-P-1100SM ~ Remove brake shoes on rear axle AR42 10-P-0165SM 13 Check color coding or lhreacl«I connection of AR42.10-P-0013-05SM wheel brake cylinder (2) on lhe brake hose (1) (U lnslalfaijon: Identify the brake fine (2) eccon!i<igly. Refer to: I Mar1< brake tln8$ AR42.10-P-0013-05SM "Yellow' tocking pain! •BR00.4!>-Z-1027•07A •Red" sarety palnt •BR00,4!>-Z•102&-07A 14 1 Release tnreade<1 connec11on of brake Hne IW Collect brake fluid in a suitable container. (2) on wheel brake cyilnder (1) Seal the connections using suitable plugs. (U lnslall;otion: Do not bend brake line (2), cl1ecl< ks routing, leakproofness and freedom of movement relative to ll1e rear axle. ~ •8A42.10-P-1003-04E [S'.] ·450589099904 15 Replace brake llne (2). Only Wthe brake line (2) has been released et the corresponding screwing point W the col<>< coding is red. Model 450.3/4 up lo 2.1.03 AR42 10-P-0017SM Model 450.3/4 as of 3.1.03 up to 31.12.04 AR42 IO-P-0017SN Model 450.3/4 as c,11.1.05, except model AR42.10-P-0017S0 450.418 16 Undo t>otts (3) on wheel brake cylinder (1) I!!!! •8A42.10-P-1001-16C and remove wheel brake cylinder (1) 7 Clean braJ<e carrier plate 8 lnstaU in the reverse order
Number¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 19 · Applies to: 450, 451
Designation Model .S0.314 BA42.10-P-1001-16C Wheel brake cylinder to brake carrier plate Nm 8 ~ Brake lines, brake hoses Number Designation Model 4 50.3/4 BA42.10-P-1003-04E Brake line to rear wheel brake cylinder Nm 18 Box wrench bit Auxiliary repair materials Number Designation Order number BR00.45-Z-1027-07A "Yellow" lod<ing paint Lad<fabrik Slider GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 BR00,45,Z-1028-07A · r<ed" safety paint I Lacklabrik Bader GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. •49 711 381607 Faic+49711383092
26. 0O-P-0001-01 FF¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 20 · Applies to: 450, 451
Notes on position of transmission number Model 450.3/4 and 452.3/4 [Il The transmission number (arrow) is located in the lower area on the engine side on the transmission. Model 454.0 [Il The transmission number (arrow) is located below the starter on the transmission. Model 450.3/4, 452.3/4, 454.0 with transmission 717.4 P26.00.2068-04
P26.1o-.2067•09¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 21 · Applies to: 450, 451
9.2.07 P26.1o-.2067•09 Transmission 6 Connector B43 Gear position 2 Airducting 7 Bolts M11 Transmission motor 4 Connector 8 Exhaust system bracket 5 Connector P:26.10-2068-09 1 Transmission 12 Bracket 16 Nut 9 Bolts 13 Clip 17 Ground/ins 10 Charge alr cooler carrier 14 Intake manifold 11 Vacuum line 15 Bolts M1 Stat1er
Transmission¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 22 · Applies to: 450, 451
1 Transmission 18 Bolt& 19 Bracket 20 Ground I/no 1'26.10-2069-04 llul Iii! Remove/install I& 0anoer1 Rlsk of death cause<1 by vehicle slipping or Align vehicle between colum1'S of vehicle lift ASOO OO-Z--0010-01A toppfing off of lhe lifting platfomi. and position four support plates at vehicle l;tt support points specified by vehicle manufacturer. 1 Push doWn brake pedal several 6mes IW To reduce any vacuum. 12 Remove the c:lutch actualor AR25 20-P-0125SM 13 Disconnect batter, ground One AR54 10-P-0003SM 14 Remove rear ax.le shafts AR35 30-P-062-0SM i:, I Remove air ducting (2) 16 Unplug connector at gear position (843) I (2) Do not damage 10<:klng labs as olherwise the connector will no longer be tocked mto place. [I] lns1allation: Ensure that the connector latches properly. 17 Unplug connector (4) I (2) Do not damage the catch lugs, otherwise !he plug (4) w\R not 10<:k anymon,. II) lnstallatlon: Ensure lhat the connector (4) latches property. " Disconnect plug (5) on gear motor (M17) I® Do not damage lhe latching lugs, otherwise the plug (5) wlll not lock anymore. [I] lns13llatlon: Pay attention to correct latching of tile plug (5). 19 Unplug connector (6) I (2) Do not damage the ea1ch tugs, olherwise plug (6) wlll not lad< anymore. [I] lnstalladon: Pay attenUon to correct latching of U,e plug (6). 10 Unscrew bolts (7) m,o exhaust system I~ 'BA49 1,n ·HXlHHJ bracket (8) 11 Unscrew bolts (9) at transmisSion (1) and remove charge air cooler carrier (10) 12 Unc:lip vac,,um line (11) from bracket (12) 13 I Loosen clamp (1~) and pull vacuum une (11) olfin1ake manffolcl (14) 14 Unsaew bolts (15) on transmission (1) l!-3 'BA15 30-P-1001-01E 15 Loosen nut (16) on suirter (M1J and remove ground line (17) 16 Remove bolts (18) from bracket (19) IW lnSlallatlon: Observe the positioning (arrow) of the ground line (20) on the brackel (19). 17 Remove rear engi.ne mount on the left AR22.10-P•1160SN 18 Position suim.ble blod< of wood be!V,een the turllOc:ilarger and crossmember and lower w Do not damage the OIi Une. the engine until the turt>ocharger oontactS the crossmember 19 Unscrew bolts (arrows) and remove W Installation: Grease transmission shaft transmission (1) lightly. Pay attenilon to dlfferen1 lengtl1 of the boll$ (arrows). The bolts (arrows) mus1 be
Noles on bolted connections with seij tapping Model 450.314¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 23 · Applies to: 450, 451
- III Noles on bolted connections with seij tapping Model 450.314 AHOO 00,P-0007-01SM screws ~ "BA2610-P-1001·010 i20 Install in the reverse otder ~, Con-eel transmission oil level ~ A P Manual transmission • cheek oil level, correct Al'26 00-P-2610SM 22 Coonect STAR OIAGNOSIS !li<"A D Coonect STAR OIAGNOSIS and read out A000.00-P-2000-04SM faultmemo,y STAR OIAGNOSIS diagnosis syslem 23 Ched< program status "Trust Plus" IW Program status "Trust Plus• Is located In the menu structure: • Main menu - Systems menu - MEG control u.nit menu - Diagnosis service menu • Oata and program stall.ls menu III If the cletennlned value Is •59159• or larger, lhe vehicle Is equipped with the system Trust Plus and with the program pulsing dutch. STAR OIAGNOSIS diagnosis system 24 Program transmiSSlon adaptation I W The "program transml$Slon adaptation" menu is located In the menu structut&: - Majnmenu - Diagnosis menu • Sys,tems menu • MEG control unft menu - Actuator aduation menu - Transmission menu - Transmission adaptation menu STAR OIAGNOSIS diagnosis system ~5 Program engagement of dutch/ [[I] The •engagement or clutch/ disengagement or clutch polnt disengagement of clutch Point'° menu is located fn the menu strudure~ • Main menu .. Diagnosis menu • Systems menu • MEG control unit menu - Actuator actuation menu -Clutch menu - Engagement point menu STAR OIAGNOSIS diagnosis system 126 Program point limit vatue I W The "Program point lmlt value" menu Is located in the menu structure: • Main menu • Diagnosis menu • Systems menu • MEG control unh menu - Actuator actuation menu • ClutCh menu ~ Point liml1 value menu STAR OIAGNOSIS diagnosis system 127 Close STAR DIAGNOSIS ~ A D Connect STAR DIAGNOSIS and read out AOOO.OO-P-2000-04SM fauttmemory STAR OIAGNOSIS diagnosis system 8 starter Number Designation Engine Engine 160.910 160.920 8A15.30-P-t00t-01E Bolt, starter to lfan$JTli$$iOn Nm 23 23 ~ Complete manual transmission
Number¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 24 · Applies to: 450, 451
Designation Trans- mission 717.4 in model 450.3/4, 452.3/4, 454.0 BA26.10-P-1001-01 D Bolt of transmission to engine Nm 23 ~ Exhaust system Number Designation Engine Engine 160.910 160.920 BA49.1O-P-1001-01 J Bolt connecting exhaust system to Nm 23 23 transmission
AR26.10-P.0020SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 25 · Applies to: 450, 451
9.2.07 p~ 10-2067-09 1 Transmission 6 Connector 843 Gear posltlon 2 Airducting 1 Bolts M-11 Transmission motor 4 connector 8 Exhaust system bracket 5 connector P26.10-2066-09 1 Transmission 12 Bracket 16 Nut 9 Bolts 13 Clip 11 Ground line 10 Charge air cooler carrier 14 Intake man/fold 11 Vacuum line 15 Botts M1 Starter
Transmiss.lon¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 26 · Applies to: 450, 451
1
Transmiss.lon
18
Bolts
19
81acket
20
Ground line
~
. 10-2069-04
ll
Notes on bolted connections with self tapping Mo<lel 450.3/4¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 27 · Applies to: 450, 451
- .. - III Notes on bolted connections with self tapping Mo<lel 450.3/4 AHOO OO.P--0007-0ISM screws 13 'BA261().P-1001-010 0 Install in the reverse order 21 Correct transmission oR level t.i"AP Manual transmission • ched< oil level. correct AP26 QO.P-2610SM 122 Conned STAR DIAGNOSIS ~ AD Conned STAR DIAGNOSIS and read otrt AOOO, 00.P-2000-04SM fault memory STAR DIAGNOSIS diagnosis system 123 Check p,ogram •talus "Trust Plus" W Program status "Trust Plus• Is located In the menu structure: - Main menu • Systems meou -MEG conltOI unit menu - Diagnosis seMCe menu • Data and program status menu IIJ If the detennined •• , .... rs "59159" or larger, the vehicle is equipped with the system Trust Plus and w1t'1 the program pulsing clutch. STAR DIAGNOSIS diagnosis system 24 Program t,ansmlssion adaptation ll!J The "program transmission adaptation" menu is located in the menu structure: • Main menu ... Diagnosis menu • Systems menu - MEG control unl'I menu • Actuator actuation menu • Transmission menu • Transmission adaptation menu STAR DIAGNOSIS diagnosis system 25 Program engagement of dutch/ W The ·engagement of clutch/ disengagement of dutch point disengagement of clutch polnr menu ls localed in the menu structure: - Majnmenu - Oiagn0$ls menu • Systems menu • MEG control unit menu -Actuator actuation menu - Clutch menu • Engagement point menu STAR DIAGNOSIS diagnosis system 26 Program point limi1 value IW The "'Program point limit value" menu is located in the menu structure~ - Ma;n menu • Otagnosis menu • Systems menu • MEG control unit menu - Aceuatot actuation menu - Clutch menu • Point lim'it value menu STAR DIAGNOSIS diagnosis system 27 C!ooe STAR DIAGNOSIS l'i""AD Conned STAR DIAGNOSIS and read out AOOO OO.P-20l)0.04SM fault memory STAR DIAGNOSIS diagnosis system 8 Starter Number DesignatJon Engine Engine 160.910 160.920 BA15,30-P-1001-01E Bolt. starter to transmission Nm 23 23 13 Complete manual tran&mlsslon
Removennstall clutch¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 28 · Applies to: 450, 451
14.11.02 P25.10-2027-0SI Shown on engine 160.910 1 Clutch 4 Bo/IS 7 C•nterlng &leeve 2 C,,p 5 Release levw 8 Drive plate 3 Cn,nkcas• 6 Output rod ~ Remove Lt:. oangerl Risk of death caused by w,hlcle sUpplng or Align vehk:le between the columns or the ASOO.OD-Z-0010-01A loppling off ol lhe lilting platform. llfti119 platform and posttion the lour supl)()rt plates at \he r,n;r,g platform support poinl$ ' specllied by the vehlcle manulac:turer. 1 Push clown brake pedal seYeraJ limes IW In order to efiminate any vacuum present 2• Dlsconnec:t batt•ry ground cable AR54 10-P-0003SM 3 Remove rear axie shafts AR35.30-P-o820SM 4 Remove transmissio<I Model 450.314 wi1h lransmission 717.407 AR26 10-P-0020SM /408/476 Model 450.3 /4 wi1h transmission 717.409 AR26 10-P-0020SN 5 Detach end COYe< (2) 6 Tum crankshan al belt pulley until mounting I W Before the last mounting sc,ew Is bolls of clutch (1) can be accessed through unsc,ewed the clutch (1) must be held access opening (arrow) at crankcase (3) and securely so that tt does n"4 fall down. remove mounting bolts of clutcil (1) ~ Sodtet wrench btt •4~ 7 Remove clutch (1) 8 Uns,:mw bo~• (4) on release lever (5). 9 Unhook the release lever (5) from the prMSure mushroom profile (6) and remove 1W ' Install 10 Grease pressure mushroom profile (6) lightly Transmission shaft grease "BROO 4S-Z-1062-06A 11 n,sh centenng sleeve (7) onto ttansm1Ss10n input sllaft as far as stop. 00 Centering sleew, •4 12 Push relea.., lever (5) onto centeri119 sleeve W Pay attenUon to the latching release lever (7) and hook raiease lever (5) into spring on (5) on the pressure mushroom profile (6), O<Jtput rod (6). 13 Screw in bo~ (4). I~ "BA25 20.P-1001-0IC 14 Remove centering sieeve (7). 100 Centeri119 sleeve ·•50589003400
Sctew in mounting screws of Clutch (1)¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 29 · Applies to: 450, 451
17 Sctew in mounting screws of Clutch (1) 18 Inst.all closing cover (2) 19 Install transmission 20 Install rear a,cle shafts 21 Connect ground ceble to battery 22 Connect STAR DIAGNOSIS ~ AD Connect STAR DIAGNOSIS and read OUI fautt memory 123 Check program status -rrust Plus· 124 Program transmission adaptation 125 Program engagement or clutch/ disengagement or Clutch point . ~ I Program pornt limrt value 27 Ctose STAR DIAGNOSIS 1.-i""AD Connect STAR DIAGNOSIS and read out fau~memory !!!!I Clutch mechanism I Number I Designation [1] Replace mounting screws. Rotate crank$haft until the respective mounting screw can be screwed in. ~ lfil Socket wrench bd Model 450.3/4 with transmission 7 17.407 /408 /476 Model 450.3 /4 with transmission 717 .409 STAR DIAGNOSIS diagnosis system [1] Program status -rrust Plus· is localed In the menu structure: •Main menu • Systems menu • MEG control unit or EOG control unit menu • Diagnosis servlee menu - Data and program status menu III II the de1"nnlned value is "59/59" or larger, the vehicle Is equipped with the system Trust Plus and with Ille program pulsing dutch. STAR DIAGNOSIS diagnosis system W The "p,ogram transmission adaptation• menu is tocated In the menu structure: -Malnmenu • Diagnosis menu • Systems menu - MEG control unit or EOG control untt. menu • Actuator actuation menu • Transmission menu • Transmission adaptatfon menu STAR DIAGNOSIS diagnosis system I W The ·engagement or Clutch/ disengagement of clutch point" menu is k>cated in the menu structure: -Main menu - Diagnosis menu - Systems menu - MEG control unit or EOG control unit menu - Actuator aduation menu • Clutch menu - Engagement point menu STAR DIAGNOSIS diagnosis syotem ITIJ The •Program point llmft value" menu Is located ill the menu structure: - Main menu - Diagnosis menu - Systems menu • MEG control unit or EOG control unit menu - Aduator aduation menu • Clutch menu - Point limit vatue menu STAR DIAGNOSIS diagnosis system STAR DIAGNOSIS diagnosis system I Model 450.3 I Model 450.4 'BA25.10,P-1001-01C '450589020900 AR26.10f'-0020SM AR26 10-P-0020SN AR35 30-P•0620SM AR54 t0-P-0003SM A000 00-P,2000-04SM "WH58.30-Z-1048-13A "WHS8.30-Z-1048-13A "WH58.30-Z-1048-13A "WH58.30-Z· l048-13A 0WHS8.30-Z•1048-13A ADOO 00f'-2000-04SM "WH58 30-Z-1048-13A
Number¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 30 · Applies to: 450, 451
Designation Model Model 450.3 450.4 BA25.10-P-1001-01C Bolt, clutch module to driver 1st stage Nm 20 20 2nd stage .c 90 90 Step3 A• 10 10 450 589 02 09 00 450 589 00 34 00 Socket Centering sleeve Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger ar 6511 1801 00 Repair materials Number Designation · Order number BR00.45-Z-1062-0SA Transmission shaft grease Q0001893V000000000
~R20.00.P-1142SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 31 · Applies to: 450, 451
~ ralnlllll In coolant NGINE 160.910 In MO et 450.3 /4 up to WME01MCO12H106037 ENGINE 160.920 in MODEL 450.3 /4 as of WME4503001J000001 ENGINE 660.940 In MODEL 450.3 /4 1 Cap 2 ExplJ.Jlslon re.servofl' 3 Hosaclamp 4 Coolant hose Modification notes 1.2.08 operation step to drain coolant from cylinder crankca$8 no longer appDe~ Drain I& 0angerl Risk of Injury to skln end eyes caused by scaldlng from contaCI with hot cootant spray. Risk of poisoning caused by swallowing coolant cw Notes on ~ant 1.1 Remove air Inlet 1.2 Open windshield ,! Tum cooling system cap (1) on engine radlato, (2) a half wm counterclod<wlse, telieve the pre$Sure and then unscrew the cooling system cap (1) ~ Remove underfloor panelS • Loosen hose damp (3) on coolant hose (4). delach coolant hose (4) from rad,ato, and drain off COOiant FIiiing 5 Posttlon coolant hose (4) on radiator and fut In place wtth a hose clamp (3) ~ lower vehicle with vehicle lift 7 Pour In coolant and bleed cooling sy5tem IJ$"BB COOiant specifications i.i"BB Antioorroslon/antifreeze aoents /Sheet 325.0\ !19.2.08 P20,00-2347-06 Do not open cooling system unless coolant AS20.00-Z-OOO 1-01A temperature is below WC. Open cap slowly and release lhe pressure. Do not p(MJI COOiant Into beverage container$. Wear proteellve glo'ies, protedlve clothing and safety glasses. AH20 OO-N,2080.QlA On model 450,314 except 450.◄ 18 ARl\3 25-P-1401SM In case of model 450.418 AR61 30,P,1001SM W Catch coolant In a suitable vessel IW Replece-hose clamp (3). AR2000-P-1142-0SSM [i] -◄so5890n100 [i] "450589206300 Sheet 310.1 8B00 ◄O-P-03l0-01A Sheet325.0 8800.<IO.P-0325-oOA
I& Danger!¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 32 · Applies to: 450, 451
Risk of accident caused by vehicle starting Secure vehicle to prevent it from moving by AS00.00-Z-0005-01A off by itself when engine is running. Risk of itself. Injury caused by contusions and burns Wear closed and snug-fitting work clothes. during starting procedure or when working Do not touch hot or rotating parts. near the engine as it is running 9 Run engine until warm III Until the coolant fan motor cuts in. 10 Turn coolihg system cap (1) on engine radiator (2) a half turn counterclockwise, relieve the pressure and then unscrew the coo.ling system cap ( 1) 11 Check coolant level in the expansion W The engine coolant level in the coolant reservoir (2) and correct if necessary expansion reservoir (2) must be positioned at the max. marking. l~BB Coolant specifications Sheet 310.1 BB00.40-P-0310-01 A ~ BB Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325-00A 12 Seal expansion reservoir (2) with cap (1) 13 Rais.e vehicle with vehicle lift 14 Install underfloor paneling AR61 .30-P-1001 SM 15.1 Install air inlet On model 450.3/4 except 450.418 AR83.25-P-1401 SM 15.2 Close windshield In case of model 450.418 450 589 07 21 00 Pressure pump Filling device
Crankcase¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 33 · Applies to: 450, 451
Cap 2 Crankcase 3 Catch ◄ Bolt 5 Beltpulley Modification notes Bolt. clutch module to driver NoIe concerning replacing belt pulleys made oul of sheet SIep 6 metal • added ~l!,I Remove/Install 1 Remove poly-V belt 12 Detach end cover ( 1) 13 11 um crankshaft at lhe belt pulley (5) untU IW An approx. so• crank angle BOTC ror moontjng bott lor clutch is accessible through the access opening on the crankcase (2) cylinder 1. II Remove moonting bolt lo, dutch on clutch OOCalcll plate and ,eplace by catch (3) 8 15 Remove bett pulley (5) bolt (4) W tnstallatlon: Replace bott (4). Engine 160.910 /920: I 8 Engine 660.940: 1 8 16 Delllcll belt pulley (5) I W Pry off belt pulley {5) ff necessary with a sultable assembly levee. ITl The sealing surface of the belt pulley (5) to the radial shaft. sealing ring must be dean, tree of grease and dry. [I] Installation: II a belt pulley (5) made out of sheet metal is installed then this must be replaced by one ma<je out ol cast Iron. 17 Install i:n the reverse Ofder 8 Flywheel, driven plate, vibration damper, starter ring gear Number Designation Engine Engine 160.910 160.920 8AOG.3()..P•1001-01J Belt pulley / vibration damper to crankshaft Stage 1 Nm 140 140 10.4.07 P13.21•2018-08 •BA25 t().P-1001,0IC AR13 22·P•1202SM •450589004000 ' BA25.10-P·100t-OtC ·BA03.30-P•1001-01J 'BA03 30·P· 1 001-01 K
Insert the heads of the rivet hnk bolts in the¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 34 · Applies to: 450, 451
13 Insert the heads of the rivet hnk bolts in the groove 14 Lay the web of the riveting tool on both rollers on the rivet link 15 Tighten the pressure spindle to a torque of 10Nm 16 Remove the riveting tool 17 Turn mobile thrust piece by so•, so that the rivet profile is pointing to the chain guide 18 Place riveting tool with groove directly above W Oil or grease the thrust piece. the centre of the bolt Individually rivet the bolt on the rivet link. 19 Tighten the pressure spindle to a torque of W Repeat the riveting procedure on the 20Nm second bolt. 20 Check riveted chain links for freedom of W Check the mounting link clearance using movement check gauge. The largest measuring mounting link must pass over the riveted chain link. The largest smaller mounting link must not be able to pass over the riveted chain link. 21 ihe riveted link array must be even and centered W Replace if this is not the case. 122 Detach retainer i,iJ Chain repair kit • 450589059900 123 Inspect timing W The marki ng on I.he belt pulley/vibration damper should be in line with the marking on the timing case cover. The bore hole on the camshaft sprocket should be in line with the upper edge of the cylinder head separating surface. 24 Install cylinder head cover AR01 .20-P-5014SM Chain repair kit
to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 35 · Applies to: 450, 451
20.7.04 n to WME01MCO12H106037 ENGINE 160.920 In MODEL 450.3 /4 from WME4503001J000001 t.,J Remove , Remove cylinder head cover AR0120·P·501◄SM 2 Posltion piston of cylinder 1 to ignition TDC W Tum lhe engine at the crankshaft In the direction of rotation of lhe engine until lhe marking on the bett pulleyMbration damper ls In line with lhe marking on tho timing case cover and lhe bore hole on lhe camshaft sproci<el is in line with lhe upper edge of lhe cylinder head separating surface. 13 Mount retainer onto the cylinder head WSee F1g. A. ~ Chain repair k~ •450589059900 i. Tum tne camshaft. sprod<.et until the eh.ain IW Remove all parts which could fall Into the link to be undone ls accessible chain shaft. Cover chain shaft and cylinder head wilh a ffulMree rag. 5 Pos~ion lhe chain separation tool and push IL!.JSeeFig. B. out the chain bott ~ Chain repair kil ·•5()589059900 6 Remove the chain separation tool ~ Install ~ Conned up lhe new conlrol chain and lhe I LlJ Hold the control chaln lensloned and In one to be replaced flfghl away from the camshaft sprocket Mark the Joint ~ Tum the engine clockwise al the pulley IW See Fig. c. wheel unlil the new conlrol chain is Remove lhe rag before turning the engine. posltioned. 9 Disconnect the marked chain link and I W Cover chain shaft and cylinder head with remove the old control cllaln ftufl.free rag. 10 Insert the new chain lfnk I W Insert Imm the direction of the camshaft. 11 lnsen the movable thrust piece inlO the I W The beveled surfaces must point 10 the riveting lool open side of the riveting lool.
Insert the heads of the rivet hnk bolts in the¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 36 · Applies to: 450, 451
13 Insert the heads of the rivet hnk bolts in the groove 14 Lay the web of the riveting tool on both rollers on the rivet link 15 Tighten the pressure spindle to a torque of 10Nm 16 Remove the riveting tool 17 Turn mobile thrust piece by so•, so that the rivet profile is pointing to the chain guide 18 Place riveting tool with groove directly above W Oil or grease the thrust piece. the centre of the bolt Individually rivet the bolt on the rivet link. 19 Tighten the pressure spindle to a torque of W Repeat the riveting procedure on the 20Nm second bolt. 20 Check riveted chain links for freedom of W Check the mounting link clearance using movement check gauge. The largest measuring mounting link must pass over the riveted chain link. The largest smaller mounting link must not be able to pass over the riveted chain link. 21 ihe riveted link array must be even and centered W Replace if this is not the case. 122 Detach retainer i,iJ Chain repair kit • 450589059900 123 Inspect timing W The marki ng on I.he belt pulley/vibration damper should be in line with the marking on the timing case cover. The bore hole on the camshaft sprocket should be in line with the upper edge of the cylinder head separating surface. 24 Install cylinder head cover AR01 .20-P-5014SM Chain repair kit
up to WME01MC012H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 37 · Applies to: 450, 451
25.1.06 n up to WME01MC012H106037 ENGINE 160.920 in MODEL 450.314 as of WME4503001J000001 1 BHringpln 2 Cylinder helld 3 Tensioning rail POS.10-~2 3 Tensioning rail 4 Chain sprocket on camshaft 5 Timlng chain for valve assembly 6 Bolts 1 Chain tensioner 8 SI/derail 9 Chain sprocket on camshaft drive POS.10-2~ 1..,1 1.;J Remove/install I& oangert Rlsk of explosion caused by oxyhydrogen No fire, spar1<s, open Rames or smoking. AS54 10-Z-0001-0lA gas. Risk of poisoning and caustic bums Wear acid--resistant gloves, clothing and caused by swallowing batte,y acid. Risk ol safety gla$$8s. Only po,,r battery add Into Injury caused by bums to sl<in and ~ sultable and appropriately marked containers from battery acid or when handling damaged lead-acid batteries I.!!) Notes on battery All models AH5' 10-P-0001-0IA 1 Read out fautt memory IW If necessary, eliminate any fautts In control unfts.. ~ AO Conn~ up STAR DIAGNOSIS and read out ADOO OO-P-2000.0,CSM fauttmemory STAR DIAGNOSIS diagnosis system "WH58 30-Z-1048-13A ·~-----~ -
Sparl< plug connector puller¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 40 · Applies to: 450, 451
19.7.02 Sparl< plug connector puller 2 Sparl< plug connector R4 Sparl<plug l - --
- . ' Pl S.10-2092-06 Modification notes 115.3.05 !Spark plugs j 'BA1510.P-1001-01B li<>lt<>! Remove/Install I& Danger1 RJsk of death caused by contact wit/1 parts Do not touch parts which conduct high AS15.1 O·Z-0001-01A conducllng high voltages. voltages. Persons who have electronic implants (e._9. pacemakers) must not perform any work on the ignition system. 1 Remove CBS rear end ~AR Except model 450.418 AR88.20.P-19005M li2"AR Model 450.418 AR88.20.P-f900CR ~ Unscrew catch al engine compartment cover and remove engine compartment cover 3 Unplug ·spa<1< plug connector (2), lrom the ® The spa,!< plug connector puller (1) must spa<1< plugs (R4) through slight rotation of the engage securely (arrow) since the jgnition spar!< plug conneclor puller (1) cable can be cut through by the spar!< plug connector puller (1) if tt slips. @ Never pull out a spar!< plug connector (2) by the ignition cable since the ign~lon cable can be torn out of the connector thereby destroying the spalk plug connector (2). [II Replace spar!< plug connectors (2) that have been Hooded with fuel with new spar1< m"9S There is the danger of short-circuiting if the battery is connected up due to loose lying spark plug connectors in the starter area. 119 "WH58.30-Z-1021-17A 4 Clean spark plug recess in the area of the spa<1< plugs (R4) and blow out 5 Unscrew spa<1< plugs (R4) ~ 'BA15 10-P-1001-018 6 Install in the reverse order ~ Spark plugs
BA 15.1O-P-1001-01 B¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 41 · Applies to: 450, 451
Spark plugs Initial tightening Nm 28 23 torque Retightening Nm 20 23 torque Commercially available tools Number Designation WH58.30-Z-1021-17A Spark plug connector wrench
up to WME01MC012H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 42 · Applies to: 450, 451
21.8.07 on up to WME01MC012H106037 ENGINE 160.920 in MODEL 450.3 /4 as of WME4503001J000001 ENGINE 660.940 in MODELS 450.3 /4 (except 450.418) Shown on engine 160.910 1 Oil filter cov,,r 2 Sealing ring 3 Oil filter &lement P18.DD-2086-04 llol Removal w Change the engine oil only When the engine is at ope111ting temperature 1 Remove engine compartment cover 12 I Pull oil dipstid< Out 01 the OIi dipst,ck guide tube 13 Screw on cap for oil filler opening 14 Sudk>n off engine oil I® Only insert the oil extraction probe when the engine is not running otherwise there is a risk of collisk>n with the c,ankshalt. ~ 0450589286300 5 Insert oH dipstick ln lhe oil dipstick guide tube I& Danger! Risk of death caused by vehicle slipping or Align vehicle between columns of vehicle lilt AS00.00•2•0010--0IA toppling off of the lifting plalfonn. and pcsftion four support plates at ••hicle lilt support points specified by velllcle manufacturer. j; Raise vehicle with vellicle lilt 7 Unsc,ew oil filter cover (1 ) and removo oil filter element (3) IL;;] ' Inst.II " Insert oil filter element (3) and sc,ew on oil I W Replace seal Jing (2) and oil f,tte, filter cover (1) element (3). Coat seailng ring (2) with engine oil ~Engines 160.910, 160,920 •BA 18.20-P-1002-01 J ~ Engine 660.940 •BAt8.20-P-1002-0tK ~ Lower vehicle with lifting platlofm 10 Unocrew cap for oil filler opening 11 Pour ln engine oil !ID "8F18.00.P-1001-01N !& Dangerl Risk of accident caused by vehicle starting Secure vehicle 10 prevenl it from moving by AS0000-Z.()()()5.()1A off by itsetf when engine is running. Risk of itself. Injury caused by contusions and bums Wear closed and snug.fitting work clothes. durlng starting procedure or when working Do not toudl hot o, rotating parts. near the engine as it is n.innlng 12 Conduct engine test run and check engine for leaks whilst it is running 13 Check engine oij level by means of oil 12) The oil level must be within the a.r<!a dipstick marked on the 011 dipstick otherwise there Is the threat of engJne damage. (il Let engine run for approx. 1 minute, then switch off and wait approx. 5 minutes. Checl< oll level and corred ff necessary. 14 Install engine compartment cover
Number¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 43 · Applies to: 450, 451
Designation Engine Engine Engine 160.910 160.920 160.920 (upto45 (S5 kW) kW) QA18,20,,P. 1002.ou Oil filter screw cap Nm 23 23 23 ~Ollfllter Number Designation Engine 660.940 SA 18.20-P-1002-01 K Ori filter screw cap Nm 23 ID C..pacities of engine lubrication system Humber Designation Engine 160.910 Engine 160.920 8F18,00-P-1001 .01N Engine oil FiUing capacity L- 2,5 3.00 (oil and filter cllanga) Specif,catlons for Operating Sheet Fluids Sheet - 8800 •o-P-0229-05 8800 •o-P.0229-45 A A - ~ Ca~itles of engine lubrlcallon system Number Oeslgnallon Engine 660.940 8Ft8.00-.P-1001-01N Engine oil Fining capacity lilers 2,7 (oil and fitter change) Specifications for Operating Sheet Fluids 8800 40-P-0228-01 A Sheet 8800 ~P-422B-o3 A Sheet 8800 40.P-4228-05 A Sheet 8B00 40-P..0229.01 A - 8800 ~P.()229-03 A Sheet 8800 40-P-0229-05
WME01MC012H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 44 · Applies to: 450, 451
19.7.06 WME01MC012H106037 ENGINE 160.920 in MODEL 450.3 /4 WME4503001 J000001 1 Measuring po;nt 2 Measuring point 3 Meawrlng poinl A Longitudinal direction 8 Ttan$Ve,se direction a Upper reversal point of 1-51 piston ring b Bottom dead center of piston • c t.ower reversal point from o/1 scraper ring 2 ,,,,.------.... 2 b 3 C 3 P01.40--0228-06 Figure item, etc. Work instructions 1, 2, 3 Measuring points on the cylinder liner IW Measure cleaned cylinder liners with an 'BE01.40-P· 1UU.<-U1 L Inside caliper at measuring points (1, 2. 3) in the directjpn of travel {A) a.nd transverse direction {B). ~ "WH58.30·Z-1011-12A III If there is excessively high wear and a damaged running surfaoe the engine must be . replaced. Referto:t Remove/Install engine Engine 160.91 o AR01 1 O-P·2400SM Engine 160.920 AR01 10-P-2400SP v nack van,es ,or cvnno r oore y Number Designation Engine Engine 160.910 160.92019211 9221923 8E01,40-P-1002-01l Cyti.nder liner dia. Standard dimension mm 63.5 66.5 Pem1issib~ deviation from a mm 0.000 lo 0.01 0.000 to 0.01 true cylindrical form {when new) Wear lim~ In longttudinal and mm 0.15 0.15 transverse direction Runout mm 0.07 0.07
AH01 .00-P-0001-01 FF¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 45 · Applies to: 450, 451
Notes on position of engine number Shown on engine 135.9 ill The engine number (arrow) is located in the bottom area on the transmission side on the crankcase. Model 450.3/4, 452.3/4, 454.0
from WME4503001J000001¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 47 · Applies to: 450, 451
1 Connector 2 Engine wiring hamess 3 Mounting 7 Bolts 8 Bolts 9 Tie slTBp 10 Air cleaner box 4 Connector 5 Connector 11 Cable 12 Vacuum line 13 Intake manifold S4111 14 N3/f0 3.11.03 P01.10-2A86--09 011 pressure switch P01.10-2430..09 Bracket MEG 1.0 engine electronics control unit
Remove line (11) on lhe air fitter box (10)¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 49 · Applies to: 450, 451
19 Remove line (11) on lhe air fitter box (10) ,?0 Remove fuel lines on the engine AR47 2!'>-P•l000.0 ISM ,?1 Unclip bracl<et (14) ,?2 Remove !he vacuum line (12) on Ille air Inlet I W Pay attentio<1 to routing of the vawum pipe ( 13) and remove from lhe holders in the line (12), area of the engine compartment ~3 Remove lhe ground fine (IS) ,?4 Lower the engine unlit lho follOwiflg I® Lowe< lhe engine slowly and ooly just wo11<steps can be pefformed enough (about 1 0 cm) not to damage lhe engine mount a1 lhe froot ;25 Remove poly-V-bett of supercharger Only for code (101) air-conditioning unit Plus AR\3 21.P-1202SM or code (129) air-conditioning unit Plus (with combination filter and extemal temparature lndicato,) smart&passion. f26 Take off refrigerant compressor Only to, code (IOI) air-conditioning unit Plus AR83 5S-P0 5300-02SM or code (129) alr-condltioolng unit P1us (with combination filter and external temperature indteator) smart&passion, 8 0 BA33,5$.P-100-01J 8 0 BA83.5S-P·1002-01 J 8 "BAa3.5S-P-1003-01 J ~7 Remove the hose for the combination valve on the secondary aw pump 28 Remove eoolanl hoses and lines on the AR20, 20-P-3865-06SM engine ~ Disconned wiring hamess at starter AR15 30-P-7100-0:lSM 8 "BA15 30-P-1002-0IE 30 Disconnect Iha line (18) oo the generator ~ "BA15 40-P-1002-0IG (G2) 31 Remove screw (16) W The fact lhat Ille engine mount (arrow) is preadJus1ed means Iha! Ille cen1ra1 se,ew belween Iha bearing shell and n,bber element must not be loosened, 1B "BA22.10-P-1004-01M , .. Lin Ille ong,ne u$lng lhe Idling device and W The factthat the engine mount (arrow) is unscrew bott (17) preadjusled means lhat the central screw belween lhe bearing shell and robber elemenl must not be loo$ened, E3 "BA22 \0-P·l004-0\M 3J Lower the engine oomp .... ly 3JI Remove clutch W To be performed additionally when AR25 I 0-P-OOSOSM instl!lling an ET engine. 135 Remove/install tutbocharger W To be performed additionally when lnstamng an ET engine. Engine 160,920 AR09 40-P-6020SP 36 Remove lnla.ke manifold W To be performed additionally when AR09 20-P-1310SM inslalfing an ET engine. 37 Remove ignition coils W To be performed additionally when ARIS l2•P•2003SM instamng an ET engine. 38 -ve•tartor W To be performed additionally when ARIS 30-P•7100SM Installing an ET engine. 39 Remove generatOf W To be performed additionally when AR 15 40-P-5032SM installing an ET engine. 40 Remove coolant themnostat W To be performed additionally when AR20, 10-P•2460SM installing an ET engine. 4\ Remove the assembly carrier L1I To be performed additionally when AR0l 10-P·JuvvSM installing an ET engine, 42 Remove rear engine mount oo the right W To be performed additionally when AR22 10-P-1 t60SM ln•talling an ET engine. 43 Remove rear engine mount on the left W To be performed additionally when AR22 10-P-\ 160SN Installing an ET engine. 44 Remove front engine mount W To be performed additionally when AR22.10-P~330SM ln$talllno an ET enalne~
Number¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 50 · Applies to: 450, 451
Designation Engine 160.920 8A15.3-0•P•1002-01E Cable at starter terminal 30 Nm 8 E3 Atternato< Number Designation Engine 160.920 8A15.40-P-t002-01G Cable to generator circuit B• Nm 8 f!3 Engine mounts, engine supports Number Designation Engine 160.920 BA22.10-P-1004-01M Bolt of front engine support to frame-type Nm 58 integral support Bl\22.10-P-1005-0IM Bolt of rear engine support to fram&type Nm 58 integral support §!l AC compressor Number Designation Engine 160.920 BA83.55.P-1001·01J Screw for refrigerant compressor bracket to cylinder Initial Nm· 12 head tightening Subsequent Nm 10 tightening BA83.55-P-1002-01 J Bolt, refrigerant compressor to bracket Nm 20 BA83.55-P-1003-0IJ Bolt, refrigerant compressor basic carrier rails Nm 20 . Re-moval assembly Adaptation
Downstream of catalytic converter,¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 51 · Applies to: 450, 451
,n Downstream of catalytic converter, up to WME01MCO12H106037 ENGINE 160.920 in MODEL 450.3 /4 (except 450.418) Downstream of catalytic converter, from WME4503001J000001 02 sensor downstrwm of cataJyt;c convert.er 2 Catalytic converter 3 Connector 4 Bracket 5 Latch 6 Engine comparlment cover -~ 1,_;_1 Remove/Install 1 Disconnect ground cable from battery 2 Remove CBS rear 3 Tum up the latch (5) and take off the engine compartment cover (6) 14 Take out connector (3) from bracket (4) and unplug connector (3) 5 Remove 0 2 sensor downstream of catalytic converter (1) from catalytic conv,irter (2) 6 Install in the reverse order 802sensor Number Designation BA14.00-P-1001-018 O 2 sensor at exhaust pipe/ exhaust Nm manifold 28.8.02 P14.00-2060-06 AR54 1 ~P-0003SM AR88.2~P-1900SM lfil Socket wrench bit '450589040900 I]] Installation: The 02 sensor downstream of catalytic converter (1) must have a sufficient gap at the top (arrowed) from the rear CMS. ~ 'BA14.00-P-100t-01B Engine Engine 160.910 160.920 50 50
Upstream of catalytic converter,¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 52 · Applies to: 450, 451
In Upstream of catalytic converter, up to WME01MCO12H106037 ENGINE 160.920 in MODEL 450.3 14 (except 4S0.418) Upstream of catalytic converter, from WME4503001J000001 1 Connector 2 Laich 3 Engine compartment cover G3/2 02 s""sor upstream of TWC [KATJ ";;f t._;! Remove/Install 1 Oisconne<:t ground cable from battery 2 R&move rear CBS . '3 Tum up the latcli (2) and take off the eng,ne compartment cover (3) 4 Remove the tie strap from connector (1) and unplug connector (1) 5 Unscrew the 02 sensor upstream ofTWC [KAT] (G3/2) 6 lnstaJI in the reverse order B o2sensor Number Designation 8A t4.00-P-1001-018 o 2 sensor at exhaust pipe/ exhaust Nm manifold 28.8.02 P14.00--2059-06 AR54 1 O-P-0003SM Model 450.314 except 450.418 without Code AR88 20·P· 1900SM (P15) Brabus 1st Edition (FFO) or Code (P18) complete gear set 17!>-R16/225•R17 Brabus (DFO) . Model 450.314 except 450.418 with Code AR88.20·P• 1900SN (P15) Brabus 1st Edition (FFO) or Code (P18) complele gear set 17!>-R16/225-R17 Brabus (OFO). Model 450.418 AR88 20-P-WOOCR IW Installation: Ensure tllat cooneclor (1) is securely engaged. llil '450589040900 ~ 'BA 14.00-P-1001-01 B Engine Engine 160.910 160.920 50 50
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 53 · Applies to: 450, 451
22.5.06
'"
up to WME01MCO12H106037
ENGINE
160.920 In MODEL 450.3 /4
as ofWME4503001J000001
1
Camshaft
2
Timing chain
3
SHI
4
Boll
5
Camshaft bNring cap
P05.20•21'M4
PoS,20-214'9-01
Modification note$
115.506
jllott, camshaft sprocl<et to camsllaft
!Engine 160
j •BA05 20-P-1001-0tG
l<>f li,;)
Remove/install
1
Remove cylinder head cover
AR01 20-P-5014SM
2
Position piston of cylinder 1 10 Ignition TDC IW Tum the engine at the crankshaft In the
directiOn of rotation of the engine until the
marl<lng on lhe bett pulley/\/ibratlon damper i,
In line wilh the marl<lng on the timing case
cover and lhe bate hOle on the camshaft
sprocket Is In line wllh the upper edge of the
cylinder head sepa,ating surface (arrow).
Rotate cn,nkshaft in dlrection of rotation of
engine. The cams on cylinder 1 must pclnt
up at an angkt.
3
Marl< camshaft spr<>cket and timing chain (2) I W trmallatlon: Ensure tr.at the marking of
toeachotMr
the timing chain (2) Is aligned wtlh lhe
marl
Number¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 54 · Applies to: 450, 451
Designation Engine Engine 160.910 160.920 BAOS.20-P-1001-01 G Bolt, camshaft sprocket to camshaft Stage 1 Nm 21 21 Stage 2 4 • 90 90 Stage 3 4 • 10 10 BAOS.20-P-1002-01 G Bolt of camshaft bearing cap to cylinder Initial torque Nm 11 12 head Continued torque Nm 8.4 12 450 589 00 01 00 Open end wrench
Shown without tensioning rail¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 56 · Applies to: 450, 451
1 2 3 4 5 6 7 8 Timing chain for valve assembly Sllderail Chain tensioner Bolts Chain sprocket on oil pump Bolt Timing chain for oil pump Crankshaft !~~ Removing/installing 1 Install holding device for engine block 2 Remove timing case cover 3 Remove bolts (4) from chain tensioner (3) 4 Remove chain tensioner (3) 5 Install in reverse order ~ Timing chain drive Number Designation BA05.10-P-1001-01G Bolt for chain tensioner on crankcase Nm 27.9.04 8 6 P05.10•2316-01 AR01 .00-P-0201 SM AR01.40.P-8000SM ·~ *BA05.10-P-1001-01G Engine Engine 160.910 160.920 12 12
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 57 · Applies to: 450, 451
28.8.02 n up to WME01MCO12H106037 ENGINE 160.920 in MODEL 450.3 /4 as ofWME4503001 J000001 Bolts 2 Plug of engine wiring harness 3 Intake Ignition c.able 4 Outlet Ignition cable T1l1 Ignition coll cylinder 1 T112 Ignition coll cylinder 2 T1l3 Ignition coil cylinder 3 P15.12-2046-06 lol llll Remove/Install 1 Disconnect ground cable from battery AR54.1 CI-P-0003SM 2 Remove CBS Rear AR8a.20-P-1900SM 3 Remove engine compartment cover 14 Unplug piug of engine wiring harness (2) to cylinder 1 ignition coil (Tl/1 ). cylinder 2 ignition coil (T1/2) and cylinder 3 ignition coil (T1/3) 5 Unplug intake igniUon cable (3) and exhaust ® In no case unplug ignition coll plug at Ignition cable (4) to cylinder 1 ignition coil ignition cable. The coil wire can be cracked (T1/1 ), cylinder 2 ignttion coil (T1/2) and from the connecting parts of the ignition coil cylinder 3 ignition coil (T1/3) plug and therefore be destroyed 6 Unwew bolts (1) and take out cylinder 1 I!!!! "BA15.12-P-1003--01G ignttion cgil (T1/1), cylinder 2 ignition coil (T1/2) and cylinder 3 ignition coil (T1/3) Install in the reverse order 18 ECI Ignition system Number Des.lgnatlon Engine Engine 160.910 160.920 BA15.12-P-'1003~tG Bolt of ignttion coil module to cylinder head Nm 14 14
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 58 · Applies to: 450, 451
28.8.02 m up to WME01MCO12H106037 ENGINE 160.920 in MODEL 450.314 from WME4503001 J000001 1 Plug connector 2 Intake manifold 817 Intake air temperature sensor P07.52-2013~6 ~~ Removing/installing 1 Remove engine compartment cover 2 Unplug plug connector (1) at intake air W Installation: Ensure secure latching of temperature sensor (B17) plug (1), 3 Press together the retaining detenls (arrows) Or'I the temperature sensor for intake air (817) and remove the temperature sensor for intake air (817) from the inlake manifold (2) 4 Install In the revarse order 5 Read out DTC memory ~AD Connect STAR DIAGNOSIS, interrogate fautt A000.00,P,2000-04SM memory Diagnosis system STAR DIAGNOSIS -wH5a.30-Z-1048-13A l:Ommerc1a11 avauante 1 0015 Number Designation H58.3-0-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 65111801 00
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 59 · Applies to: 450, 451
31.10.02 m up to WME01MCO12H106037 ENGINE 160.920 in MODEL 450.3 /4 from WME4503001J000001 1 Spsrl< plug connector puller 2 Sparl< plug connector R4 Spark plugs P 15.10-2092-06 P09.20-2074-07 3 Vacuum line 7 Fuel feed line 10 Cable 4 Intake man/fold 11 Cable 11 Control line 5 Cable 9 Vacuum line 12 Connecting pipe 6 Fuel retum line
Intake man/fold¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 60 · Applies to: 450, 451
4 Intake man/fold 13 Bo/!$ 14 Gasket Y62/1 Fuel Injector Cylinder 1 Y6212 Fuel Injector Cylinder 2 Y6213 Fuel injector Cylinder 3 ~~ Removing/installing & Danger! Rjsk of death. Death may resun if contact is made with parts carrying high voltages. l&oangerl R1$k of exploslon caused by fuel ignfting, risk of pomnlng caused by inhaling and swallow1ng ftlel as well as risk of Injury 10 eyes and skin caused by contact with rue!. 1 Disconnect ground cable of battery :z Remove Idle spee<I control (ISC) actuator 3 Remove intake manifold sensor ~ Remove intake air temperature sensor 5 Extract spark plug connector (2) through slight turning with the spark plug connector extractor(!) on inlet and outlet sides of the spark plugs (R4) 6 Detach vacuum line (3) on the intake manifold (4) 7 Detach line (5) on the intake manifold (4) 8 Detach fuel return line (6) on the fuel rail 9 Detach fuel feed line (7) on the fuel rail 10 Detach line (8) on the intake manifold (4) 11 Detach vacuum line {9) on the intake manifold (4) 12 Unclip line (10) from brackets on the intake manifold (4) P09.20-2Q7$-06 Do not touch parts which conduct high AS15.10-Z-0001-01A voltages. Persons who wear electronic implants (e.g. heart pacemakers) must not carry out work on the ignition system. No fire, sparks, open flames or smoking. AS47.00-Z-0001-0IA Pour fuels only into suitable a.nd appropriately marked containers. Wear protective clothing wt.en handling fuel. AR54 1 O-P-0003SM AR3022-P-1152SM AR07 04-P-O!OOSM AR07 52-P-1465SM @ The spark plug connector extractor (1) must engage securely ('<11Yow) since the ignition cable can be cut through by the spark plug connector extractor(!) ~ ij slips. Never pull out a spark plug connector (2) by the ignition cable since the ignttion cable can be tom out of the connector thereby destroying the spark plug connector (2). [I] Spark plug connectors (2) whicll have been flooded with fuel should be replaced. There tS the danger of short-circuiting if the battery is connected up due to loose lying spark plug connectors (2) in the starter area. [\g "WH58 30-Z-102H7A I I
Detach control line (11) on the intake¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 61 · Applies to: 450, 451
13 Detach control line (11) on the intake Only for code (803) 40 kW gasoline engine manffold (4) EU3155 HP, (804) 33 kW gasoline engine EU3/ 45 HP, (805) 45 kW gasoline engine EU3161 HP. ® Only pull out control line (11) In an axial direction otherwise there is danger of breakage on th'e connecting pipe (12), [II Installation: The connecting pipe (12) must be clos.ed off on vehicles without an electric switot19ver valve. 14 Unscrew botts (13) and take off intake W Take note of the condrtion of the cable on manffold (4) the fuel injector. III lnstallaUon: Observe the tightening sequence for the bolts (13). See I Tightening pattern for intake manifold fixing AR09.20-P-131 Q.03SM 8 "BA09.20-P-1001-01J 15 Pass spark plug connectoI for the 1st cylinder through the opening on the intake manifold(4) 16 Disconnect plug connectors for fuel injector W Replacing the intake manifold (4): I for Cylinder 1 (Y6211), fuel injector for Cylinder 2 (Y6212), fuel injector for Cylinder 3 (Y62/3) and remove the Intake manifold (4) Mnrlify fm~t n:1if with foel injacto.r AR07.03.P-1450SM 17 Close off air intake channels on the cylinder head with suitable rags 18 Blow out spark plug bores with compressed air 19 Remove gasket (14) on the intake manifold ITl Installation: Replace gasket (1 4). (4) Do not push gasket (14) placed on the intake manffold (4) over the sharp edges on the cylinder head. 20 Install in the reverse order ~ Intake manifold, intake manifold preheating Number Designation Engine Engine 160.910 160.920 BA~-1001,01J Bolt, intake manifold on cylinder head Initial tightenrng Nm 12 12 . Subsequent Nm 10 10 tightening Commercially available tools Number Designation H58.30-Z-1021-17A Spark plug connector wrench
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 62 · Applies to: 450, 451
28.8.02 In up to WME01MCO12H106037 ENGINE 160.920 in MODELS 450.3 /4 from WME4503001J000001 1 Connector 2 Bolt 4 L.atch 5 Engine compartment cover B28 Intake manifold pressure sensor P07.04-2159-06 rn.;;i Removing/installing 1 Unscrew latch (4) and remove engine compar1ment cover (5) 2 Pull plug (1) on the intake manifold pressure W Installation: Ensure secure latching on sensor (B28) out the plug (1 ). 3 Unscrew bolt (2) and pull out the intake manifold pressure sensor (828) ,~ 'BA07.04-P-1001-01A 14 . Install in the reverse order ~Senson, Number Designation Engine Engine 160.910 160.920 BA07.04-P-1001-01A Boll of pressure sensor to intake manifold Nm 6 6
excep 1¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 63 · Applies to: 450, 451
with CODE (806) Gasoline engine, 37kW / 50hp (M160/1) with CODE (B07) Gasoline engine, 45kW / 61hp (M160/1) with CODE (B10) Gasoline engine, 55kW / 75 PS (M160/1) as ofWME4503001J000001 A 1 PIJ,Jn comprewon ring 4 Piston crown 2 Tape,-feced ring 5 Pistons 3 Th,_,,art oil scrape, ring 6 Pliers llol Remove 1 Remove piston (5) ~ Remove the plain compressioo ring (1) 3 Remove taper-faced ring (2) ~ I Determine Ille thidlness of the removed taper.faced nng (2) 15 1 Remove me mree-part o-7021SN W Use plier$ (6). ~Pilers '450589143700 IW use plier$ (6). ~ Pilers "450589143700 IW The new taper-faced ring (2) must be selected according to the thickness determined from the removed taper-faced ring (2) and Installed. ~ Caliper gage '450589001900 IW Do not remove with pf,ers (6). The three• part oil scraper ring (3) must be removed by hand. I W Note lnstaHatlon position 'Top• or the manufacture.I"$ designation must ~nt to the plston crown (4) .. Pliers "450589143700 I W Pay attention to the detannlned taper- face ring s!Rngth: The new taper-faced ring (2) must be AAWIM """'J'lffftl'IO tn lhA th.if-.k~4t
[I] Note installation position¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 64 · Applies to: 450, 451
'Top' or the manufacturer's designation must point to the piston crown (4) .. lfil Pliers ·450589143700 10 Install the three-part oil scraper ring (3) W Do not install with pliers (6). The three- part oil scraper ring (3) must be installed by hand. I]] Picture A: The spring (arrows) must be located in the guide of the expander (7). [I] Pay attention to the offset, 120° respectively, of the piston ring end gaps of the expander (7), top multi-piece oil ring (8), bottom multi-piece oil ring (9). 11 Install piston (5). AR03.1 0-P-7021 SN 450 589 00 19 00 450 589 14 37 00 Measuring caliper Pliers
from WME4503001J000001¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 65 · Applies to: 450, 451
25.1.06 from WME4503001J000001 (B/~ - 10 . - 9 <B 2 P03. 10-2\01-09 1 Bolt$ .. Pistons 9 Bolts 2 Connecting rod bearing cap 5 Cylinder liner 10 Crankcase bottom secdon 3 Connecting rod 6 Injection pipe 12 Retaining strap 12 2 Connecting rod bearing cap 3 Connecting rod 1 Piston crown 8 Bearing shell
Main bearing shell, top¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 66 · Applies to: 450, 451
11 Main bearing shell, top 13 Main bearing shell, bottom P03.10.2 102-01 ~ Removing &Oanger1 Risk of accident caused by vehicle starting Secuno vehicle lo prevent tt from moving by AS00.00-Z-OOO>OIA off by i!seff when engine is running. Risk of ftseff. injury caused by contusions a.nd bums Wear closed and snug-f111Jng WOl1< eloth8$. during starting procedure or when woOOng Do not grasp hot or rotating parts. near~ running engine I&Danger1 Risk or explosion caused by fuel ignillng, No rire, sparks, open flames or smoking. AS47 OO-Z-0001--01A risk or poisoning caused by Inhaling and Pour fuels only Into suttable and swallowing fuel as well as r1sk of Injury to appropriately marked containers. eyes and skin caused by contact with fuel. Wear prolective cJolhing when handling fuel. r& Danger! Rlsk of explosion caused by oxyhydrogen No fire, sparks, open flames or smoking. AS54.10-Z-OOOl--01A gas. Risk of poisoning and caustic burns Wear aclckoslslant gloves, clolhing and caused by swallowing battery acid. Risk of safety glosses. Only pour battery acid Into injury caused by bums to skin and eyes suaable and appropriately marked containers from battery acid or when handling damaged lead,,acid batteries & Danger! Risk of Injury to sl\fn and eyes caused by Do not open cooli09 system unless coolant AS20 00-Z-0001--0lA scakling from contact with hot coolant spray. temperature is below so•c. Open cap Slowly Risk of poisoning from swallowing coolant and release pressure. Do not pour coolant Into be\'erage containers. Wear protective gloves. protedive clothing and safety glasses. 1 Disconnect battery ground cable AR54 10.P-0003SM [2 Read oot fault memory IW If necessary, elm inate eny faults In contl'OI units. r,;i°'AD Connect up STAR DIAGNOSIS and read out AOOO.OO-P•2000-04SM fault memory STAR DIAGNOSIS dlagnosls system -WH58 30-Z-1043-13A t! Remove engine AR01 10.P-2400SP ii Remove lransmi$$.ion AR:26 I 0-P-0020SM Remove alternator AR15 40-P·5032SM I, I Remove $tat1er AR15 ..u-P-71w;,M 17 Remove cylinder head AR01 3Q.P.5800SN 18 Remove olJ pan AROt 45-P-7500SM Remove timing case cover AR01 40-P-8000SM 10 Unscrew bolts (9) on crankcase bOttom If!!!! •BA01.40-P-1005--01M section (10) 11 Carefully detaeh crankcase bottom section IW lnstallallon: Clean sealing surfaces, coat (10) from engine bl~ using a rubber mallet sealing surfaoe with sealant and remove Sealing compound •sR.00.45-Z-1053--0lA 12 Unscrew bolts (1) of connecting rod bearing I® Tension liming chain to l)feven1 cha1'1 cap (2) on connecting rod (3) from jumping and damaging guide ra~. uJ Mark Installation Posttion of connecting rod bearing cap (2) on appropriau, connectJng rod (3) In color (arrow). uJ Romie relevant connecting rod (3) Into PoSit.ion. Pay attention to engi.ne1s direct.ion o rotation. 8 •BA03.10-P-1001--01K 13 Remove piston (4) with connecting rod (3) I® Use a suitable lool and do not use anv
CiJ When removing pistons (4), twist by 20•¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 67 · Applies to: 450, 451
so that cooneding rod (3) can be guided past Injection p!pe (6). Ci] Asslgnm8'1I of piston (4) - cylinder liner (5) must be strlctly observed. 14 Remove bearing Shell (8) from connecting rod bearing cap (2) and from connecting rod (3) Ill CtHnlng 15 Clean cylinder liner (51 16 Clean piston (4) W Remove any carbonization on pislon aown(7). ~ Checking 17 Check cylinder liner (5) for damage Ci] N04eS for evafuatlon of cylinder contad Engines 160.910/ 920 AH01 40-P-0001-03SM sutfaoe 18 Ched< piston (4) and conneding rod (3) fo, W The piston (4) and connecting rod (3) are damage not separate replacement parts. The engine must be "'1)1aced ii damage has occurred, see: 1 Remov1'1Q and Installing engine ARO! 10-P·2400SP i.,;i . Install 19 Insert bearing shell (8) into connecting rod W Pictun, A: Replace bearing shell (8). bearing cap (2) The lnstaDation poslllon of bearing shell (8) should be fitted to the rear side with 160 02 11 bright color in the connecting rod bearing cap (2). ~ Insert bearing shelf (8) in Connecting rod (3) W Picture B : Replace bearing shell (8). The installation position of bearing shell (8) should be fitted to the rear sidewitl1160 02 10 dalk COior with tl1e connecting rod (3). ~, Insert piston (4) with connecting rod (3) in 121 use a suitable tool and do not use any cyUnder liner (5) from lop force; otherwise, piston (4), cylinder liner (5) and injection pipe (6) will be damaged. CiJ Assignment of piston (4) - cyUnder liner (5) must be stridly observed. CiJ The arrow on piston aown (7) must paint In direction of !ming gear. When inserting pistons (4), twist bo/ 20• so that connecting rod (3) can be guided past the injection pipe (6), CiJ use a tensioning strap (12). [I] Ensure that bearing shell (8) remains in its installation position. !§'.I Tensioning strap •45058900t4()() 22 Place connecting rod (3) and connecting rod W Ensure inslallatlon position of connecting bearing cap (2) on aankshatt journal. rod bearing cap (2) on apl)fOpriate connecting rod (3). r,!3 Screw in bolts (1) of connecting rod bearing W The bolts (1) must be t,ghtened witl1 cap (2) on connecting rod (3) r torque befo,e cranl\Shan Is rotated, •BA03.10-P-t00t-01K 124 Inspect main bearing shell, top ( t 1) I W Cheek coocfrtion of main bearing shell, top (11 ), check comict pos~lon and replace W nt>Ce$&a,Y. ~5 Inspect main bearing shell, bottom (13) I W Ched< condition of main bearing shell, bottom (13), check correct posalon and "'1)1aoe if necessary. ~6 Install crankcase bottom section (10) 27 _,...,., ,n bolts (9) on aankcase bottom
L
"01\vl.40-P-lw.>-VIM
sedion (tO)
28
lnsta11 timing case cover
AR0140-P-8000SM
29
Installing oil pan
ARO! 45-P-7500SM
30
Install cylinder head
ARO! 30-P-5800SN
,_ ............ _ ......
f
onnect groun ca le to battery¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 68 · Applies to: 450, 451
35 onnect groun ca le to battery 3SM Crankcase, tlming case cover, end cover Number Designation Engine 160.920 BA01.40-P-1005-01M Bolt, crankcase bottom sect.ion 8mm Stage 1 Nm 21 Stage 2 ". 90 6mm Nm 9.5 ~ Connecting rod Number Designation Engine 160.920 BA03.10-P-1001-01K Bolt. connecting rod cap to connecting rod Stage 1 Nm 15 Stage2 ;(" 90 / ' ~ '- 450 589 00 14 00 ,/ Retaini:ng strap Commercially available tools Number Designation WH58.30-Z·1048-13A STAR DIAGNOSIS diagnosls system, Compact Passenger Car 65111801 00 Repair materials Number Designation Order number BR00.45-Z-1053-01A Sealing compound Q0000282V00000OOOO
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 69 · Applies to: 450, 451
15.4.02 '" up to WME01MCO12H106037 ENGINE 160.920 in MODEL 450.3 /4 (except , 450.418) as of WME4503001J000001 ENGINE 660.940 in MODEL 450.3 /4 (except , 450.418) P13.22-2087..o9 1 Clips 4 Nut 7 Adjusting screw 2 841/tcovar 5 Bracket 8 Torque wrench 3 son 6 Poly-v-t,elt 9 Gauge (poly V-belt tens!on) Iii.ii Remove 1.1 Remove wfleelhousing liner In rig.ht rear IWexoept 450.418. AR83 IO-P•1400SM fender ~ Pull out the spteader pin on the clip (1) and remove the belt cover (2)
I Remove the alternator cover Model 450.3 wtth Engine 160.910. 660.940 AR15.40-P-5032·02SM upto 14.11.99 Model 450.3 wtth Engine 160.910. 660.940 AR 15.40-P-5032-02SN as of 15.11.99, model 450.3 wtth engine 160.920. model 450.4 ~ Slacken the bolt (3) for the attemator on the IW Do not remove poly V-bett (6) when ...sembly carrier and the nut (4) for the el')Qioe is warm. altemalor al the brad<el (5) ~Box wrench •◄50589042100 ~ Joint socket wrench b~ '450589060900 5 Remove poly-V-belt (6) 11<.il Install 6 f"ij on polyV-bett (6) IWlnspect poly V-belt (6) for wear and dama.ge 7 Tension the poly V..t>elt (6) via the adjusting W The attemator must be easy to swivel screw (7) at the alternator before tensioning begins. For the fltSI instlllatlon, apply a torque of approlt. 45 Nm. for repeal Installation, apply a torque of approx. 40 Nm at the adjusting screw (7) using the torque wrench (8).
'BA 13.25-P-1001-0IJ¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 70 · Applies to: 450, 451
~-
'BA 13.25-P-1001-0IJ
Engine 160: t
8
'BA13.25-P-1001·01N
~
Box wrench
'450589042100
~
Joint soci
with CODE (101) Air conditioning Plus (with outside temperature indicator) (FFO)¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 71 · Applies to: 450, 451
15.4.02
,n
with CODE (101) Air conditioning Plus (with outside temperature indicator) (FFO)
with CODE (129) Air conditioning Plus (with combina.tion fil!Er and outside temperature Indicator), smart & pusion
up to WME01 MCO12H106037
ENGINE
160.920 in MODEL 450.3 /4 (except , 450,418)
with CODE (101) Air conditioning Plus (with outside temperature indicator) (FFO)
with CODE (129) Air conditioning Plus (with combination filter and outside temperature Indicator), smart &
pa.ssion
as of WME4503001J000001
ENGINE
660.940 In MODEL 450.3 /4 (except, 450.418)
with CODE (101) Air conditioning Plus (with outside temperature indicator) (FFO)
with CODE (129) Air conditioning Plus (with combination filter and outside temperature indicator), smart &
passion
1
Cover of Poly-V-i,.Jt
2
Sprea<Wp/n
3
Rivet
4
Clip of tensioning pulley
S
Tensioning pulley
6
Po/y-V-belt
7
Bolt
8
Bolts
S
Tensioning pulley
6
Poly-V-belt
7
Bolt
•Id
Remove
1
RemoYe poly-V bett (6)
AR13.22•P•1202SM
12
RemoYO rivet (3) from bracket (arrow) lrom I W Pull spreader pin (2) out of rivet (3.
cover of poly-V-bett (1)
13
RemO\le cove< of poly-V-bett (1)
14
RBmoYe cap of tensioning pulley (4) with
suitable tool (arrow)
15
Slacken bolt m at tenslonlno O
Slacken bolts (8) from tensioning pulley (5) at¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 72 · Applies to: 450, 451
6 Slacken bolts (8) from tensioning pulley (5) at timi,ngcase 7 Remove poly•V bell (6) W Check poly-V-belt (6) for damage and wear, replace If necessary. ,_:j ' Install 8 Position poly•V•belt (6) W Tensioning pulley (5) must be located In final position •Ioosen· (180" countetelockwlse). 9 Adjust tensioning pulley (5) W Place tensioning pulley (5) through swinging of bracket (via elongated hole) at poly-V-belt (6) zero clearance (without tension}. 10 Tighten bolts (8) from tensioning pulley (5) at Engine 160: 1 timing case ~ "BA13.25-P-1001-01K Engine 660: 1 ~ 0 BA 13.25-P-1 003-01 J 11 Clamp poly-V•belt (6) I W Twist tensioning pulley (5) around 180" clockwise. 12 Tighten bolt (7) at tensioning pulley (5) Engine 160: 1 ~ "BA13.25-P•1002-01K Engine 660: i ~ •BA 13.25·P-1004-01J 13 Check pre-tensioning of poly-V-belt (6) I® Cheek poly-V-belt (6) only when engine is lukewarm or cool. At higher engine temperatures the pre-tensJoning is not correctly adjusted. [fl Only use measuring tool in Ulustrated area. In order to exclude measuring faults, carry out multiple tests, Adjustment value "new belt": approx.. ' 400 Nm, adjustment value •otd belt": approx. 300Nm. IS'.J Gauge (V-belt tension) 0450589002100 14 Mount cap of iensioning pulley (4) 15 Install poly-V-belt cover (1) l! l tnsert rivet (3) in bracket and press in spreader pin (2). 16 Install poly V-belt (6) AR13.22.P-1202SM ~ Belt tensioning device Number Designation Engine Engine 160.910 160.920 BA13.2S-P-1001-01K Bolt of poly V-belt tensioning device carrier to Nm 20 20 t!,nlng case BA13.25-P-1002--0·1K Eccentric bolt to poly V-belt tensioning device Nm 21 21 carrier ~ S.lt tenslonlng device Number Designation Engine 660.940 BA13.25-P•1003--01J Bolt of poly V..t>elt tensioning device carrier to Nm 20 timing case BA13.2S-P-1004-01J Eccentric bolt to poly V-belt tensioning device Nm 21 carrier
Righi rear engine mount,¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 74 · Applies to: 450, 451
on Righi rear engine mount, up lo WME01MCO12H106037 ENGINE 160.920 in MODEL 450.3 /4 Righi rear engine mount, as ofWME4503001J000001 ENGINE 660.940 In MODEL 450.3 /4 (except , 450.418) Right rear engine mount f Engine mount 2 Screw 3 Crossmember " Bolts 5 Bolts i..;j i;_.J Remove/Install 1 Ul1$Cl'9'W bo" (2). crossmember (3) at right frame-type Integral support 12 Support engine with suitable engine hoist 13 Remove bolts (4). 14 Unscrew botts (5) a1 frame-type Integral support and remove engine mount (1) 15 Install in lhe reverse order E3 Engine mounts, engine supportS Number Designation 8A22.10-P-100H)1M Bolt of engine support to cylinder head 8A22.10-P~100S-01M Bott of rear engine support to lram&-type Integral support 13.11.02 "22.10-2113-<lG l'!!l "BA35 10.P-1003-0lF I W If the engine mount (1) is reused, the center bott -n the bearmg •""" and the rubber element mus, not be released, because the engine mount (1 ) is preadjusted. 8 With engine 160 '8A2210-P·1001-01M 8 With engine 660 ' 8A2210-P-1001-01 N I~ With engine 160 'BA2210-P-100S-01M 8 With engine 660 '8A22.10.P-1005-01N Engine Engine 160.910 160.920 lnitlal lightening Nm 28 28 Subsequenl Nm 23 . lightening Nm 58 58
Number¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 75 · Applies to: 450, 451
Designation Engine 660.940 BA22.1O-P-1001-01 N Bolt of engine support to cylinder head Nm 28 BA22.1O-P-1005-01 N Bolt of rear engine support to frame-type integral Nm 58 support ~ Rear axle earner Number Designation Model 450.3/4 BA35.1O-P-1003-01 F Bolt of crossmember to frame-type integral Nm 65 support
R01.30-P•5800-01 SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 76 · Applies to: 450, 451
Tightening diagram of cylinder head bolls 8 Cylinder head Number Designation BA01.30-P-1001-01K Bolt of cylinder head lo crankcase BA01 .30~P·1002-01 K Bolt, cylinder head to timing case cover / ' ~ ' 450 589 00 10 00 SOCket wrench lllustrate<I on engines 160.910 and 920 Tightening pattern and screw diagram 1st stage 2nd stage Step3 4th stage Tighten cylinder head bolts (1 to 10) in the order given by the lightening diagram. Flrst fully tighten cylinder head bolts 1 to 8 completely and then ~ten cylinder head bolts 9 and 10. I.U Slac!<en in the reverse order. Engine Engine 160,910 160.920 Nm 21 21 ... 90 90 ... 90 90 ;(" 10 10 Nm 27
ENGINE¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 78 · Applies to: 450, 451
ENGINE n 160.920 in MODEL 450.314 (except, 450.418) 660.940 In MODEL 450.314 (except, 450.418) Charge air cooler ~~ Remove/Install 1 Remove engine compartment cover t"!l Check 2 Check charge air cooler (1) lrll Cleaning 3.1 Clean charge air cooler (1) ,f Install in the reverse order 20.8.04 P09.41•2319·06 W Check charge air cooler (1) for contamination, leaktightness and damage. III Use a strong source of light. W If contamination was established.
AP98.00-P-9B50SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 79 · Applies to: 450, 451
Inspect body for damage to paintwork 19.6.06 1 2 P98.00-2907-07 1 Allla subjected to stone impact 2 Area under CBS rear 3 Screwing on points for rear-end customized body panels Modification notes 131 .3.06 !Disassembling of parts deleted l::!l Checking 1 Check vehicle paintwork W Open tailgate and check screwing on points for rear-end customized body panels (3) for corrosion. III Check painted outer surfaces, chipping- prone area (1), area under rear-end customized body panels (2) and rear-end customized body panels (3) for damage, if necessary vehicle paintwork subject to a C~AH Damage and stress caused to paintwork by separate order. AH98.00-P-8070-02SM external influences
Brake system - inspect fluid level¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 80 · Applies to: 450, 451
22.8.07 Shown on model 450.3 1 MAX marking 2 MIN marking 3 Brake ffuld reservoir P42.00-2079-04 & Danger! Risk of poisoning caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by bra.ke appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. & Danger! Risk of injury cal!Sed by moving parts Atways remove ignttion key when working on AS82.30-Z-OQ01-01A that can pinch, crush or, in extreme cases windshield wiper mechanism. even sever extremities. (2) Brake fluid notes AH42.50-P-0001-01A ® Notes on repairs to brake system AH42.00-P-0003-01A 1.1 Remove service grill on the right On model 450.3/4 except 450.418 1.2 Open windshield In caseofmodei450.418 2 Check fluid level W The brake fluid level must be between the MAX (1) and MIN (2) markings embossed in the brake fluid reservoir (3). If the fluid level is too low, establish and eliminate the cause - As a separate repair order. If no cause can be found, correct brake fluid level. ~BB General brake fluid Sheet330.1 BB00.40-P-0330-01 A ~ BB Brake fluids (DOT 4 plus) Sheet 331.0 8800.40-P-0331-00A 3.1 Install service grill on the right On model 450.3/4 except 450.418 3.2 Close windshield In case of model 450.416
ENGINE¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 84 · Applies to: 450, 451
ENGINE 1 Pin n 160.920 In MODEL 450.3 /4 660.940 In MODEL 450.3 /4 (1>•cept , 450.418) 2 Spreading clfp 3 Cover 4 Gauge (V-belt tension) 5 Po/y-V-belt of g,merator 6 Po/y-V-belt of refrigerant compressor Ii.;! Remove 1& Danger! Rlsk of accident caused by vehlcte ,tarting off by itself when engine is running. Rlsk of Injury caused by conwsions and bums wllen working in engine during starting procedure 1 ~ AR Remove rear ull(jert>ody paneGng ~ n.cmove cover (JJ ~' l'i"°AR Remove cover of generator ~ Check ~ Crank engine by hand 5.1 Check condition of POiy-V-belt of rerrigerant compressor (6) ~ AR 6 Check condition of POly-V-belt of generator (5) ~ AR 7.1 Check poly V-bett Ien,lon at refrigerant compressor (6) 22.7.02 Secure vehlcte to prevent H from moving. ASOO OO-Z--0005-01A Wear closed and snug-fitting wot!< clothes. Do not grasp hot or rotating pans. AR61.30-P·1001SM I W Remove pin (1) wlOI suitable pliers from spreading clip (2) end remove cover (3) On model 450.3 up to 14. 11.99. AR 15.40-P-5032-02SM On model 450.3 as of 15.11.99 and 450.4 AR15.40-P.S032-02SN W Crank engine three times. Only wlOI code (01) Nr conditioning Plus (with outside temperature indicator) (FFO) or code (129) Air cond~lonlng Plus (wl1h combination fitter and outside temperature Indicator), sman & passion [i] Crank engine a little in direction of rotation or engine, if required: 1 -subject to separate repair order Replace POly•V•bett of refrigerant compressor (6) Remove/install POiy V-bett of compressor AR13.21·P•l202SM IW Crank ellgine a little in direction of rotation of engine, if required; l -subject to separate repair order Replace POly•V•bett of generator (5) Remove/install poly V-bett AR13.22•P•1202SM Only with code (01) Alr cond~ionlng Plus (with outside temperature indicator) (FFO) or code (129) Air oonditlonlng Plus (with .. .. - - ·-
f P82.10-P-$260-06SM I¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 86 · Applies to: 450, 451
Adjust headlamps Modification notes 121.3.06 fdiustment patterns of headlamps added Workshop equipment E5$.40-Z-1006-19A Headlamp adjustment testing unit Perform side adjustment ofthe left front lamp untt (E1) or right front lamp unit (E2) at the adjustment screw (1). 2 Perform heighl adjustment of the left front lamp unit (E1) or right front lamp unit (E2) at the adjustment screw (2). Adjustment pattem for low beam (rightahand traffic) • When setting the height, the light-dark boundary must have the same coverage as the honzontal broken line (4) of the device. For the side adjustment the kinked line (5) must be under the oentral marl< (6) statt at !he horizontal separating line (4). III When changing over the low beam from tight-hand traffic to left-hand traffic, !he triangle which results from the sep;,raling line (4) and the kink line (5) must not be illuminated. Adjusting pattem for low beam (left-hand traffic) • When setting the height, the light-darl< boundary must have the same coverage as lhe horizontal broken line (4) of the device. For the side adjustment the kinked line (5) must be under the central mark (6) start at the horizontal separating line (4). III When changing over low beam from left-hand traffic to righl-lland lrafflc, the lriangle which results from the separating line (4) and the kinked line (5) must not be illuminaled. Adjustment pattern of high beam o The fight focal poinl should be located on the relevant central mark (6). fn the event of a deviation: Check seat of bulb. P82.10-3247 --04 P82.10-0:Z03-01 6 4 P82.t0-'347--01
Shown on model 450.3 as of 11.02.02¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 87 · Applies to: 450, 451
Ef
Leff front lamp unit
E2
Right front lamp unit
E511
Left front fog l•mp
ES/2
Righi front fog lamp
Modification notes
121,3.06
Procedure modified
121.3.06
..ajustment patterns of headlamps added
f21.M6
!Adjustment patterns of headlamps ad
IAP82.1 0-P-8260-04SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 89 · Applies to: 450, 451
Workshop equipment IWE58.40-Z-1006-19A I Set or inspect fog lamps I Headlamp adjustment testing unit 1 Adjust front fog lamp at the adjustment screw (1) of the left front fog lamp (E5/1) or right front fog lamp (E5/2). Adjustment pattern for front fog lamp • The light-dark boundary must be as horizontal as possible at the height of the appropriate dividing line (4), correct if necessary. P82.10-4337-01 4
Read out OTC memory¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 91 · Applies to: 450, 451
11 Read out OTC memory W If necessary, eliminate any faults in the control units. Check wiring harness IIJ Carry out function check on completion of repair ~ AD Connect STAR DIAGNOSIS, interrogate fault AD00.00-P-2000-04SM memory Diagnosis system STAR DIAGNOSIS -WH58.30-Z-1048-13A ~ 452 589 02 99· 00 452 589 02 99 01 452 589 02 99 02 452 589 02 99 03 Wiring harness repair kit Crimper 0.35 - 1.0 Crimper 1.5 - 2.5 Crimper 4.0 - 6.0 Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
Heater/Ventilation operating¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 92 · Applies to: 450, 451
module 2 Air distribution cable 3 Catch 4 Clamp 5 Lever lo!~ Removellnstall 1.1 Disconnect left and right tweeter ~AZ 12 Remove instrument cluster 3 Remove cockpit ciock 4 Remove Tachometer 5 Remove front center console 6 Remove Instrument panel 7 Remove heater/ventilation operating Unit (1) 8 Remove catch (3) from air recirculation cable (2) and unhook air distribution cable (2) from heater/ventilation operating unit (1) r Remove clamp (4) from air distnbution cable (2) and unhook air distribution cable (2) from lever (5) of air distribution box 10 Remove air distribution cable (2) ,, Install in the reverse order 5.9.05 P83.10-255e--04 W Only for vehicles with sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO). code C17. See i Retrofit sound system AZ82.62.P-0002SM I l!I Do not disassemble instrument cluster. ""54.30.P-601:,:;M uJ Installation: Variants and parameters of instrument cluster do not need to be µ, ugrarnn ,ed. AR54 .30.P• 1 000SM AR54.30.P-1100SM AR68.20.P-201 0SM AR68.1 O.P-1 000SM W Only remove heater/ventilation operating AR83 20.P-1850SM un~ (1) to the extent that the air distribution caole (2) i.s accessible and can be removed. (il Installation: The air distribution cable (2) must be adjusted after installing the heater/ ventilation operating untt (1}. See i Adjust heater/ventilation operating unit (1) AR83.20.P-185o.01 SM cable W lll$tallation: When routing, ensure that air distribution cable (2) can move freely and rnrates correcily. I lnstallatlon: The air distlibution cable (2) must be routed and secured In such a way that it is protected from damage and vibration.
up to WME01MC012H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 98 · Applies to: 450, 451
18.6.02 n up to WME01MC012H106037 E NGINE 160.920 in MODELS 450.3 14 (except 450.418) from WME4503001J000001 t Catalytic converter 2 Plug connection 3 Nuts 4 Bncket o.f catalytic converter 5 Bolls G3/1 02 sensor down.stnulm or catalytic converter P49. 10.22:ZO.OO 11,.g I.,! Remove/Install 1 Remove CMS at rear ARBa 20-f>-1950SM 12.1 Repair retaining damp ot exhaust $'f$lem I W If retaining damp is defective. The entire catalytic converter need not be repl.loed ff lhe retalniflg damp is defedlve, see: I Remove/install retaining damp of exhaust AR49 10-P·5504SM system :t Take connector (2) out of tho brad<et and oeparate ~-1 Unscrew 02 sensor downstream of ca1aly1ic -I 450.3 /4 wilh engine 160.910, only in convetter (G311) from catalytic converter ( 1) case of 40kW gasofine engine, EU3 hp, code 803 33kW gasoline engine. EU3 hp. code 804 45kW gasoline engine, EU3 hp, code 805 51kW gasoline engifle, EU3 hp, code B09 Model 450.3 /4 with engine 160.920, in case of gasor.ne engine, 37kW / 50np (M160/1 ), code806 gasoline engine. 45kW /61hp (M160/1). code807 gasoline engine, 55kW / 75hp (M160/1). code 810 uJ Installation: The 02 senso< downstream of catalylic converter (G3/1) must show an adequate distance to lhe CM5-<oar al lhe top ~rrow). •BA14.00-P-1001-01B ~Sod<el •4505891M0900 5 Remove nuts (3) ll!J Treat nuts (3) with anti-seize compcund before unscrewing. uJ Installation: Replace slud bo~s. in case ~ were un~ewed ~ the nuts (3).
'BA49.10-P-1002-01J¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 99 · Applies to: 450, 451
8 ::, \ I 'BA49.10-P-1002-01J 6 Unscrew bolts (5) of catalytic converter W Installation: Screw in bolts (5) finger- bracket (4) to transmission tight at first, mount catalytic converter (1) free of tension and only then tighten the bolts (5). 8 'BA49.1O-P-1001-01 J 7 Take out three way catalytic converter (1) W Installation: Insert three way catalytic converter (1) and position horizontally, in the center and free of tension. 8 Install in the reverse order 802sensor Number Designation Engine Engine 160.910 160.920 BA 14.~-1001-01 B 0 2 sensor at exhaust pipe/ exhaust Nm 50 50 manifold 8 Exhaust system Number Designation Engine Engine 160.910 160.920 BA49.10-P-1001-01J Bolt or exhaust system to transmission Nm 23 23 8A49.10-P· 1002-01J Nut of exhaust system to manifold Nm 30 30 Wrench Socket
Center console¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 100 · Applies to: 450, 451
1 2 Center console Electrical connector · and installing cockpit switch group 3 Electrical connector 20.9.02 P54.25-3208-07 S611 Cockpit switch group ~~ Removing, Installing 1 Unclip cockpit switch group (S6/1) from W Release catch mechanism using a center console (1) suitable tool. [I] Installation: Pay attention to routing of cables and ensure cockpit switch group (S611) is properly engaged. 2 Unplug electrical connector (2) and electrical ® Do not damage the catch lugs otherwise connector (3) and remove cockpit switch the plug can no longer lock. group (S6/1) [II The connecting piece must remain on the printed circuit board. [I] Installation: Ensure that the electrical connector (2) and electrical connector (3) are properly engaged. 3 Install in the reverse order 4 Set cockpit clock See owner's manual
Clutch plate¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 102 · Applies to: 450, 451
19.2.07 Clutch plate 2 ~ Catch 3 Bolts 4 Dowe/pin P25. 10-2028-04 ~ll,J ' Remove/install 1 Remove clutch AR25.10-P--0050SM 2 Fix clutch plate .(1) In place with catcl\ (2) lS'I "450589004000 3 Remove bolts (3) and take off clutch plate (1) III Installation: The clutch plate (1) can together with U>e catch (2) only be placed on the crankshaft in one position. The dowel pin (4) must point in the direction of the transmission. 8 Engine 160.910/920 'BA03.30-P-1002-01 J El Engine 660.940 'BA03.30-P-1002-01K 14 Install in the reverse order El Flywheel, driven plate, vibration damper, starter ring gear Number Designation Engine Engine 160.910 160.920 BA03.30-P-1002-01J Bolt. driven plate to crankshaft Stage 1 Nm 47.5 45 Stage 2 &· 90 90 S Flywheel, driven plate. vibrajjon damper, starter ring gear Number Designation Engine 660.940 BA03.30-P-1002-01K Bott, driven plate to crankshaft Stage 1 Nm 45 Stage2 &" 90 450 589 00 40 00 Catch
Front br.>cket¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 103 · Applies to: 450, 451
11.8.03 Front br.>cket 2 Bracket 3 Positive terminal cover 4 Cable N10/t0 SAM control unit P54.25-3656-06 ...Q~I Remo\le/lns.tall 1 Read out fault memory W tfneoessary, etiminate any faults in the control untts. t_...AD Connect STAR DIAGNOSIS and read out AD00 OO-P-2000.04SM fault memory STAR DIAGNOSIS diagnosis system "WH58.30-Z-1 048-13A 2 Remove foot support on passenger side AR68.3o.P-1 340SM , Dfsconned battery ground cabh? AR54.1o-P-0003SM 4 Remove tie straps on front bracket (1) L!J ln$tallatlon: Install 118W tie straps. 5 Release SAM control untt (N10/10) from front bracl<et(1) 6 Loosen lock on bracket (2) 7 Push SAM control unit (N10/10) upwards out of the hinge guides 8 Remove positive pole cover (3}, unscrew the nut under tt and remove line (4) 9 Detach all plugs 10 Remove SAM control unit (N10/10) W When exchanging the SAM control unit (N10/10) all the fuses must be taken over from the okf part. Damaged fuses must be replaced. 11 Install in the reverse order Concluding the work 12.1 Program the locking system ill Only W the SAM control untt (N10I10) is ffilaced. All the keys which belong to the vehicle must be taught in. (I] Follow the Instructions in the DAS. r,;j-AD Connect STAR DIAGNOSIS and read out ADO0.OO-P-2000,.04SM fault memory STAR DIAGNOSIS diagnosis system "WH58.30-Z-1048-13A 13 Set time W See owne(s manual. 14 code radio
Bolts¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 104 · Applies to: 450, 451
13.6.05 Bolts 2 Gen-enttor bntek•t 3 Bolts for liming c..,se cover P01,00--2765-04 4 Bn1cket for engine block P01,oo..z766-11 11<>1 Remove & Dang,,r1 Risk or death caused by vehicle slipping or Align vet>lcie .,.,_n the columns of lhe ASOO 00-2-0010.0lA toppling off the lifting platform. lilting platlorm and PoSltion lhe lour wpport plates at lhe Oiling platform support points speeified by the vehlcle manuradurer 1 Remove CBS rear end Except model 450,418 AR88 20.P-1900SM Model 450.418 AR88 20.P, 1800CR 12 Remove CMS Rear AR88.20.P-1950SM 13 Remove right rear wheel AR40 10.P-1100SM 14 Remove inner fender from rear fender AR88 1(}.P-1400SM 15 Remove bolt ror =smember on frame-type See: I in,egral support on tile right Removing/installing rear axle erossmember AR351S-P-0250SM 16 Remove the a.ltemator cover AR15.◄0.P,5032-02SN 17 Remove pofy.V-belt I AR13 22-P-1202SM 18,1 Remove pofy-V-belt or supercharger Only oo vehicles with Air conditioning Plus AR1321.P,1202SM (with outside temperature indicator) (FFO), code 101. 19 Remove bolts (1) for atemator (2) bracket 10 Remove alternator (2) bracket 11.1 JK&move lhe poiy-v-oell tensfoning device ror ;only on vehicles with Air conditioning Pfus ARl321 ·P•;>,W:,M comp,essor (With outside temperature indicator) (FFO). code 101. 12 Remove rear engine mOtJnt W At right rear. AR2210.P-1160SM [I) Support using a su~able lifter. 13 Unscrew bolts ror 11mlng case cover (3) lnslllll bracket 14 Mount engine block (4) bracket on timing W PidureA.
Nm 127¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 106 · Applies to: 450, 451
MS Nm 127 ~ Engine mounts, engine supports Number Designation Engine Engine 160.910 160.920 BA22.10-P-1005-01M Bott for rear engine support on frame-type Nm 58 58 integral support ~ Engine mounts, engine supports Number Designation Engine 660.940 BA22.10-P-1005-01N Bott for rear engine support on frame-type integral Nm 58 support 450 589 29 63 00 Retainer
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 107 · Applies to: 450, 451
22.5.06
,n
up to WME01MCO12H106037
ENGINE
160.920 in MODEL 450.3 /4
as of WME4503001J000001
P01..30-2170-09
1
Cylinder head
6
Airline
10
camShafl sprocket
2
ConnKtor
7
Bolls
11
Cylinder head bolt$
3
Wastegate valve
8
Holder for the air-conditioning
4
Connector
compressor
9
Bolt
Modification notes
115.5.06
!Bolt, camshaft sprocket to camshaft
el
Removing
&oanger1
Risk of accident cause<! by vehicle starting
off by ilSeK when engine Is running. Risk of
Injury caused by contusions and b<Jms
during starting procedure or when working
near the engine as ft ii running
&oangerl
Risk of explosion caused by l\lel igniting,
risk of polsonlng caused by lnhaUng and
swallOwtng fuel and risk of Injury lo skin
and eyes caused by contact with l\lel.
it:. Danger!
Risk of explosion caused by oxyhydrogen
gas. Risk of poisoning and caustic bums
caused by swallowfng battery acid. Risk or
Injury caused by bums ro skin and eyes
lrom battery acid or when handling damaged
lead-acid batteries
& Danger!
Risk of Injury to skin and eyes caused by
scalding from contact will1 hot coolant Sl)(8y.
Risk of poisonlng /Tom swallowing coolanL
1
Disconnect battery ground cable
~
Read out fault memory
Y31l6
Boost pru.svre switchover
valve
!Engine 160
I
·BA05.20-P-100 H) 1 G
secure vehlele to prevent ft lrom moving by
AS00.00-Z-0005-OIA
ilSeJI.
Wea, closed and soug-flttlng wol1< clot!les.
Do not touch hot or rotating par1s.
No fire. sparks, open Rames or smoking,
ASA7 00-Z-0001-0IA
Pour fuels only into sul1able and
appropriately mall
Number¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 110 · Applies to: 450, 451
Designation Engine Engine 160.910 160.920 BAOS.20-P-1001.01 G Bolt, camshaft sprocket to camshaft Stage 1 Nm 21 21 Stage 2 ,,,. 90 90 Stage 3 ,,,. 10 10 ~ Refrigerant compressor Number Designation Engine Engine 160.910 160.920 BA83.55•P·1001·01J Bolt, refrigerant compressor brack.et to cylinder head ln~ial torque Nm 12 12 Continued Nm 9.5 10 torque BA83.5S-P-1002-01J Bolt, refrigerant compressor to bracket Nm 20 20 BA83.55-P-1003-01J Bolt, refrigerant compressor. basic carriers Nm 20 20 450 589 00 01 00 450 589 00 10 00 Openendwre<ld1 Socl<et wrench Commercially available tools Number Designation WH58.30-Z-1048-13A . STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 111 · Applies to: 450, 451
12.9.02 up to WME01MCO12H106037 ENGINE 160.920 in MODEL 450.314 as of WME4503001J000001 ENGINE 660.940 In MODELS 450.3 14 Oil pan 2 Bolls P0 1. ◄~2111-01 ~ Ill! Removlnwtnstalllng 1 Suction off-engine oil r.;irAP Engine oil and filter change AP18.DO-P•D101SM 2.1 Remove engine preheating heating eJemeflt W Only models 450.300 /400 with engine AR83 70-P-5310SM 660.940 with Canada, code L27. 3 Remove bolts (2) for on pan (1) from Engines 160.910, 920 see: J crankcase ~ "BA01.45-1'•1001-01J Engine 660.940, refer to: i ~ •BA01.45-f'-1001-01 K 4 Carefully detach oil pan (1) from crankcase W Installation: Clean sealing surfaces, coal using a rubber mallel and remove sealing surface with sealanl Sealing compound 'BROO 45-Z-1053-01A III Notes on applJcation of sealant to oil pan AH01.45-P-0001-0 1 SM 5 Install in reverse order ~ Oil pan Number Designation Engine Engine 160.910 160.920 BA0t.45-P-1001.01J Bolt for oil pan on crankcase and timing case Initial torque Nm 12 12 cover Continued torque Nm 9 9 ~Oil pan Number Designation Engine 660.940 BA01.45-P-1001-01K Bolt for oil pan on crank.case and timing case Nm 12 cover Repair materials Number Designation Order number 8R00.4~-t053-01A Sealing compound Q0000282VOOOOOOOOO
BA 15.40-P-1005-01 G¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 113 · Applies to: 450, 451
Bolt for alternator bracket on MS Clearance hole Nm 9.5 9.5 crankcase M6 Blind hole Nm 12 12
Remove/install fender liner in rear fender¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 114 · Applies to: 450, 451
30.3.05 Shown on model 450.3 1 Plastic nuts 2 Fender liner P88.10-2185-03 l~-~J llJ Remove/install 1 Unscrew plastic nuts (1 ). 2.1 Remove corresponding mounting clip, · W Only if attachment parts are installed. attachment part on fender liner (2). 3 Remove fender liner (2) from rear fender_ W Do not damage plastic parts 14 Install in the reverse order
Floor Covering¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 115 · Applies to: 450, 451
22.3.07 1 Floor Covering 2 Compressor 3 Passenger-side footrest P68.30-2872-04 ~~ Remove/install 1 Move right seat toward rear 2 Remove vertical strut paneling next to center On vehicles with code (RHO) Right-hand AR68.00-P-1500-01SM console drive vehicle 3 Fold down floor covering (1) in area of <l!l Do not break or tear floor covering (1) passenger side footwell when folding down. 4 Remove compressor (2) On vehicles with breakdown set 5 Remove passenger side footrest (3) W The passenger side footrest (3) is fastened in the outer area with two sheet metal nuts. 6 Install in the reverse order
Footwell cover¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 117 · Applies to: 450, 451
1 Footwell cover talm 1 2 3 Remove/install footwell cover on passenger side 2 Air recirculation box 3 4 Right wheelhouse Carrier cover Remove/Install Loosen footwell cover from air recirculation [I] Installation: Press Velcro strip on at floo1 box (2) and from right wheelhouse (3). covering in area of right wheelhouse (3). Remove footwell covering (1) W Pull front footwell cover (1) downward (arrow) and pull carrier cover (4) out. Install in the reverse order 18.9.02 P68.30.2612•07
Removennstall rront module¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 118 · Applies to: 450, 451
Shown on model 450.3 Coola1tt upansJo,r reffrVO!r 2 Cooling $yslem cap 3 Coolant ho$8 , Coolant hose Shown on model 450.3 Coolant upans/o,r f9$8fYo/r 5 Front cro,,smember 6 Belt 7 Rall 5 Front Cf0$$tm!mber 6 Belt 7 Rall 8 Coolant hO$e 10 CMS-I 11 AC/Ines 12 Water drain h0$8 13 Coolant h0$e 9 10 capacitor CMS front Hom 21.11.06 P82.30-21'4-09 H2 M412 Engine coolant fan motor P62.30.21C5-09 814 Outside tempenture display tem,,.rature sensor E1 Left front/amp unit E2 Right front lamp unit
O.ngerl¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 119 · Applies to: 450, 451
I& O.ngerl rusk of Injury 10 Sl<ln and ey<>s caused by Do not open cooling system unless coolant AS20 OO-Z-0001.()IA scaldlng from contact witll Mt cooi.nt spray. temperature is below 90•c. Open cap slowly Risk of poisoning caused by ....,,.I1Qwing and release the pressure. Do not pour coolant oootant Into beverage containers. Wear protective g:loYes, procedlve dothing and safety gtas.ses-. I& Danger! Ris.k of injury causea by moving ~rts Atways remove 1gniti0n key when worx1ng on I"""-' -30-Z<JUUI-OIA that can pinch, cnnh or, In extreme cases Wlf'ldShiekS wiper mechanism, even HVGr extremities. 1 Rem011<1alflnlet Only model 450.3 /4 exoept 450,418. AR83 2S-P-1401SM 12 Re""""' !font CB~ Model 450.3 /4 e•OOjlt 450.4!8 AR88.00,P,t010SM Model 450.418 AR88 00.P-tOIOCR 3 Ol,en cooling system cap (2) on coolaot I W Rotate one revolution counterdod<.wise. expansion reservoir (1) release overpressure. then remove cooling system cap (2). 14 Oi:scharge aJr conditioning $)'$lem Model 450,3 /4 except 450.4 18 AR83 30-P•1760SM On vehicles with CODE (101) Air conditioning Plu$. 5 Remove underfloor panetl~ AR61 30-P·1001SM 6 Separate oon_nector at coolant fan motor (M4/2) 17 Disconnect connector ff'Om' ootside Only on vehicles with CODE (IOl) Alf tempefature Indicator temperature sensor conditioning Plus. (B14) ~ Oisconned: con.neecor from hOtn (H2) Only for vehicles up to 31.12.98 " Re-move rlvel for whfflhouse mount on left and righl on front crossmember (5) 10 Detach coolant hose (3) from radiator W Collect coolant 11 Press wheeJhouse cove, to side and remove COOiant hose (4) from c«>lant expansion reservo<r (1) ~2 Remove coolant hose (13) and coolant hose Exoept model 450.33 134135 up to 10.01 .00 (8) from coolant e,panslon reservoir (1) @ Avo<I radial load to pipe fitting on heater housing. danger of breakage. 13 Unscrew nuts lo< AC tines (11) from Only model 450,3 /4 except 450.41 B condenser (9), remove sealing rings and plug On vehicles wl\h CODE (IOI) Air oondttloning ACllnes (11) Plus. 14 Unscrew mounting bOlts from CMS rront (t0). 15 Unwew mounting bolts (arrows) above left front la,np u.nit (E1) end right front lamp untt (E2) 16 Uns.c:rew mounting bOlts from front crossmember (5) 17 PuR waterdreln hose (12) onteft and right Only on vehicles with oode (V29) Elec:trie oot of holes In front etossmem.ber (5) glass sliding roof (FFO). 18 Unscrew bolt (6) tonn ran (7) 19 Oi$C:Onnect eonneetotS from left front lamp un~ (El) and right front I.mp untt (E2) 120 Remove front module u;_g ' Inst.all 121 Position front module rzi Connect left rront I.mp untt (El) and right front I.mp un~ (E2) ~ Slide water drain hose (12) on left and right Only on vehicles wi\11 oode (V29) Electric into holes in front c,ossmember (5) glass sfidlng roof (FFO). ,14 Install rront erossmember (5) IW Pic:tu,e B. Use locating pins (7 .5 mm dla. btt) on both sides for positioning front CfQS;smember ($) (arrow) E3 •BA62.30-P· 1004-o2B 25 Tighten bott (6) on rail (7). i26 Tighten mounting bolta (arrows) above left IW Pic:tureA. front lamp unit {E1) and right front lamp unit (E2) 127 Install CMS front (10) 11!3 'BA62.30-P• 1009-02B 128 lnse~ sealing ring and install AC lines (11) Only model 450.3 /4 except 450,418. on condenser (9) On vehlCIM with CODE (101) Air conditioning
Remove/install front seats¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 121 · Applies to: 450, 451
25.3.02 P91. lo-249<~ 1 Bolt 4 Bolt 7 Clip 2 Bolt$ s Metalcffp 8 Connector 3 Bolt 5 Wiring hame-ss 10 Seat 9 Side airbag cable 10 Seal P91.10-24no4 ~It] Remove/lnstllll 1.1 Disconnect gro<1nd cable from battery Only on-• with code (113) side airbag AR54 10-P.0003SM {FFO). 2 Unscrew screw (1) from ben end lilting 11'"1 "BA91 40-P·1001.01G 13 Remove sea1 bett ou1 or~ guide 14 Push seal (10) lnlo IIS foremost posttlon. I W The seat is removed 10 imp,ove !he UnSctew rear bolts (2) or the seat rails on the display. console 8 "BA91.10-P•1003-01 G 15 Push lhe seal (10) Into the re,,rmosl position. W lns13.11"1ion: F .. t safNI in lhe bolts (2). Unscrew the rront bolts (3. 4) ollhe seat rails Press lhe fronl of lhe seat (10) downwards on the console unbl lhe seat rails rest on lhe console over lhe entire length. Screw in lhe front bolt (3) then bok (4) !!3 ' BA9110·P·100ol.o1G 16.1 lilt up seat (10) and unelip wiri'1g hamess (6) Onlyon vehicles with code (113) side airbag from lhe metal c11p (5) of the seat console (FFO), ($17) heated sealS (FFO) or bett lock r~nitiOtl. [I) To unclip the wiring ha mess (6) open lhe metal clip (5) downwards uslng a
Detach connector (8) with clip (7) at the seat Only on vehicles with code (113) side airbag¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 122 · Applies to: 450, 451
7.1 Detach connector (8) with clip (7) at the seat Only on vehicles with code (113) side airbag console and disconnect connector (8) (FFO), (S17) heated seats (FFO) or belt lock recognition. IJJ Compress locking device (arrows) and disconnect plug. 8 Remove seat (10) W Installation: Do not trap electrical lines between seat console and seat rail. Push seat back gently until both seat rails lock in position. 9 Install in the reverse order 10 Move seat (10) into the center position by W The noise of the seat locking in position means of the seat fore/aft adjustment (click) can be heard. 11 Move the front area of the seat (10) to and W If there is movement of 1 to 2 mm fro transverse to the direction of travel between the top and bottom rails, the seat (arrow) (10) is not OK. ~ Front seats Number Designation Model 450.3/4 BA91.10-P-1003-01 G Bolt, seat adjuster to front console NM 30 BA91.1O-P-1004-01 G Bolt, seat adjuster to rear console NM 30 8 Seat belts/emergency tensioning retractors Number Designation Model 450.3/4 BA91.40-P-1001-01 G Belt end fitting screw NM 30
Remove and install front seat backrest¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 123 · Applies to: 450, 451
9.9.02 P91.10-2S1 6-09 Shown on model 460.3.,. of 15.11.99 1 Seat bolster 5 Bolts, rear Se.ti shell 9 Side airbag 2 P/B$1/c strip 6 Sldebag wiring hamess plug 10 Sldebag bolts 3 Clip 7 Si~ wiring hsmess 4 Nuts, front seat shell 8 Cllp 11 Bolts P91.10-2516-01 ~ l,.;l RemoY&nnstall & Dangorl Risk of Injury. lnjurie$ may resun when Store airbag unit with exptJlsion area on top, AS91 OO-Z-0001--0lA performing testing or repaiJ WOfl< on airbag or do not subjed to temperatures above 100 emesgen,cy tensioning retract0< units. •c. When working on these units. disconnect I/le power supply. (2) lnstrucuons ror perfonning repair, body work AH91 HSM and welding on vehi<:les with alrt,ags and ETR units ill Legal regulations on handfing and storing AH91 00-P-OOQ4.-0IA airbags and emetgency tensioning retractors 1.1 Remove rront seat backrest roam For model 450.3 as or 15.11.99 and model AR911o-P·1120SM 450.4 1.2 Remove front seat For model 450.3 up to 14.11.99 AR91 10.P•IOOOSM 2-1 Remove la.rge luxury cushion For model 450.3 up to 14.11.99 with large AR91 1o-P·3305SM ruxury cushion 3.1 Remove left and right backrest beads rrom For model 450.3 upto 14.11.99 seatrrame IS'.] '450589079900
Unhook plastic strip (2) from seat shell at¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 124 · Applies to: 450, 451
5 Unhook plastic strip (2) from seat shell at W Start at hinges. seat upholstery (1) [I] Installation: Ensure that seat upholstery is not creased (1). 6.1 Remove clips (3) of sidebag wiring harness Only In vehicles with code (113) sidebags (7) from seat shell (FFO) [I] Installation: Route sidebag wiring harness (7) between the transverse pipe and rear wall of badlrest frame and above the I.ink rod. 7 Un.screw front seat shell nuts (4) and rear ~ •BA91.10-P· 1001-01G seal shell bolts (5) at seat rails and remove seat shell ~ -aA91.10-P-I002-0tG 8 Detach seat handwheel from link rod 9.1 Detach sidebag wiring harness plug (6) from Only in vehicles wtth code (113) sidebags sidebag (9), remove clip (8) from bacl<rest ffiO) frame and remove sidebag wiring harness Installation: Connector must be correctly (7), engaged. Check connector for damage. 10.1 Unscrew sidebag bolts (10) from backrest Only in vehicles with code (113) sidebags frame and remove sidebag (9). (FFO) III Installation: Screw in bolts of sidebag (10) finger-tight, align sidebag (9) flush with sidebag cover and tighten bolts of sidebag (10). ~ •BA91.60-P-1003•01 C 11.1 Removing si<lebag cover Only in vehicles with code (113) sidebags (FFO) III Push back catch lugs and remove sidebag cove-r. [II Installation: Ensure latching of catch lugs. 12 Unscrew backrest frame bolts (11) from seat rail, push backrest frame back and remove from journals. 13 Remove seatbelt budlle [N"'i •BA91 40-P-1 003-0lG 14 Install in the rev·e,se order ~ Front seats Number Designation Model 450.314 BA91.10-P-1001 ..QI G Nut, seat shell to front seat adjuster Nm 22 BA91 .10--P-1002-0 1G Bolt, seat shell to rear seat adjusting device Nm 30 ~ Seat belts/emergency tensioning retractors Number Designation Model 450.314 BA91.40•P-1003·01G Screw oo seat belt buckle Nm 30 ~Airbag Number Designation Model 450.314 BA91.6().P• 1003-01C Bolt. sidebag to seat backrest Nm 6
C/11>$¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 125 · Applies to: 450, 451
450.4 1 C/11>$ 2 Beltguide 3 &lcJ<rest frame Remove/install front seat backrest foam part 4 Clip$ 5 Hud restraint upholstery clips 11.9.02 P91,10.2517-09 6.1 L•II backrest frame upholstery 6.2 Right backrest frame upholstery P91,t0..2S18-07 7 Fastening woat/Je,slrip 8 Front bending tabs 9 Lower bending tabs 10 Retaining wire tr.~ t;;J Remove/Install 1 Remove rront seat AR9l .10-P-IOOOSM 12., Pull cup-holder panel out of bad<rest lrame Only when installing new lront seat bad<rest (3) and remove clips (1) on the backrest frame 13.1 Remove belt gukle (2) Only when Installing new front seat backrest ® Remove carefully, otherwbe the backrest frame (3) may get scratched. [l) lnstallatlon: install new belt guide (2). 14.1 Remove clips (4) on the bad<rest frame (3) Only when lnstaUing new front seat backrest 5,1 Pull panel out of the backrest frame (3) Only when instamng new front seat backrest 16 Pull headrest upholstery clips (5) O<Jt of~ IW lnstallaHon: Install new h&ad restra1nl backrest frame (3) upholstery clips (5) 7 Release ellps O<Jt of the bores on the let\ llllJ •450539079900 backrest Ira me upholstery (6.1) (D lnstallatlon: tnsta.11 new clips.
Remove fastening weatherstrip (7) under¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 126 · Applies to: 450, 451
8.1 Remove fastening weatherstrip (7) under Only on vehicles with code (113) side airbags side airbag cover (FFO). ITJ Installation: The fastening weatherstrip (7) must sit correctly under the side airbag cover. 9 Release clips out of the bores on the right [;t'J .450589079900 backrest frame upholstery (6.2) ITJ Installation: Install new clips. 10 Bend open front bending tabs (8) on the ® To ensure the strength of the front backrest frame (3) bending tabs (8), only bend these open until the retaining wire can be removed. II] The front bending tabs (8) may only be opened and closed once. II] Installation: Bend the front bending tabs (8) using a plastic mallet until they touch the backrest frame (3). 11 Unhook retaining wire out of the front lfil •4505B9079900 bending tabs (8) and place foam part on seat cushion 12 Bend open lower bending tabs (9) on the ® To ensure the strength of the lower backrest frame (3) bending tabs (9), only bend these open until the retaining wire (10) can be removed. IIJ The lower bending tabs (9) may only be opened and closed once. II] Installation: Bend the lower bending tabs (9) using a plastic mallet until they touch the backrest frame (3). 13 Unhook retaining wire (10) out of lower lfil •450589079900 bending tabs (9) and remove foam part 14 Install in the reverse order 450 589 07 99 00 Assembly lool set
AR15.40-P-5032-02SN¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 127 · Applies to: 450, 451
Remove/install generator cover Slacken catch lug (2) and catch lug (3) of generator cover at engine mount. 2 Guide cover with pin (1) out of generator bracket, swivel out between oil pan and axle tube and remove. 3 Install in the reverse order.
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 129 · Applies to: 450, 451
In up to WME01MCO12H106037 ENGINE 160.920 In MODEL 450.3 /4 as ofWME4503001J000001 1 2 3 • cooler 5 6 7 8 9 M1616 d!W 1 2 3 4 5 6 17 '3 p;'i"AD 9 Engine wiring harness Vacuum fine Retaining clip Intake manifold cha,;i. air Screw clamp Screw clamp Plug connection Retaining cllp Bolts Throttle valve actuator Remove/Install Remove engine compartment oover Unclip engine wifing harness (1) and vacuum line (2) from retaining dip (3) or intake manWold charge air cooler (4) Sl<>d<en screw damp (5). screw damp (6) and remove Intake manifold cnarge air coole, (4) Disconnect connector (7) at throttle valve actuator (M16/6) Pull wifing heme$$ out or retaining ellp (8) Unscrew bolts (9) at lhrottle valve actuat0< (M16/6) Remove lhroltle valve aclualOr (M1616) and remove gasket carry out tunc11on test of lhroltle valve actuator (M16/6) Conned STAR DIAGNOSIS. interTOgate fau• memory Install in the reverse order ~ ME.SF! fuel Injection and ignitlon oyatem Number Designation BAD7.81-P-1001--01B Bott to throttle valve actuator W Installation: Pay attention to cor,eet routing of the engine wiring harness (1) and the vacuum line (2). ~ IW Installation: Pay attention to the cor,eet latching or lhe connec10< (T). ~ Engine 160.910 ~ Engine 160.920 I W Installation: Replace seal. Diagnosis system STAR DIAGNOSIS Engine Engine 160.910 160.920 Nm 9 BA07.e 1-P-1002-0t8 Screw or etedronic accelerator adjusting mctor to Nm 9 intake manifold 30.8.02 P07.5'-- "BA09 41-P-1001-01E •BA07 61-P-1001-018 •BA07.61•P• 1002-0t B AOOO OO-P·2000-o4SM "WH53 30-Z· 1048-13A
Number¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 130 · Applies to: 450, 451
Designation Engine Engine 160.910 160.920 BA09.41-P-1001-01 E Screw clamp of charge air coolilng Nm 3 3 Commercially available tools Number Designation WH58.3'0-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00
68.00-P-1500-01SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 131 · Applies to: 450, 451
Modlflcatlon notes Remove, install paneling of vertical strut next to center console 0.3.06 Right-hand S1eering version added, model 450.418 excluded Right-hand steering Unscrew bolts (arrows) below end caps (1) and remove accessory parts from paneling on vertical strut (4). IIl Only on vehicles wijh accessory parts on vertical strut (4). 2 Unscrew bolts (2) for center console paneling on vertical strut paneling (4). 3 Drill out rivets (3) from vertical strut paneling (4). 4 Remove vertical strut paneling (4). Left-hand steering Unscrew bolts (arrows) below end caps (5) and remove accessory parts from paneling on vertical stnrt (6). III Only on vehicles with accessory parts on vertical strut (4). z Unscrew bolts (7) for center console paneling on vertical slrul paneling (6). 3 Remove plastic rivets (8) on left and right front vertical strut paneling (6). 4 Remove vertical strut paneling (6). P68.00-3262·06
Remove/install fender liner in rear fender¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 132 · Applies to: 450, 451
30.3.05 Shown on model 450.3 1 Plastic nuts 2 Fender liner PSS.10-2185-03 [g]~ Remove/install 1 Unscrew plastic nuts (1 ). 2.1 Remove corresponding mounting clip, W Only if attachment parts are installed. attachment part on fender liner (2). 3 Remove fender liner (2) from rear fender. [I] Do not damage plastic parts 14 Install in the reverse order
Remove/install seat belt buckle (front seat)¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 134 · Applies to: 450, 451
11.9.02 MODELS 450.3/4 (except 450.418) with CODE (L27) Canada 1 Seatbelt buckle 2 Mounttng .screw 3 Wiring harness for seat belt buclcle detection P91..40-2536-04 I~~ Remove/lnstall 1 Un<lo mounting screw (2) on seat belt buckle ~ 0BA91 40-P-1003-0IG (1) 12.1 Remove front seat ill On models 450.3 /4 with Canada L27 AR91 10-P-1000SM code, the wiring harness for the seat bell buckle detection (3) must be removed from the front seat. 3 Remove belt buckle (I) 4 Install in the reverse order ~3 Seat belllllemergency tensioning retractors Number Oes.ignation Model 450.314 BA91.40.P- 1003-0 1G Screw on seat be~ buckle Nm 30
Remove/install seat console¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 135 · Applies to: 450, 451
10.9.02 1 Seat console 2 Bolts P91.10-2509-04 ld~ Removennstall 1.1 Remove seat drawer with housing Only on vehicles with code (S01) seat drawer AR91 .1 0-P-3000-01 SM under the driver's seat (DFO) and (142) lockable seat drawer under the driver's seat (DFO/FFO). 2 Remove front seat AR91 .1 0-P-1 000SM 3 Unscrew bolts (2) of the seat console (1) W Installation: Rear fastening holes must be 406 mm apart before final assembly takes place. ~ *BA91 .1 0-P-1005-01G 4 Install in the reverse order ~ Front seats Number Designation Model 450.314 BA91. 10-P-1005-01G Bolt, console to floor panel Nm 30
AR91 .10-P-3000-01SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 136 · Applies to: 450, 451
Remove/install seat drawer with housing Pull out drawer (1) as far as the stop. 2 Press drawer (1) inwards at the side and pull out of the housing (2). 3 Drill out rivets on the housing (2). 4 Remove housing (2). 5 Install in the reverse order.
usaness commerc a ve 1c e reg1s ra ,on, ranee¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 137 · Applies to: 450, 451
15.5.02 usaness commerc a ve 1c e reg1s ra ,on, ranee 1 Screw 2 Separating panel 3 Vertical strut 4 Screw 5 Screw 6 Spacer washer PSB.74-2005-06 ~~ Remove/Install 1 Unscrew screw (1) from separating panel (2) at vertical strut (3) and remove rubber washer. 2 Unscrew screw (4) 3 Unscrew screw (5). 4 Remove spacer washer (6) and separating panel (2). 5 Install in the reverse order
Clamp¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 138 · Applies to: 450, 451
19.9.06 1 Clamp 2 Clamp 3 Alrductlng 4 Rivet PIS,30-2181-09 5 Boll$ 9 Diode line 13 Boll$ 6 TransmJWon 10 Huf 7 c~ air cooler carrier 11 Line Af 6 Knock sensor 8 Connector 12 Connector M1 Starter lol llll Removo/lnstall 1 Disconnect battery ground cable AR54. IQ..P-OOOlSM 2 Remove bolls 10 cross strui at the rear W Model 450.4 AR61 25-P,6600SM !E 'BA61.25.P• 1001-01 C 3 Release rear drive module ARO! OO-P-3050SM 14 Lever off ctamp ( 1, 2) on air ducting (3) using
Remove intercooler¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 139 · Applies to: 450, 451
6 Remove intercooler W Remove all cable ties on the electrical AR09.41-P-6B17SM lines on the charge air cooler. 7 Remove poly-V belt for supercharger W Only vehicles with code 101, Air AR\3.21-P-1202SM conditioning Plus (with outside temperature Indicator) (FFO), 8 Detach reffigerant compressor W Only vehicles with code 101, Air AR83 55-P-5J00-02SM conditioning Plus (with outside temperature Indicator) (FFO). I]] Place refrigerant compressor to the side with lines connec(ed. 9 Remove bolts (5) on transmission (6) and remove charge air oooler (7) carrier 10 Disconnec( plug (8) on knock sensor (A 16) @) Do not damage catch lugs, othefWise I plug (8) will not loci< anymore. I III Installation: Ensure that plug locks in I position (8)- 11 Remove diode line (9) at altemator W If only one diode line'(9) Is Installed. ~ "BA15 40-P-1007-0\ G 12 Pull out the plug (12) on the starter(M1) 13 Remove nut (10) on starter(M1) and remove W Lay line (11) outside the working area so line (11) that removal from the starter (M1) is not obstructed. ~ "BA15.30-P-1002-01 E 14 Pull engine wiring harness behind the starter IW Otherwise there will not be enough room (M1) and lay outside the working area to remove the starter (Ml). 15 Unscrew bolts (12) on -transmission housing l!!l -BA15.30-P-100-01 E 16 Ult starter (M1) up and out W Pull starter (Ml} out of transmission housing and swiv~ outwards through cutout on the transmission housing (arrow). 17 Install in the reverse order ~ Starter Number Designation Engine Engine 160.910 160.920 BM5.3Q.P-1001·01E Bolt, starter to transmission Nm 23 23 BA15.30-P-1002-01 E Cable at starter terminal 30 Nm 8 8 8 Diagonal strut to underbody Number Designation Model 450.4 BA61.25-P-1001-01C Bolt, diagonal strut to undert>ody Nm 70 8 Alt.emator Number Designation Engine Engine 160,910 160.920 BA15.40-P-1007-01G Diode line to alternator Nm 8 8
Illustrated on mod.i 450.3¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 140 · Applies to: 450, 451
28.11.05 Illustrated on mod.i 450.3 1 StHrlng whHI 2 Wrench .soc.lret R1213 Driver SI/Ng squib P-1-8,10-2754-11 Modlflcation notes 111.11.os jNote, replace stee(lng wheel and picture revised ~1...1 R•move/lnatall I& Dangert Risk of Injury caused by performing testing Store airbag unit$ with deployment side AS91 00-2-0001-0lA or repair wor1< on airbag or emergency facing up; do not e,cpose to temperatures tens.iooing retractor units.. greater than 100 •c. When W'Ofk.ing on theSe units, disconneet the pawet supply, I® Noles on performlng repair, body work and Models 450.314 AH91.00.P-OOOZ-01SM welding on ,renlcles with airbags and ETR units iW Legal regu1auons on handling aJld storing airbags and emergency ll!nsionlng retractors 1AH91 00-P-0004-01A 1W Replace ,reeling wheel (I) on vellldes up to If lhe steeling wheel (I) is replaced, then a build date 2.1.2003 version with attached contact un~ Musing ls supplied as a replacement part. Mt'lwll\/Af th.lit hn1,111Jnn ,.,...~ nnf hAWl A
Tachometer¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 142 · Applies to: 450, 451
2.9.02 1 Tachometer 2 Bolt 3 Center console 4 Bolts P54.30-6867-01 ~~ Removing, installing 1 Disconnect ground cable from battery AR54.1 0-P-0003SM 2 Remove instrument cluster AR54.30-P-6015$M 3 Remove cockpit switch group AR54.25-P-1 OO0SM 4 Unscrew bolt (2) from center console (3) 5 Unscrew bolts (4) 6 Pull cable out of retaining clip at bottom of instrument cluster paneling 7 Lift center console (3), pull out tachometer W When replacing the tachometer (1 ), (1) below center console (3) and remove transfer the old color ring. 8 Install m the reverse order
excep¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 143 · Applies to: 450, 451
tn excep with CODE (B06) Gasoline engine, 37 kW/ 50 HP (M160/1) with CODE (807) Gasoline engine, 45 kW/ 61 HP (M16011) with CODE (B10) Gasoline engine, 55 kW 175 HP (M160/1) as of WME4503001J000001 1 Bolt 6 Turbocharger 2 Oi//ine 7 Seal 3 Clip 8 Bolt 4 Hose 9 Coolant line 5 Bolts 10 Bolt 6 Turbocharger 16 Aneroid c.apsule wa.stegate 17 Bolt 18 Shield 19 Bolt 20 Cool1mtllne 21 C//p 22 Air intake duct 23 Nuts 11 Clip 12 Alrlnta.keduct 13 Bolts 14 Brac~et 15 Ground strap 21.10.03 P00.40-2191-09 POQ.4~2·118-06
Remove lambda probe¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 144 · Applies to: 450, 451
3 Remove lambda probe IW Oxygen sensor downstream of catalytic AR14 0O-P-5303SM converter. 4 Remove catalytic converter AR49 1 0·P·5500SM 5 I Unscrew bolt (1) on 011 line (2) on the Lil Place a suitable re<:eptacle underneath. crankcase and remove seating rings ITJ Installation: Replace S-ealing rings. 8 •BA09.40-P-1003-01F 6 Loosen clamp (3) and pull out oil line (2) with W Installation: The clamp (3) must be hose (4) replaced after detaching. 7 Unscrew bolts (5) of oil line (2) on l!!!!l · BA09.40-P· 1001-01 F turbochalJler (6) 8 Remove oil line (2) and gasket (7) W Installation: Replace seal (7). Note installation position of gasket (7) (arrow). 9 Unscrew boll (8) on coolant line (9) on W Installation: Replace sealing rings. turbocharger (6) and remove sealing rings 8 •BA20.20-P-1002-01 J 10 Unscrew bolt (10) on coolant line (9) on I W Place a suitable receptacle underneath. crankcase and remove sealing rings ITJ Installation: Replace sealing rings. 8 •BA20.20-P·1001-01J 11 Remove the coolant line (9) 12 Slacken clamp (11) and remove air intake duct (12) on turbocharger (6) 13 Unscrew bolts (13) on braci(et (14) W Installation: Observe positioning of ground strap (15) on brad<el (14). 14 Remove the control on the aneroid capsuJe (2) Carefully pull out control line just In an wastegate (16) axial direction since otherwise the connecting pipe on the aneroid capsule wastegate (16) could break off and thus the aneroid capsule wastegate (16) would have to be replaced. 15 Remove bolt (17) from shield (18) 16 Unscrew bolt (19) on coolant line (20) and W Installation: Replace sealing rings. remove sealing rings 8 •BA2□.20-P-1002-01J 17 Slacl<en damp (21) and detach air intake I rn Installation: Checi( gasket on air intake duct (22) on turbocilarger (6) duct (22) and replace if necessary. During insertion of air intake line (22) make sure that gasket is not damaged. Wet the gasket wil'1 water before putting on air intake line (22). 18 Take off control lfne on turbocharger (6) 19 Remove combination valve AR14.30-P-71 00SM 120 Remove nuts (23) and lhe turbocharger (6), W Installation: Replace gasket and shield shield (18) and gasket (18). Observe tightening sequence of nuts (23), see: t Tightening pattern for turbochalJler (6) AR09.40-P-e020-1 0SN l!!3 •BA14. 10·P-1002-01F 21 Install in reverse order 8 Exhaust manifold Number Designation Engine 160.920 8A14,10•P•1002·01 F Collar nut for exhaust manifold on cylinder Nm 16 head
8 Radiator, coolant hoses¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 145 · Applies to: 450, 451
Number Designation Engine 160.920 BA20.20-P-1001-01J Banjo bolt for coolant line on crankcase Nm 19 SA20.20·P-1002-01 J 1 Banjo bolt for coolant line on turbocharger Nm 19 I
Remove/install underbody paneling¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 147 · Applies to: 450, 451
10.10.02 !'61,20-2024-07 Shown on model 450.30 1 Ra.r paneling 2 Fuel radi11tor grill 3 Front paneling P61 .20-2047-07 Shown on model 450.418 Rear paneling 3 Front paneling i~ lei Remove/Install l&Oangerl Risk of death cased by vehicle slipping or Align vehicle between the columns of the ASOO.OO-Z-0010-01A toppling off of the lifting platfonn. hydraulic hoist and posttion the four support plates below the hoist support points specified by the vehicle manufacturer. 1 Raise vehicle with lifting platform W When positioning lifting platform observe recesses in covers. 2 Unscrew bolts from rear paneling (f) 3 Slightly lower rear paneling (1) at rear and pull out of mounts of front paneling (2) 141 Unscrew botts from fuei radiator grtll (2), In case of model 450.30 remove fuel radiator grill (2) 5.1 Remove clips (arrows) from front paneling (3) In case of model 450.416 6 Unscrew botts from front paneling (3) 7 Remove front paneling (3) 8 Install in the reverse order
fR83.55-P-5300-02SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 148 · Applies to: 450, 451
8 AC compressor Number BA83.55-P-100t-01I BA83.5S.P-1002-011 BA83.5S-P-1003-011 8 AC compressor Number BA83.55-P-1001•01J 8A$3.6-6..P-1002-01J BA83,55,P,1003-01J IT ake off refrigerant compressor Designation Screw for refrigerant compressor bracket to cylinder head Bott. refrigerant compressor to bracket Bon, refrigerant compressor basic carrier rails Designation Screw for refrigerant compressor bracket to cylinder head Dolt, refrigerant c;.ompre6sor to bracket Bolt, refrigerant compressor basic carrier rails Shown on ENGINE 160.910 Remove plug from air conditioner compressor pressure switch (5). 2 Undo bolt (1) at refrigerant compressor (A9). 3 Unscrew bolt (2) and then botts (3) and remove bracket (4). 4 Unscrew boll (1) from refrigerant compressor (A9) and attach refrigerant compressor (A9) to body. III Do not attach refrigerant compressor (A9) to refrigerant lines, since these deform easify. Engine 660,940 Initial Nm 12 tightening Subsequent Nm 9.5 tightening Nm 20 Nm 20 Engine Engine 160.910 160.920 Initial Nm 12 12 tightening Subsequenl Nm 9.5 10 tightening Nm 20 20 Nm 20 20
P01.00-2327~¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 149 · Applies to: 450, 451
4.9.02
P01.00-2327~
Ad8ptatlon
2
The TDC detection device
3
Pressure toss tester
,1.,jll,J
Removl"9flnstalllng
1
E11gage 6th gear
12
~ AD
Connect STAR DIAGNOSIS, lntem,gate the
ADOOOO-P-2000-()4SM
fauttmemocy
Diagnosis system STAR DIAGNOSIS
"WH58 30-Z-104S..13A
3
Remove spari< plugs
!~ AP
Replace spari< plugs
AP15 10-P.1580SM
f4
Screw in adapter (1) into tile spari< plug
thread
llli'.l Adaptation
•450589019100
5
Mount the TDC detection device (2J on tile I~ Pressure loss teste.r
·•50589172100
8dapter(1)
16
Tum the rear wheel in the direction of travel
unol the pi$ton in the TDC detection device IW Block the opposite rear wheel,
(2) drop$ suddenly (cylinder at lgn~ioo TDC)
7
Apply pari<lng b
Adaptation¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 150 · Applies to: 450, 451
450 589 01 91 00 Adaptation Pressure loss tester Commercially available tools Number WH58.30-Z-1048-13A I diagnosis system, Compact assenger Car 65111801 00
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 151 · Applies to: 450, 451
22.7.02
IO
up to WME01MCO12H106037
ENGINE
160.920 in MODEL 450.3 /4 (except , 450.418)
as ofWME4503001J000001
ENGINE
660.940 In MODEL 450.3 /4 {except , 450.418)
1
Clamps
2
Filler element
P09,10.2071-0<
l~~l ll;J
Removennstall
1
Remove engine compartment cover
2
Slacken clamps (1) and remove housing
cover
3
Push bael< filter guide (arrow) and remove
ll!.I If a·wet air cleaner (BRABUS) is used,
filter element (2)
then this is to be cleaned using cleaning fluid
and then wetted on both sides with
impregnation fluid.
Only the cleaning kit released by smart
should be used.
For further details·, see t.he operating
instructions for the cleaning kit.
Do not wring out filter element.
A heat gun can be used to accelerate the
drying process.
Select the temperature preselection of the
heat gun sufficienlly low so that the filter
element is not damage by the hot air flow.
lfil Hot-air gun
•450589016300
4
Remove coarse contaminaUon
I
Bolls¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 152 · Applies to: 450, 451
28.11.05 1 Bolls 2 Rail 3 Clamp P83.00•2105--04 , Combination filter 5 A/Tow P83.00-2192-06 lo!odlficalion notes ps.10.os !Note on dire<;tion of installation completed !Step 5 ~~ Remove/install 1 Remove front CBS f.i:"AR Remove/install CBS front end AR88 OO-P-1010SM 12 Unscrew screws (1) and remove rail (2) 3 Loosen damps (3) on cover at top and on right 14 Remove cover from combination filter (4) upwards out of service opening. 5 Install new combination filter (4). IITl Inst.allalion: When installing ensure that the combination filter(4J is used in the air flow direction (arrow). For this purpose an arrow (5) Is attached to the combination fi~er (4). 6 Install in the reverse order
Spark plug connector puller¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 153 · Applies to: 450, 451
2 s~ plug connector R4 Sparlcplug Modification notes 115.3.05 l5park plugs ,iii!lel R•move/lnstall I& Danger! Risk of death caused by contact with parts conducting high vol~•- 1 Remove CBS reer end t~AR r~AR ~ Unsaew catch at engine compartment (,t)V8t and remove engine compartment cover 3 Unplug spalk plug connector (2), ft001 the spark plugs (R4) through slight rotation of the spark plug connector puller (1) f4 Clean spal1< plug recess in the area of the spalk plugs (R4) and blow out 5 Unscrew spark plugs (R4) 6 Ins.tall In the reverse order t!3 Spark plugs 19.7.02 P15.10-2092-06 j •BA1510°P0 1001-018 Do not touch parts which conduct high AS1510-Z·0001-01A voltages. Persons who have electronic Implants (e.g. pacemakers) must not perform any work on the ignition system. Except model 450.418 AR88.20·P•1900SM Model 450.418 AR88.20.P-1900CR ~ The spalk plug connector puller ( 1) must engage securely (arrow) since Ille ignition cable can be cut lllrough by the spark plug -connector puller (1) If It slips, @ Never pull out a spark plug connector (2) by the ignition cable since the ignition cable can be tom out of the connector thereby destroying th& spark plug connector (2). [i) Replace spark plug connectors (2) that have been flooded with fuel with now spark ctr There is the danger of short<drcuitlng if Ille battery is connected up duo to loose lying spal1< plug connectors In the starter area. ~ -WH58.3Q.Z-1021-17A !!!!i "8A15.10.P·1001·018
BA15.10-P-1001-01B¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 154 · Applies to: 450, 451
Spark plugs Initial tightening Nm 28 23 torque Retightening Nm 20 23 torque Commercially available tools Number Designation WH58.30.Z-1021-17A Spark plug connector wrench
Dri/1/ng template¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 157 · Applies to: 450, 451
6.7.05
Dri/1/ng template
2
Rivet nuts
3
Brocket
4
Center""" rest
5
Bolts
6
Bolts
3
Bre,:ket
5
Bolts
lei
Remove
1
Remove drive< seal
~ AR
RemovennstaD ltonl seat
ARB I 1 O·P· 1 OOOSM
~
Install
2
Cul out drilli,>g template (1) and install In
IWAttach using adhesive tape.
center on right retaining fitting
3
Mark holes
W Use center punch.
4
Cover seal bolster and seat bael<resl
1<2> Cover seat bolster and seat bad
8 Center annrest¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 158 · Applies to: 450, 451
Number BA68.20-P-1001-01C Twist drill set Workshop equipment jWE58.40-Z-1001 ::03A Designation Model 450.3/4 Bolts, center armrest to retaining Nm 13 fitting for seat j Drill (electric/pneumatic}
P83.7<M9'57-09¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 159 · Applies to: 450, 451
16 WaterhOff 17 Water hOff 18 Pipe clamp 19 Ru.bber-bonded metal bufrer 20 Fuel metering pump 22 Mecanyl fuel fine 23 Metal fuel extractor 21 Rubber grommet 2.4 Information stick.er 25 Worl<s label dupllcale k1o<liflcation notes fork procedure 8dded lA Dangerl R.isk of Injury caused by bums to skm and eyes. Risk of poisoning caused by mhaluig fumes when wor1dng with heat-shrinkable tubing, lADangerl Risk of explosion caused by fuel Igniting, risk of poisoning caused by inhaling and swallowing fuel encl risk of Injury to eyes ancl skin caused by contad with fuel. lA Danger! Risk of injury to skin and eyes caused by scalding lrom contad with hot cootant spray. Risk of poisoning from swallowing coolant w Notes on lns1811ing stationary heater w Notes on stril)plng wires 1 Diseonnect battery ground cable i;;i'"AR Disconnectfconned battery's ground cable . .... ...... " ' ' P83.70-49S8-01 Work in well v.enti.lated rooms onry. Wear ASOO 19-Z-0001-0IA safety glasses with side protedlon and protective gloves. No fire, sparks, open flames or smoking. AS<l7 00-Z-0001-01A Pour fuels only into suitable and appropriately mal1<ed contamers. Wear protedlve dOlhing when handfing fuel. Do not open cooling system unless coolant AS20.00•Z-000I-0IA temper.,ture Is below 90 •c, Open cap slowly and release the pressure. Do oot pour cootant Into beVer.,ge containers. Wear prot~ gloves, protective clothing and safety glasses. Model 450.3'4 AH83 70-P-0008-02SM Models 450.3'4, 454.0 AH00.1!I-P-1000-12SM Crimper and wire sltfpper AR54 1 O-P-0003SM
I Mount end piece 120 mm (5) onto exhaU$t¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 161 · Applies to: 450, 451
3" I Mount end piece 120 mm (5) onto exhaU$t muffler ustng damp and shape so it faoes downwatds 35 Route clrculatlon pump wiring harness lo clrc;ul.!lion pump and cut lo length M ConMC:t cltt:ulation pump wiring ha.mess to IW Use Rayehem solder jolnl connector, eit<:ulation pump (I] Blue fine to blacl< fine. (I] Brown line to brown fine. 07 !Drain coolant i;.--A R OrainlfiU in c:oolanl AR2000-P•1t42SM Elli Oetach coolant Noes IW Seefig. B. (I] Coolant lines Included In 5QOpe or del~ry. (I] Section 1 iS 620 mm plus 180" curved section, section 2 Is 600 mm. 39 Fil ch.a.ting protection and lnsulatk>n to [[I] Seelig. B. sedloOnded metal butler (19) and collar nut to given hole on fvet tank ~8 cut vehicie's fuel rctum line at suitable point and fit metal luel exiroctor (23) 149 Fasten Mecanyl fuel line (22) uSing clamp to III! Mount Mec;anyt fuel line (22) up lo tile metal fuel e><Ua«or (23) Joint, to avoid ~ny blistering. Flt chafe p,otection to Mecanyl fuel line (22) and wiring harness at • harp 0<1ges. 50 Route Mecanyt fuel line (22) parallel lo ""'1icle's fuel line upslfflam or tank fdler ned< IW F"a in Position with tie straps. to the fuel metering pump (20) 51 Cut Mecanyt fuel line (22) to length and fit to fuel metering pYmp (20) 52 Mount Mecanyl fuel line (22) using damps to W Mount Mecanyl fuel fine (22) up 10 the fuel metering pump (20) joint, to avoid any blistering. Frt chafe prote~on to Mecanyt fuel line (22) and wiring harness at sharp edge:t. 53 Mount Mecanyl fuel line (22) using clamp 10 (I] Moun! Mecanyt fuel line (22) up lo Ille healer untt fuel Inlet (26) Join~ to avoid any bll!tering. F~ Chafe pro1ection 10 Mecanyl fuel line (22) and wiring harness at sharp edges. 54 RDute fuel metering pump wiring harness I lil Ax In position with lie •traps. (20) and cul 10 length 155 Push rubber grommet (2 t) ov,n wiring hamess M Crimp Rot plug 10 fuel metering pump wiring harness and connect ~7 Oetermln,e center of hole for lnsortk>n of end piece 120 mm (5) on underfloor protection 58 o,;q ~ 43 mm In underfloor paneling DriR (ele~rlc/pneumallc) 'WE58.40.Z· 100H)3A
FIiierup¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 163 · Applies to: 450, 451
1 FIiierup 2 Sticker for 9asollne quality 3 Intake man/fold 4 Sticker ~ Sticker N3/10 MEG engine elecltonlcs conltol unit It.ii Removing 1 Kemove air oeaner eiement ~ AP Replace air cleaner element ~ Installing 12 Install air filter element for BRABUS p;i"°AP Replace air cleaner element ~ Enable BAABUS software p;i"°AD Connect up STAR DIAGNOSIS and read out fautt memory 14 Clean adhesive surface on Inner side of filler cap (1) with sllicone free cleaner then remove the p,oleetlve foll on Ille sticker of gasoRne qualily (2) and glue the sticker lo the Inner side of the filler cap (1) 5 Clean adhesive surface on Intake manilold (3) with sUicone free cleaner ~ Apply adhesive compound onto total surface of sticl<er (4) then pla<:e stict.er (4) onto Intake man~old (3) and press on 7 Clean adhesive surface on MEO engine electronics control unit (N3/10) wi111 silicone free cleaner, remove protective foil on Ille stlel<er (5) and glue sticker (5) onto the MEG engine elecltonlc:s control unll (N3/10) 17.2.03 POl.0().235- AP09 10.P-OOSOSM AP0910.P-0980SM IW Programming or ll1e software is only possible alter enabling It by mean• of a tmnsaetion number (TAN). The order form for enabling is obtainable from Ille Mart<et PerfOfmance Center (MPC). [D Follow Instructions In OAS. ADOO 00-P-2~SM ST AR DIAGNOSIS diagnosis system "WH58.30-Z- 1048-1JA IW The adhesive surface must be dry. clean, free of wax and grease. The adhesive temperature range is ,s•c to 35'C. W The adhe$1ve compound is lneJuded ifl the performance kit (SB 1) BRABUS. III The adhesive surface must be dry, clean. free of wax and grease. The adhesive temperature range ls to be s•c 1035'C. After 48 hours Ille adhesive has reached its optimal adhesion. W The adhesive surface must be dry. clean. free of wax and grease~
IAR40.20-P-0323-02SM I¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 164 · Applies to: 450, 451
Adjust front axle toe Front ax.le toe~in test values Number Designation Model Model Model 450.3/4 450.314 450.3/4 up to 14.11.1999 asot15.11.1999 as of 8.1.2001 up to 7.1.2001 up to 2.1.2003 BE40.20-P-1001-07B Fronl axle overall loe-in 4. 0•24• (± 10'i 0°22'(:tS') 0·2s· (± 10') El Track rod Number Designation Model 450.314 BA4MO-P-1002-01F Locknut on track rod Nm 50 450 589 01 09 00 Open-ended socket wtench Loosen clamps of bellows al tie rods (2). 2 Loosen nut (1) on both sides. 3 Rotale the tie rods (2) to adjust the loe-in. III Check that the bellows are not twisted after adjusting the toe-in. 4 Tighten nut (1) on both sides. s Tighten clamps of bellows al lie rods (2).
AP42.10-P-4251 SN¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 165 · Applies to: 450, 451
Check lining thickness of brake pads and condition of brake disks 8.1.07 1 Brake pads 2 Brakedisk P42.10-2614-11 l.'.:!J Checking 1 Check lining thickness of brake pads (1) on W Check brake pads (1) in the installed front axle condition. Observe recommended wear limit so that wear limit is not dropped below up to the next maintenance service. If necessary: ! Replace brake pads (1 ). - subject to separate repair order. ~AR Remove/check/install front axle brake pads AR42 10-P-1600SM 2 Inspect brake disk (2) for scores and Cfacks W If necessary: ! Install new brake disk (2). ~~AR - subject to separate repair order. Remove/install front axle brake disk AR42.1 0-P-0230SM
BE40.20-P-1002-06C¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 166 · Applies to: 450, 451
Caster with o• w11ee1 toe +7° oo· ( ± 1° 00') +7" 00' (± ,. 00') Front axla toe check values Number Designation Model Model Model Model 450,3/4 450.314 4.50.314 450,314 up to 14.11.1999 asof15.11.1999 as of 8.1.2001 as of 3.1.2003 upto 7.1.2001 up to 2. t .2003 BE40.20-P-1001-078 Front axle overall t~in &' +o· 24' < :to· 10·> +o· 22• (±o· 10·1 +O' 28' ( ±0' 101 +0' 26' (± 0" 10') Test values for toe-out on turns Number Designation Model Model Model 450.314 450.314 450.314 as 018.1.2001 upto14.11.1999 as of 15.11.1999 upto 7.1 .2001 BE40.20-P-1001-08C Toe .. out on turns with the inside wheel /4" -2· 06' (±0° 20') -2' 06' ( ± O' 20') -2• 06' (:!:0° 20') steered through 20° Inspection and setting data of rwr a de camber Number Designation Model 450, 4S1, 4S2 8E40.20,P-1001-09U Rear ax'8 camber &' -2· OO' ( ± o• 30') lns-pection values for toe-in at rear axJa Number Designation Model Model Model 450.314 450.3/4 450.314 up to 14.11.1999 as of 15.11.1999 as of 03.01.2003 up to 02.01.2003 8EA0.2Q..P-1001-10F Total rear axle toe & ' +o· 20· ( ±O" 10·> +o· 10· (± O' 10·> +o· 10· < ± O' 12') Te5t values for driveline angle Number Designation Model Model Model 450.3/4 450.3/4 450.3/4 as of a.1.2001 upto 14.11.1999 as of 15.11.1999 up to 7.1.2001 BE40.20-P-1001-21A o,tvetine angle &' +O' O' (±0' 30') +o• O' ( ±0' 30') +O' O' ( ±0" 30') ~ nerod Number Designation Model 450.314 BA46.40-P-1002-01F Lock nut to tie 10d Nm 50
H00.00-P-2000-01 SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 167 · Applies to: 450, 451
Chassis number breakdown 1 (1st to 3rd digit) world manufacturer code 2 {4th to 6th digit) model series, corresponds to 1st to 3rd digit of vehicle model designation (450=coupfl, city-coupe or cabriolet, 452=roadster, 454=forfour) 3 (7th digit) body shape, corresponds to 4th digit of vehicle model designation 4 (8th and 9th digit) engine code, corresponds to 5th and 6th digit of vehicle model designation 5 (10th digit) steering, corresponds to 7th digit of vehicle model designation (1=/eft-hand drive vehicle, 2=right•hand drive vehicle) , 2 3 4 i I 7 6 (11th digit) Manufacturing plant (J, K, L=Hambach, Assembly building 4, Z=PVZ (Production Preparation Center) (Component Engineering)) Model 450.3/4 as of 3.1.03 or as of WME4503001 J000001, 452.3/4, 454.0 T i8.:@. .?. ~ , .,, , P00.00-3661·06 7 (12th to 17th digit) chassis number {production end number)
H00.00-P-2000-01 SN¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 168 · Applies to: 450, 451
Chassis number breakdown Model 450.3/4 up to 3.1.03 or up to WME01MC012H106037 1 (1st to 3rd digit) world manufacturer code 2 (4th and 5th digit) determination of vehicle category M1 (passenger car) 3 (6th to 9th digit) vehicle model corresponds here to model MC 01 of model approval 4 (1oth digit) model or manufacturer code (Example V=1997, W=1998, X=1999, Y=2000, 1=2001) 5 (11th digit) manufacturing plant H=Hambach, Z=PVZ (Production Preparation Center) (Component Engineering) WME .9l MC01 Y H 123456 1--------------' 2---------------- 3------------------.....I 4-----------------------' s----------------------....1 , ________ _. P00.00-3660-06 6 (12th to 17th digit) chassis number (production end number)
P82.35-P-8252-01 SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 169 · Applies to: 450, 451
Check setting of windshield washer system spray nozzles 1 Check adjustment of spray nozzle (1) and correct if required. [I] The individual spray jets of the spray nozzle (1) must contact the windshield in the areas A, Band C (see sketch). A~~ B~ C
H96.00.P-8070-02SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 170 · Applies to: 450, 451
Damage and stress caused to paintwork by Model 450, 451 , 452, 454 external influences Stress to paint • Temperature (cold, heat) • Humidity and UV rays • Aggressive pollutants • Mechanical effects .such as dust, sand, scratches Structure of a one-coat finish 1 Painted part 2 Dip prime coat 3 Filler, 4 Topcoat Structure of a two-coat finish 1 Painted part 2 Dip prime coat 3 Filler, 5 Sasecoat 6 Clear lacquer In add~ion to the effects caused by chemical or biological substances such as sulfurous acid (acid rain), oil soot, road salt, surfactants, ttee resin, insects, bird droppings and mechanical damage caused by washing brushes and slone chipping, damage can also be caused by moisture and W radiation from the sun. The pigmented standard finishes are particularly endangered by the type of damage mentioned last. The fine plastic film of synthetic resin surrounding and protecting the coloring pigment particles is ~stroyed in the course of lime by the effect of UV radiation exposing the coloring pigment. This makes the paint surface dull. 1'93.00-0370-01 P98.00·3234-01 When the pigment protecting synthetic layer is removed by polishing with products containing abrasive agents, even on new vehicles, the pigment weathering process begins even earlier. The degree of damage depends on the intensity and duration of the UV radiation which cannot be avoided even with the best paints. For this reason, careful care of the paint repeated at proper intervals as well as technical maintenance helps preserve the val1re of the vehicle. With good paint care. the beauty of the new pain1Wor1< can be maintained significantly longer,
ru,o . - . T¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 171 · Applies to: 450, 451
. T . - . : [ui,- . - . T -T -- -- . : f i lj I I ! !! ~ I j l! ! I 1· .1 lj !1 I '---'------'----- I j , _ _ .J...,__ __ . i ·~-~~:~_1 i[ ·~-~~~~~l i ·~~ ~"'~ _ =-J L __ __ ""' · - · - · - ·JL.- , - ..,,. - - _ _ J ~ ~-l00QM8 - · N4,"':-;- ' -
H3/9¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 172 · Applies to: 450, 451
3/10 H3/9 1147-7 ttJ-30 U75 X26/9 -Instrument cluster Instt:Ulllent cluster Insti:ument cluste:t CIEL t~ansmitter / receiver Central electronic5 BEG 1. 0 motor electronics control uni·' EDG control module ABS control unit Valid for diesel engines Valid for gasoline engines Interior com.paz:tment/a.ssembly connecta
P72.00-2 1 ◄ 1--09¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 173 · Applies to: 450, 451
13.1.05 P72.00-2 1 ◄ 1--09 1 Door hinges 3 Hinges 5 Rear-end door lock 2 Door checlt srrap 4 Hinges I&" Danger! Risk of Injury caused by fingers being When moving components, ensure that no AS00.00-Z-0011-01A jammed or pinched when removing, body parts or limbs are within the operating installing or aligning hoods, doors, lrunk lid/ range of moving parts. rear-end door or sliding roof. 1 Lubricate door hinges (1) and door checl< ill Use spray lubricant. strap (2) on left and right. 2 Lubricate hinges (3) at rear-end door on left and right. 3.1 Lubricats hinges (4) at rear window on left and right W Model 450.3 only i4 lubricate rear-end door lock (5). -SR00.45-Z-1079--0SA Re 1rmatana1s pa Number Designation Order number BR00.45-Z-1079-00A Grease A 001 989 26 51 10
HO0.0O-P-0002-01 SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 174 · Applies to: 450, 451
Notes of position of chassis number [I] Position of chassis number (arrow) up to 03.09.2001. [I] Position of chassis number (arrow) as of 04.09.2001. Model 450.3/4 i P60.00-2242•04
up to WME01MCO12H106037¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 175 · Applies to: 450, 451
ENGINE 160.920 In MODEL 450.3 /4 as of WME4503001J000001 ENGINE 660.940 in MODEL 450.3 /4 (except 450.418) ENGINE 660.940 in MODEL 450.3 /4 (except 450.418) with CODE (L27) Canada Shown on model 450.3 1 Spring clip 2 Hand brake lever 3 Air !Iller box 4 Cabletie Shown on model 450.4 11 Pin 12 Folding clamp 13 Bracket 14 Base Jack with removal fixture 15 Rearbolts 16 Front bolls 17 Intake air duct 5 Main wiring harness 6 Ground strap 7 Nuts 22.8.06 P01.00-2317-09 B Wheelhouse cover 9 Bolts 10 Feed air guide
I Pull nano brake 1ever(2). press ou1 sprtng¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 176 · Applies to: 450, 451
12 I Pull nano brake 1ever(2). press ou1 sprtng clip (I ) downwards and release hand brake lever (2) 3 R&move engine compartment cover W See OperatO<"s Manual 4 Remove cable tie (4) of the main wiring harness (5) at air filter box (3) Wlnstallation: Install new tie straps. 5 Take ground slrap (6) out of bracket Model 450.33 /34 135 /44 /45 6 Remove CBS rear end W On model 450.3 /4 with code L27. Canada, Ille CBS rear muSI be loosened and Ille side marker disconnecled from Ille Inside before removal Model 450.3 /4 without code P15. BrabtJs ISi AR88.20•P· 190CSM Edition (FFO) or without code P18. complete wheel set 175-R16/22.5-Rl7 Brabus (DFO). except modlel 450.418 Model 450.3 /4 with code P15. Brabus 1st ARaa 20•P-l 900SN Edition (FFO) or willlout code P1 s. complete wheel set 175-R16/225-R17 BrabtJs (DFO). except model 450.418 Model 450.4 18 AR68 20-P-1900CR 7 Unscrew nuts (7) at left rear wheelhouse Model 450.3 /4 exoept 450.418 cover (8) 8 Pull out left rear wheelhouse cover (8) Modol 450.3 /4 exoept 450.418 9 Unscrew bolls (9) on air filter box (3) and pull out supply air guide (10) 10.1 Remove rear undertlody paneling Model 450.3 AR61 30-P-1001SM 10.2 Remove bulkhead wall Model450.4 AR61 25-P-6600SM III On model 450.4 will> code L27, Canada the btJlkhead cannot be fully removed. Protect the btJlkhead from falling using cable ties and ensure l/la1 lhe fuel hoses to the water separa10< are not damaged. II Unscrew bolt (11) of the !oldJng clamp (12) and open folding clamp (12) 12 Undip brake and rotational speed sensor line W On vehicles before the 11.9.00, the line from !olding clamp (12) and from bracket (13) to the separation point engine wiring harness must be additionally unhinged. 13 Position base jack will> removal fixture (14) 1(2) Risk of damage at oiJ cooler. if necessary at rear drive module saw off angular bend as of lifter mounting~ III The base jadlS from the companies Mazzola and AS Hydraulic can be used according to choice. lilJ Removal fixture 0450589016200 m Base jack Co. Mazzola "WH58 30-Z·1011--07A m Base jack Co. AS Hydraulic "WH58.30-Z-101 l--07A 14 Unscrew front bolls (16) and rear bolts (15) W The rear bolts (15) are longer. on body Installation: Observe tightening sequence (left fronl rtght front, left rear and right rear) The bolls at the front (16) and bobs at the rear (15) should be replaoed when replacing the vehicle body. !3 0BA3510.P-1001--0IF 15 Screw In release bolts Into bo,e holes fo, I® JuSI screw in release boK by han<l up to bolts at the front (16) and bolts at the rear threaded tappel do not tighten. othe,wise (15) damage to Ille thread will occur. III Screw In the two longer release bolls al the rear. lilJ Set of release bolts 0450589006200 16 Slowly release rear drive module I W When lowering, ansure adequate distance between the intake air line (17) and air filter box (3). On Engine 660.940 there must be enough available space between tank and frame-type Integral support. W neeessa,y slacken tank
Rear axle carrier¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 177 · Applies to: 450, 451
~ Rear axle carrier Number Designation Model 450.3/4 BA35.10-P-1001-01F Bolt, frame-type integral support to body Nm 100 450 58.9 01 62 00 450 589 00 62 00 Removal assembly Set of release bolts Commercially available tools Number Designation WH58.30-Z' 101 1-07A Base jack WH58.30-Z-1006-10A Compressed air application gun for bag sealants WH58.30-Z-1034-14A Manual application gun for bag sealants Repair materials Number Designation Order number BR00.45-Z-1076-02A Adhesive Sikaflex-254 booster ISika Deutschland GmbH Stuttgarter Strasse 139 72574 Bad Urach Germany Tel. +49 7125 940-761 Fax +49 7125 940-763 www.sika-industry.de
AH40.1 0-P-0001-01 SM¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 180 · Applies to: 450, 451
TIREFIT tire sealant Model 450 Note: TIREFIT tire sealant has a shelf life of 3 to 4 years depending on the version, measured from the date of manufacture marked on the container. After this period has elapsed or the expiration date specified on the container is exceeded the TIREFIT tire sealant should be replaced. Use: TIREFIT tire sealer can be used to seal minor perforations, especially as encountered on the tire's tread, to allow repairs at the location where the tire problem occurs. The tire can then continue in limited use until it can be replaced. The customer is obliged, after using TIREFIT tire sealant to locate the next smart service center immediately in order to replace the damaged tire. • Tires which have been treated with TIREFIT tire sealant must not be repaired. They must always be replaced with new tires of the same make and manufacture. • To avoid strong odors from the TIREFIT tire sealer, take the tire outside to bleed the air from it. i t I I c:::::Jlil A--N• ?IO•e P40.10-0311-01 Regulations fo.r disposal Dispose of used and expired TIREFIT tire sealer by emptying it into the special container for used painting materials (refer to Service Products Manual Volume 2, Chapter U, Group 00 (22), Topic 2.3). Fire hazard! No fire, naked flames or smoking. Avoid producing sparks. Avoid inhaling vapors.
P54.00.2615--0E¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 181 · Applies to: 450, 451
Code Designation Cable colors Cable colors Notes X9 Bluetooth microphone connector No pictorial representation - 1 r Shield - 2 r X58/1 Interior socket 1 rBN -2 r BKBU - ~ - .~ .... -•, . ..... ,.-! ....,,., ., '»,.. _ . ,.,, . ...... .... ZAAQQ 'O'h ~ ,. ' ~ .. ~ ,-,-=..- , _,,, . -~~-
GF00.19-P-1000.32MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 182 · Applies to: 450, 451
Arrangement and assignment of cable and plug connections. left fooLwell Code Designation X11/4 Data link connector X85/10 Heating or air conditioning connector Cable colors BK- RDBK- P54 .1 8-J118~06 Cable colors Notes 4 )-SN 5 )- BN 6 )-Gl'IWH 8 )-SKYE 14 )- gn 115 >-RDWH 1 )- SN 4 )- RDGY
GF00. 19-P-1000-35MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 183 · Applies to: 450, 451
Location and assignment of line and plug connectors- right footwell
Code¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 184 · Applies to: 450, 451
Designation Cable colors Cable colors Notes X11/4 Data link connector 4
--BN 5 --BN 6 }-GNWH 8 --BKYE 14 }-GN 16 --RDWH
F00.19.P-3000-09MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 185 · Applies to: 450, 451
Location and assignment of Z-connector sleeves (IIM connectors fn wiring harness) In tile area or tile center console iZ ~ nnector ~l.,..ve fa/17 z:314' iZ37/2 Z3713 Des lg natl on Clrouit 15 (fused) connector sleeve 23117 Z•O 2314' Z•S 237/2 ZS0/23 23713 Z60I2 2311• 23715 COtnpon•nl Oes.ignatlon - N10110 S.AM control unit - A1 lr\$ttum&nt cluster -• B24/ 15 !Tum rate and lateral acceleration sensor NOi Japan - E16 !Automatic cl\lld seat recognition airbag OFF lndicato, lamp - N2fl Restraint systems control unit - N47-5 ESP control unit - N49 Steering angle senso, - N68 Steering assist control un~ - )(2818 Driver seat ETR [GUS) connector (2•pin) Instrument cluster - radio clroult 15 (fused) connector sleeve - N10I10 SAM control unit - A2/1 smart~io9 - A2J2 smart radio 10 - N15/5 Electtonic selector tever module control unit - N23 He.at.er/AC op81'3ting unit Heated seats - N2.5l5 Front HS [SIH) conttol unft - $4/4 Right wiper switcl\ Convelllble - 584 Power soft top switcl\ LHD - X3511 Left door separaliOn point RHO - X35l2 Right door separation point CAN engine bus (low) connector sleeve CAN - A1 Instrument duster - N2/7 Restraint systems control unft - N23 Heater/AC operating unit - N49 Steering angle sensor - X11/4 Data link connector - 237142 CAN b<JS (low) connedor sleeve CAN engine bus (high) connector sleeve CAN - A1 Instrument duster - N2/7 Restraint systems conttol unit - N23 Heater/AC operating unit - N49 Steering angle sensor - X11/4 Data lin.k connecto, P00.19-3920-0E Con .. nector. Pin 3.2 1.14 4 1 A.2 28 4 3.10 2 3.4 A.3 A.3 6 1.5 5 1.11 2 C2 C2 1.9 A.7 1.9 1 14 1.6 A.8 1.8 2 6
- N68¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 186 · Applies to: 450, 451
~ - N68 Steering assist control unit 3.16 237/5 Power steering CAN bus connector sleeve (high) CAN, electric power steering - A1 Instrument cluster 1.5 - N10/10 SAM control unit 8.40 ..... N68 Steering assist control unit 3.9 240 Stop lamp signal connector sleeve - S9/1 Stop lamp switch 2 ➔ E3 Left taillamp 1 ➔ E4 Right taillamp 6 .... N47-5 ESP control unit 30 Not convertible (connector 1) ➔ X18/19 Trunk lid connector 3 Convertible (connector 1) ➔ X23/7 Soft top connector 3 Rear luggage carrier ➔ X5716 Right rear luggage carrier and rear lamps connector 1 Rear luggage carrier - X57/7 Left rear luggage carrier and rear lamps connector 6 245 ATA (EOW) sensor supply circuit 30 connector sleeve ..... N10/10 SAM control unit 2.1 -- A1 Instrument cluster 1.1 ..... A15x1 !Additional instruments connector 1 - 832 Microwave sensor 2 - 838 Rain sensor/light sensor 1 ➔ H312 Alarm siren with inclination sensor 1 UK - K44 Central locking 'Lock' relay 2 UK - K44 Central locking 'Lock' relay 6 Rain/light sensor .... K87/1 Rear fog lamp relay 6 ➔ N15/6 Automated manual transmission control unit R9 MHD ➔ N129 Starter-alternator control unit 1stM2 - S4 Combination switch 3 - X11/4 Data link connector 16 1Z50/23 Instrument cluster - radio/lR circuit 30 (fused) connector sleeve Rain/light sensor, up to 31.03.07 ..... N10/10 SAM control unit 3.8 ➔ K8711 Rear fog lamp relay 6 .... K87/1 Rear fog lamp relay 8 ➔ S9/1 Stop lamp switch 3 260/2 Front fog lamp connector sleeve Not rain/light sensor, up to 31.03.07 ..... N10/10 SAM control unit 9.14 ➔ S4 Combination switch 1 Plug 1 - X18/29 Rear fog lamp connector 1
F00.19-P-3000-01 MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 187 · Applies to: 450, 451
Locatjon and assignment of Z connector sleeves (cable connections In wi~ng harness) • engine compartment left IZ DeslgnaUon Component !Connector sleeve ZS/26 Sensor supply connector sleeve M 660 - N3/9 - 811/4 - 817 - B50 127/3 Circuit 87 connector sleeve) Infection vatve 1 to M 132 - X26 notMHO M 132, 50 kW naturally aspirated, MHO - X26 - Y62/1 - '1'6212 - Y62/3 127/4 02 sensor he.ater, wastegate valve circuit 30 connector sleeve M 132 not - X26 MHO 50 kW naturally aspirated, MHO - X26 - G3/1x1 - G3/2x1 up to 31.03.07, 50 kW naturally aspirated engine - Y27 - Y49 As of 01 .04.07 - Y58 60 kW Turbo - Y74 f[:1/5 1'-'ircu1t tH c;onnector sleeve M1 32, not MHO - X26 M660 - X26 50 kW naturally aspirated, MHO - X26 M660 - B2/5 M660 - G3/2x1 M660 - N14/2 M132 - T1/1 M1 32 - T112 M132 - Tl/3 M660 - Y27 iau Connector shhlYe cabkt end irrauta.tion not stripped, placed Inside lnsulatsd tubing Designation COi control unit l1/3 VIS l11' l&/26 Cootant temperature sensor lnta.ke air temperature sensor Fue1 temperature-sensor Interior/engine conMCtor fntetforlonglne connector CyUnder 1 fuel injection valve Cyfinder 2 fuel injection valve Cyfinder 3 fuel injection valve Interior/engine connector Interior/engine connector Conned.or. 02 setisor downstream or lWC 02 sensor upslream TWC (KAT) connector EGR (ARF) switchover valve ~juslable camshaft liming solenoid Fuel tank vent vatve Pressure regulator valve lnterlor/anglne conneclor Interior/engine connector Interior/engine conn&ctor Hot film ma$s air flow sensor 02 sensor upstream TWC (KA TJ connector Glow outp<Jt stage Cylinder 1 Ignition co~ Cylinder 2 Ignition coB Cylinder 3 lgnition coil EGR {ARF) switchover valve P00.1&-3927-06 Con• nector. Pin 1.56 1 1 1 2 3 2 2 2 4 7 2 2 2 2 2 2 3 4 6 2 4 A.7 1 1 1 2
GF00.19.P~ fiMCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 188 · Applies to: 450, 451
Locat,on and assignment of Z c;onnec:;cor •-"" (line COMedO/$ ln wlriflQ harness) • leltfootwel 12 !connector !sleeve 1Z3124 ~19/1 21912 IZ2116 1Z2911 ~· 1230/8 IZ37"2 Designation ircuit 15 (fused) COf'l.noetor sleeve. funetk>n M660 M132 MHO ICL {ZVJ .. open" connector &INve CL (ZV] "'cJosod" conne-ctOf' SIMVI ICL lZV] status .. open"' connector l lffVe ICircu(t 58L ·connector ,1 .. ve Rear luggage cani&r, up to 31.03.07 Circutt $BR (fused) COflMCI0r IINve Reer luggage carrief Front fog lamp connect« sleeve Front fog lamps, up to 31.03.07 !CAN bus (low) connector sie.ve icAN "--• - N10/10 - N3/9 - N3/10 - N15111 - N 129 - X11/4 - N10l10 -+ M14/10 - X3511 - X351'Z - N10110 - M14/1 0 - X35/1 - X3512 - N1 0/10 •• X3511 - X3512 - N10/10 - E3 - XS7/6 - ES/13 - N10/10 - E4 - ES/14 - E1911 - X57n ._ Nt0/10 - ES/1 - ES/2 824115 N1516 N47-5 u~n ..... ~,,a Poo.19-3921.00 Otsl,gnatlon Con- noctO<. Pln SAM control untt 3.3 COi oontrol uni! 2.41 ME-5fl (ME) ccotr04 unrt 1.65 Automated mtnuel tranami$&1on control un~ R.31 Statter-d.ernator eootrol unit 1$1.12 ()$ta link (()Or,eao, 8 SAM control unit 10.5 Fuel fillef flap CL IZVJ motor 3 Left d-'"'paratlon point A4 Right door separal.ion point A4 SAM control unit 10.4 Fuel filler flap CL (l\/1 motor 1 Left doc, separation Point KJ. Right door sepannion point A2 SAM control unit 8.18 Left door separation point A5 lfl!ght door separation point A5 ISAM contn:>1 unit 5.8 l.61'ltaillamp 2 Righi rear klggage catrier and reat lamps c:onnecto, 2 Left Slondlng lamp SAM control unit Right tailJamp Right gtand,ng lamp Left lioense plate tamp Left teat luggage carrier and rear lamps oonnec:tor SAM eonttol unit Leff front fog lamp Rioht fron.1 too tamo Yaw rate and late-rat acce1eta1ion sensor !Automated m,nu,111 t,r;.n,missfon control unit ESP control unit C::ffloft1~ .... 1t ............. ,.,. ....... , ., .. ~ 1 5.7 I 5 1 2 5 s., 1 I ' Rt4
F00.19-P-3000-04MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 189 · Applies to: 450, 451
Location and ass;gnment of Z connector sleeves (cable connections in wiring harness) • interior left z Designation connector sleeve 127124 Circuit connector sleeve 8711
!"71.J5 Circuit 87 ·connector sleeve M1e M660 - M132 - M660 ➔ M 132 - M132 ➔ ➔ -- up to 31.03.07, M 132 - M 132, not MHD - M 132, 50 kW naturally aspirated. MHD - Z7/36 Circuit 87 connector sleeve M2e M660
V /24 Z7/35 Z7/36 Component N10/10 N IS/6 N1516 N10/10 N10110 N319 N3/10 N3/10 N15/5 N15/6 N1516 K27 X26 X26 N10/10 N319 X26 P00.1~3925-06 Designation Con• nector. Pin SAM control unit 4.2 !Automated manual transmission control unit R.1 lAutomated manual transmission control unit R.3 SAM control unit 1.2 SAM control unit 5.11 COi control unit 2.5 ME-SF! control unit 1.66 ME-SF! control untt 1.73 Electronic selector lever module control unit 1 Automated manual transmission control unit R.7 Automated manuat transmission control unit R.8 Fuel pump relay 6 Interior/engine connector 3 Interior/engine connector 6 SAM control unit 5.11 COi control u.ntt 2.3 Interior/engine connector 4
GF00.19-P-100(}.04MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 190 · Applies to: 450, 451
Location and assignment of line and plug connectors, interior compartment, left
Code¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 192 · Applies to: 450, 451
Designation Cable colors Cable colors Notes R12/1x1 Left emergency tensioning retractor squib connector 1 l-WHGN 2 ) - VTBU X28/4 Driver seat heated cushion connector LHD RDBU - 1 l-RDBU BN- 2 l-BN X28/5 Front passenger seat heated cushion connector RL RDBU- 1 l- RDBU BN - 2 )-BN X28/6 Driver headAhoraxbag connector LHD RDVT- 1 )-BURD WHBN - 2 l-WHVT X28fl Front passenger headllhoraxbag connector RL I RDVT- 1 l-RDVT WHBN - 2 l-WHBN X28/8 Driver seat ETR (GUS) connector (2-pin) RL GYVT- 1 ) - GYVT B~ RD-=- 2 _'-B~8n ·- ..
iGF00.19-P-1000-20MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 193 · Applies to: 450, 451
location and assignment of line and plug oonnectots • rear
Code¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 195 · Applies to: 450, 451
Designation Cable colors cab! e col ors Notes X18119 Trunk lid connector Connector 1 0(18/19.1) Not convertible BKGN- 1 >- BKGN GNBU - 2 r-GNBU BKRO - 3 >- BKRO X18/19 Trunk lid connector Connector2 (X18/19.2) Not convertfble BKBU - 1 r-BKBU BN - 2 >- BN X23ll Soft top connector Plug 1 (X2317.1) Convertible BKRO - 3 >- BKRO BN- 4 >- BN WHGN- 5 r-VTWH 8UGN - 6 r- YEBU BKGN- 7 >- BKGN BKWH - 8 >- BKWH BKRO - 10 >- GYBK RDGN - 11 >- ROGN ROWH - 12 }- ROWH XZ3l1 Soft top connector Plug2 (X:1317 .2) Convertible RDGN - 1 >- RDGN ROWH - 2 >- ROWH BNRO - 3 >- GYBK YEWH - 4 >- GYWH BKBU - 6 >- BKBU
lnttriodtnglnt conn~cto,¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 196 · Applies to: 450, 451
1)12!1 lnttriodtnglnt conn~cto, PK - 1
- BHBU M ee0 BK'fE- 1 r-BKWII M 132. up to 31,03.07 BKYE- 1
- 81( M 132. not WHO. ,1S, of 01,04.07 OYPK - 1 >- M 132. 501Nl/ natur•IIY upirtltd. MHD ROYE - 2
- ROYE M 132. up to 31.03.07 ROYE - 2
- BK M 132. not MHO, nof01 ,()q..07 WH - 2 r-BH M 132. 501/di/ naturally ~ r,at.ed. MHD ROGY - 3
- ROOY M 132, up to 31.03.07 ROGY - 3 -BK M 132. not MHO, osof 0 1.D4.07 ROYE - 3
- BK M132.!!0kW n.aNr.ally .uplrated. "'HO ROON - 4 r- RDON .. eeo ROON - 4
- PKBU M 132 up to 31.03.07 RDGN - 4
- BK M 132. not MHO, uof01.D4.07 VEGH- 4 r- YEON M 132, 50kW natur•lty asph.-te d, MHO VT - 6 r- VT M 6e0 VT - 5
- GYBU M 132, up to 31 03.07 VT - 6
- BU M 132, not M HO, .u-of01.D4.07 VTWH - 6
- VTWH M 132,50kW n•turalty •spiraled, MHO YE - Cl -ve up to 31,03.07 YE - 0 r- YE M l$80, asof 0 1.()4,07 YE - 6
- BK M132. 60 kW T urbo, not M HO ROGY - Cl r-BK M132.50WI naturally .uph.ated, MHO WH - 7
- BUGH M 6e0 WH - 7
- BUGH M 132, up to 9 1.03.07 -- 1 r-BH M 132. not MHO a 0101.04.07 RDGN- 7 r-BK M 132.60kW naturally aspirated. MHD OOVT - 8
- OGVT M 132,liOkW n..turally ~iflted, MHO BNYE - 0
- 8NYE M 132,60kW naturalty aspir .. ted, MHO GHRO - 10 r-GNRO M 132. liO kW nmfrally aspirated, MHO BUPK- 12 >- BUPK M 132.50 1dfti' natuu lty aspirated, MHO 9K8U - 14 r- BK8U hi 132. 50 kW natut.tlly .asph.rl.ed, MHO
XJS716¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 197 · Applies to: 450, 451
-¶
--· XJS716 Right rear luggage oarrier and rear lamps oonneotor BKRO- 1 )- BKRO BNGY - 2 )- BNOY BKWH - 3 )- BKWH YERO - 4 )- YERO BN- 5 )- BN X57ll Left rear luggage carrier and rear lamps connector YERO - 3 )- YERO BKGN- 4 )- BKGN GYGN- 5 )- GYGN BKRD- 6 )- BKRO Xt58/10 Rear luggage carrier separation point 1 )- BKWH 2 )- BNGY 3 )- BKBU 4
- YEWH 5 )- GYGN 6 )- BKGN 7 -YEBK 8 )- GNBK g )- TR
GF00.19-P-1000-01 MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 198 · Applies to: 450, 451
Location and assignment •Of line and plug connectors. engine compartment, left
Code¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 199 · Applies to: 450, 451
· ---- ---- Code Designation Cable colors Cable colors Notes G3/1x1 02 sensor downstream of TWC [KAT] connector Engine 132 1
-gn 2 )-BN up to 31.03.07 2 BK As of 01 .04.07 3 )-BU 4 )-YE G3/2x1 02 sensor upstream of TWC [KAT] connector 1 )-GNBK M660 1 )-BURD M132, up to 31 03.07 1 -su M132. as of 01.04.07 2 )-GYWH M660 2 - BN M132, upto 31.03.07 2 BK M132, as of 01.04.07 3 ) - GYBN M660 3 )-BK M132 4 -RDGN M660 4 -WH M132 5 )-GNBU M660 i:; ~ " ~A6_6.Q_ - ~ ....... ""' ... -· - - ' -··· ' .. - ,.... J- r-1 t
GF00.19-P-1000-24MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 200 · Applies to: 450, 451
GF00.19-P-1000-24MCC Location and assignment of line and plug connectors, underfloor
Code¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 202 · Applies to: 450, 451
.,,~------~------------------~----·-···---------·-··-····-·····-·----··-·- . Code Designation Cable colors Cable colors B23x1 Power steering torque sensor connector 1 gn 2
-YE 3 )-BN 4 )-GY L6/1x1 Rpm sensor connector 1 )- RDGN 2 -BUGN L6/2x1 Rpm sensor connector 1 -RDGY 2 )- BUGY L6/3x1 Rpm sensor connector 1 -BUYE 2 )- ROYE L6/4x1 Rpm sensor connector 1 )- RDBK 2 -BUSK M19x1 Power steering connector 1 )- RD 1 )- BU 2 )- BU 2_l=.RD Notes LHD RL LHD RL __
~R42.10-P--0010MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 203 · Applies to: 450, 451
DEL
451.J/4
!Bleed brake system
!19.2.08
1
Brake nuld reservoir
2
Brake caliper
3
Wheel brake cy/lnder
P◄2.10.26SC,,06
1,.,1
Remove
& oangert
1 Ktsk of polsonfng caused by swa110wing
1 vnry pour brake fluid into sultable ano
A-• b0-,-0001-0IA
brake lluld. Risk of injury caused by brake
appropriately marked containers.. Wear
nuld coming Into contact with skin and eyes. protective clothing and eye protection when
handling brake fluid.
IW
Brake fluid notes
AH42 50-P-0001--0IA
@)
Note$ on repairs to brake system
AJ-142 ~-ll003-01A
1
Remove wheels
I W Positioo the front support plates of the
AR
Check brake pedal travel¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 204 · Applies to: 450, 451
9 Check brake pedal travel Bleed secondary circuit 10 Connect STAR DIAGNOSIS and bleed the secondary cirwit of the brake system r,/i"A D Connect STAR DIAGNOSIS and read out lauft.-no,y 11 Disconnect brake ftuid changer 12 Ch&ek brake fluid level and correct if necessary r..i"AP Brake system • inspect fluid level i<,J ' Install 13 Screw on cap of brake fluid reservoir (1) 14 Install maintenance flap 15 Raise vehicle with vehicle Ill 16 Press dust cap onto brake bleeder valve 17 Mount wheels 18 Cheek brake system for leaks l!!!l Brake cylinder Number Designation OA4l.. lo-P• 100t-o8C Btall.e btecd valve to rear axle whool bnlke cylinder 8 Front alCle floating caliper Number Designation 8AA2.10-l'-1002·10A Brake bleeder valve to brake caliper fR42.10-P-0100-01 MCC !Check brake system for leaks After bleeding the brake system, depress the brake pedal firmly several times so that the correct ciearanoe is adjusted between the brake disk and brake lining. I]) The vacuum in the brake booster Is reduced by depressing the brake pedal several times. When the hand brake Is applied a hard, pennanent actuation point must adjus1 at the brake l)e(lal when the foot brake Is depressed. If the pedal travel reduces after the brake pedal ,s pumped several times, the complete brake system should be bled, Nm W In lhe event of a soft pedal feel or long pedal trawl, bleed lhe secondary circuit of the brake system. W The instructions for secondary circu~ bleeding are specified by ST AA DIAGNOSIS A secood pe,son is needed Who assists the brake fluid changer by slowty pumping on the brake pedal. AOOO OO-P-2000-04MCC AP• 2 10-P-'210MCC AA40 10-P-1 IOOMCC AR42.10•P-0100-0IMCC Model 451.3/4 1 Model 451.3/4 Nm 7 2 Check all connections and screw Joints for klaks. 3 If nea,ssary replenish brake fluid in the brake fluid reservoir or correa brake fluid by dralning at any bleed vaJve. 4 If the test drive is earned out after a repair to the hydraulic system or the brake system, then braking with ESP regulation is to be carried out.
Brake system - inspect fluid level¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 205 · Applies to: 450, 451
21.8.07 1 Brake fluid reservoir P42.10-2632-04 & Danger! Risk of poisoning caused by swallowing Only pour brake fluid into suitable and AS42.50·2-0001-01 A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. & Danger! Risk of injury caused by moving parts Atways remove ignition key when working on AS82.30·Z-0001-01A that can pinch, crush or, in extreme cases windshield wiper mechanism. even sever extremities. ® Brake fluid notes AH42.50-P-0001-01 A ® Notes on repairs to brake system AH42.00-P-0003-01 A 1 Remove maintenance flap 2 Check fluid revel W The brake fluid level must be between the MAX and MIN marking embossed in the brake fluid reservoir (1). If the fluid lever is too low. establish and eliminate the cause. - As a separate repair order. If no cause can be found, correct brake fluid level. l~BB General brake fluid Sheet 330.1 BB00.40-P-0330-01A ~BB Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40-P-0331-00A 3 Install maintenance flap
Check brake lining thickness¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 207 · Applies to: 450, 451
21.8.07 Shown on left side of vehicle 1 Plug 2 Bralcedrum P42.10•2524-11 l::!l Checking 1 Remove stop plug (1) from brake anchor plate of left and right drum brake 2 Check lining thickness of brake shoes W The wear limit of the brake linings should be evaluate<I through the inspection hole. Observe the wear limit to ensure that the wear limlt is not exceeded before the next maintenance service. If necessary: ! Remove brake drum (2) for exact determination of lining thickness of brake shoes ~AR - subject to separate repair order. Remove/install brake drum AR42 10-P-1010MCC ~AR Remove/install brake shoes at rear axle AR42 10-P-0165MCC 3 Seal inspection hole in brake anchor plate of left and rlght drum brake using stop plug (1)
Check lining thickness of brake pads and condition of brake disks¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 208 · Applies to: 450, 451
10.7.07 1 Brake pads 2 Brake disk P42.1D-2614-11 l3J Checking 1 Check lining thickness of brake pads (1) on W Check brake pads (1) in the installed front axle condition. Observe recommended wear limit so that wear limit is not dropped below up to the next maintenance service. If necessary: .I, Replace brake pads (1 ). - subject to separate repair order. ~ AR Remove/check/install front axle brake pads AR42. 1 0-P-1600MCC 2 Inspect brake disk (2) for scores and cracks W If necessary: .I, Install new brake disk (2}. - subject to separate repair order. ~ AR Remove/install front axle brake disk AR42.1 0-P-0230MCC
Replace brake fluid¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 210 · Applies to: 450, 451
19.2.08 BIiii<• nutd reservoir 2 Brake cal/p<,r 3 Wheel bral<e cylinder Replace &Danger! Risk of Poisoning caused by swallowing Only pour brake fluid into suitable and AS42 50.Z--0001-lllA brake fluid. Risk of Injury caused by brake appropriately mal1<ed containe,s, Wear fluid coming Into contad with sllln and eyes. ~ective clothing and eye p,oll!Clioo when handHng brake fluid. (2) Brake fluid noles AH42 5().P--0001-lllA ~ Notes on repairs to brake system AH42 QO.P-0003-0IA 1 Remove maintenance flap 12 Unscrew cap of broke fluid reseMlir (1) 13 Conned brake fluid changer to broke fluid UJ Observe the operatof• manual le< the reservoir (1) and apply the specified pre .. ure brake fluid changer. to the broke system Brake ftuld change un~ h111>·//ootis afte,,..le• dalm'· --- ··i,,r -m ~ BB General brake fluid Sheet330.1 B800 40-P-ll330-ll1A ~ BB Brake fluid• (OOT 4 plus) Sheet331.0 B800 40-P-ll33 t-OOA &oanger1 Risk of death caused by vehicle slipping or Align ""hici<, between columns of vehicle Oft AS00.00-l-ll010·01A IOPl)lfng off of the lifting plalfo<m. and pooilion four support plates at yehicle lift support points specified by vehicle manufacturer. 14 Raise vehicle wlth yehfcle lift (I] PosUioo the front support plates or the yehlcle lift as far as poosible upwards, position the rear support pl.ates as far as possible downwards and secure the vehicle to pre,,..nt ft from slipping or topp6ng. 5 Remove dust caps ITom the brake bleeder valves 16 Conned hose of b<ake fluid receptade to W Close the brake bleeder valve only after broke bleeder valye or the wheel brake the b<ake fluid escaP8$ free or bubbles and cy1fnder (3) and open broke bleeder valve -out contamination (bright color of brake fluid), 8 •BA42.10.P-1001·0aC 17 Cany out the bleeding process on the left W Observe corred sequence. wheel brake cylinder (3), right bro~e cauper (2) and left brake caliper (2) in the sa.me manner
S4111¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 212 · Applies to: 450, 451
21.4.08 S4111 Oil pressure switch P18 00-2239-,04 i<..J Removing I& Danger1 Risk of a~ident caused by vehicle starting Secure vehicle to prevent it from moving by ASOO.OO-Z-0005-01A off by itself when engine Is running. Risk of Itself. Injury caused by contusions alid burns Wear closed and snug-fitting work clothes. during starting procedure or when wor1<1ng Do not touch hot or rotating parts. near the ,engine as it is running 1 Remove oil pressure switch (S41/1) AR 18 40-P-4132MCU t!I Checking 2 Screw adapter into threaded hole fur oil 11:i'.1 "450589132100 pressure switch (S41/1) 3 Attach oil pressure testing device to adapter I~ ·450589132100 4 Lower vehicle with vehicle lift 5 Remove interior flap above engine AR88.40-P-1100-03MCC 16 Check engine oil level, correct if necessary 1.a--aa Multigrade engine oils (Sheet 229.5) Sheef 229.5 8800.40-P-0229-05A tr Let the engine to run until it reaches an "BE18.00-P-1002-01E operating temperature of about 144"C, then read off the oil pressure at idle speed on the p,essure gauge of the oil pressure tester WI '450589132100 8 Increase the engine speed to 3500 rpm and "BE 18.00-P•1003-01E read off the pressure on Ille gau_ge of the oil p,essure tester with the engine warm. ~ "450589132100 9 Tum off engine 10 Raise vehicle with vehicle lift 11 Detach on oil pressure testing device from adapter and remove adapter from threaded hole fur oil pressure switch (S41/1) 1119 Install 12 Install oil pressure switch (S41/1) AR18 40-P-4132MCU 13 Lower vehicle with vehicle lift 14 Install lntetior ftap above engine AR88.40-P- 1100-03MCC l.O&CK va,ues ror 011 pressure Number Designation Engine 132 8E18 0O-P-1002-01E Oil pressure engine at operating temperature and bar 0.6101.6 idling 0E18.00•P•1003-01E Oil pressure at engine operating temperature and bar 2.5 104.3 3500rpm
Shown on engine 132.9¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 213 · Applies to: 450, 451
Elecrrlcal connector 54111 OIi pressure switch k.>I Removing I& Danger! Risk of accident caused by vehicle starting off by itself when engine i$ running. Risk of Injury caused by contusions and burns during starting procedure 01 when wori<lng near the engine as it is runnrng , Remove oO pressure switch ($41/1) I~ Ch«kJng 2 Screw adapter Into threaded hole for oil pressure switch ($41/1) 3 Attach oil pressure testing device to adapter 14 Lower vehicle wilh vehicle lift 5 Remove interior Rap above engine 6 Cheek engine oil levet. correct if necessary ~ BB Muttigrade engine oils (Sheet 229.5) ~ BB Multigrade seivlce engine oil Low SPAsh 17 Start the engine and, with the engine cold, read off the oil pressure at Idle speed on the pressure gauge of the oil pressure tesle< 13 Allow engine to run until Ol)erating temperature of a.bout SO•C h-as been reached and read off the engine on pressure for Idle speed on the oil pressure teSting device pressure gauge 19 Increase the engine speed to 3500 rpm and read off Ihe pressure on Ihe gauge of lhe oil pressure tester with lhe engine warm. 10 Tum off engine 11 Raise vehicle with vehicle Ifft 12 Detach on oil pressure testing device from adapter and remove adapter from II- hole for oil pressure switch ($41/1) l<.,J lnsUIII 13 lnstaU oU pressure switch (541/1) 14 Lower vehicle with vehide lift ~5 Install intenor !lap above engine vne.o" va1ues ror on pressure I Number I Oeslgnadon 21.4.08 Secure vehicle to prevent it from moving by ASOO OO-Z-0005-0lA ~self. Wear dosed and snu.g-fitting wori< clothes. Do not touch hOt 01 l'Oll!ting parts. Engine 132.9 AA18 40•P-l 132MCC Engine 660.9 AR18 40 P-l 132MCD lllil ·450589132100 IIS'.l •450589132100 AA88 •D-P•I 100-03MCC Sheet 229.5 8800 40-P-0229-0SA Sheet 229.31 8800 40.P-022~31A Engine 660.9 •BE18.()()..P•1001-0lf ~ '450589132100 Engine 132.9 '8E18.()()..P-1002-0IE Engine 660.9 ·BE18.00-P-1002-01 F ~ ·450589132100 Engine 132.9 '8E18.00·P•t003-01E ~ •450559132100 Engine 132.9 1Mnlt:14v-r--41J.i!M(.A.; Engine 660.9 AR 18 40.P◄ 132MCO AR88 40.P-1100-03MCC 132 I Engine
BE 18.00-P-1003-01 E¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 214 · Applies to: 450, 451
Oil pressure at engine operating temperature and bar 2.5 to 4.3 3500 rpm Check values for oil pressure Number Designation Engine 660 BE18.00-P-1001-01 F Oil pressure engine cold and idling bar 4.0 to 4.5 BE18.00-P-1002-01F Oil pressure engine at operating temperature and bar 2.0 to 2.5 idling 450 58913 21 00 Oil pressure tester
1st gear¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 215 · Applies to: 450, 451
'The power flows from the input shaft via the fixed gear of 1st gear (1) to the idler gear of 1st gear (2). The shift fork 1/3 (a) sudes the internal toothing of the shift conar 1/3 (3) into the idler gear of 1st gear (2). The torque of the idler gear of 1st gear (2) is now passed on to the main shaft (4) and from there to the differential (5). a
2nd gear¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 216 · Applies to: 450, 451
The power flows from the input shaft via the fixed gear of 2nd gear (6) to the idler gear of 2nd gear (7). The shift fork 2/4 (c) slides the internal toothing of the shift coHar 2/4 (8) into the idler gear of 2nd gear (7). The rotation of the idler gear of 2nd gear (7) is now passed on to the main shaft (4) and from there to the differential (5). l b I a
13rd gear¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 217 · Applies to: 450, 451
The power flows from the input shaft via the fixed gear of 3rd gear (9) to the idler gear of 3rd gear (10). The shift fork 1/3 (a) s6des the internal toothing of the shift collar 1 /3 (3) into the idler gear of 3rd gear (10). The rotation of the idler gear of 3rd gear (10) is now passed on to the main shaft (4) and from there to the differential (5). b I a
4th gear¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 218 · Applies to: 450, 451
The power flows from the input shaft via the fixed gear of 4th gear (11) to the idler gear of 4th gear (12). The shift fork 2/4 (c) slides the internal toothing of shift collar 2/4 (8) into the idler gear of 4th gear (12). The rotation of the idler gear of 4th gear (12) is now passed on to the main shaft (4) and from there to the differential (5). 1 b l a
5th gear¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 219 · Applies to: 450, 451
The power flows from the input shaft via the fixed gear of 5th gear (13) to the idler gear of 5th gear (14). The shift fork 5 (b) slides the internal toothing of shift collar 5 (15) into the idler gear of 5th gear (13). The rotation of the idler gear of 5th gear (13) is now passed on via the fixed gear of 5th gear (14) to the main shaft (4) and from there to the differential (5). I b a
I GF26 . 00-P-0003-03MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 220 · Applies to: 450, 451
Neutral (N position) Automated manual transmission shift lever positions, force distribution course In the transmission's N position none of the shift collars are engaged with an idler gear. a Shift fork 113 b Shift fork 5 c Shift fork 2/4 d Shifl fork R l
Reverse gear¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 221 · Applies to: 450, 451
! Reverse gear The power flows from the input shaft via the fixed gear of reverse gear (16) the sliding gear of reverse gear (17) to the reverse gear (18). The shift fork R (d) slides the s~ding gear of reverse gear (17) into the external toothing of reverse gear (18). The rotation of the reverse gear (18) is now passed on to the main shaft ( 4) and from there to the differential (5).
GF26.19.P-101 OMCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 222 · Applies to: 450, 451
Component description for the automated manual transmission control unit N1516 Automated manual transmission control unit Location The automated manual tranSl'TllSSIOO COllrOI unit ,s located in the passenger companment under the driver seat. General L The automated manual trans1111ss1on control tll1t controls. monitors and coordinates Ille complete transmission conrrot For this purpose it exchanges (CAN) data with other control units via the Controller Area Network (data bus/CAN bus) Task The automated manual transm1ss100 control urnt controls the following functions depending on the.inlbal information • Engage first gear when vehtcle 1s at a standstill • Gear change • Forced upshtft JUSt before reachmg the lll8lQmum s~ed of the engine • Forced downsh1ft when approaching the idle speed of the engine • Shift down for lockdovm • Disengaging the gear after 1 s 1f a door is opened wrthoot the root brake oc accelerator pedal being operated • Clutch operator • Morntonng clutch load N15/6 P26.19-2130-04 Signals from the following components are read in directly by the automated manual tran1ml11lon control unit: • Transmission rpm sensor (L2) • Transmission motor 1 (M1713) • Transmission motor 2 (M17/4) • Clutch motor (M18) • Eledrornc selector lever module control ullll (N1515) The following components are actuated directly by the CDI control unit: • Transmission motor 1 • Transmission motor 2 • Coupfing motor Communication via CAN takes place with the following components: • lnSDllmera cJuster (A 1) • COi cortrol urnt (N3/9) (on engine 660.9) • Motor elecrrorncs control untt (N3/10) (on engine 132.9) • SAM control unit (N10/10) • ESP control umt(N47-5)
M17/3 -~¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 224 · Applies to: 450, 451
A.1 A45 • M17/3 -~ '-:r L2 5~-------J~ t,)S112s1 T~112s2 ~
II Shown with code (V11) Softouch -¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 225 · Applies to: 450, 451
automated shift program {FFO) and with code (175) Leather sport steering wheel incl. steering wheel rocker switch system 1 Shift request 2 Transmission speed 3 Clutch request 4 Status of clutch motor 5 Request for gear change 6 Status of transmission motor 7 Engine speed 8 Reversing lamp actuation 9 Vehicle speed 10 Select/on of shift program (with code (V11) Softouch - automatic shift program (FFO)) 11 Accelerator pedal position 12 Status of foot brake pedal 13 Door status 14 Gear stage engaged 15 Actuation of gear Indicator A1 Instrument cluster A45 Fanfare horns and airbag clock spring contact E4e3 Right backup lamp L2 Transmission rpm sensor M17/3 Transmission motor 1 M17!4 Transmission motor 2 M18 Coupling motor N3/9 CD/ control unit (with engine 660.9) N3/10 MS-SF/ [ME] control unit (for engine 132.9) N10!10 SAM control unit N15/5 Electronic selector lever module control unit N15/6 Automated manual transmission control unit N47-5 ESP control unit S112s1 Steering wheel gear shifter PLUS (with code (175) Leather sport steering wheel with steering wheel rocker switch system) S112s2 Steering wheel gear shifter MINUS (with code (175) Leather sport steering wheel with steering wheel rocker switch system) CAN Controller Area Network (data bus/CAN bus) (CAN)
General function¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 226 · Applies to: 450, 451
The automated manual transmission is based on a •standard" manual transmission. The shift operations are carried out by two selector drums which are adjusted by transmission motor 1 and transmission motor 2. The current position is recorded by integrated incremental sensors. The necessary clutch engagements are carried out by the clutch motor. Operation takes place via the control unit for the electronic selector lever module or via the steering wheel gear switch (with code (175) Le~ther sport steering wheel incl. steering wheel rocker switch system). The complete control of the shift processes and clutch engagements takes place by the automated manual transmission control unit. The currently engaged gear stage as well as the gearshift recommendation are displayed in the multifunction display (A1p13) of the Instrument cluster. The following shift programs are possible: • "softip mode" The gears must be selected manually. • "softouch mode" (with code (V11) Softouch- automated shift program (FFO)) The gears are shifted automatically. Engine start Function requirements: • Move gearshift lever into position "N" • Operate foot brake • Circuit 15 On Then first the automated manual transmission control unit issues a start enable and the engine can be started with the transmitter key (I] On vehicles with code (V11) Softouch - automated shift program (FFO) "softlp mode" is selected automatically.
Starting off¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 227 · Applies to: 450, 451
To start off the vehicle the gearshift lever must be located in the shift level: • Operate foot brake, • Move gearshift lever into the shift level, • Release foot brake and • Operate accelerator pedal. The vehicle moves off. In the gear indicator "1" is displayed in "softip-mode" or "A" is displayed in "s6ftouch mode". [I] If when changing from shift lever position "N" into the shift level the foot brake Is not operated, no gear is engaged. "O" appears in the gear indicator. Selection of shift program (with code (V11) Softouch - auto mated shift program (FFO)) It rs possible to change between the two shift programs by operating the "Softouch" buttor-i on the gearshift lever. .. somp moue In the "softip mode" the driver determines when a gear is changed. • Gearshift lever forward "+": Shift up a gear • Gearshift lever back"-": Shift down a gear On vehicles with code (175) Leather sport steering wheel incl. steering wheel rocker switch system in addition the gears can be changed via the steering wheel gear switches: • Steering wheel gear switch PLUS: Upshift one gear • steering wheel gear switch MINUS: Downshift one gear The respective gear stage engaged is displayed in the multifunction display of the instrument cluster. If for a driving style which provides for optimum fuel consumption another gear than the gear engaged would be meaningful, a gearshift recommendation f rom the automated manual transmission control unit appears in the multifunction display: • Arrow up: Shift up one gear • Arrow down: Shift down one gear
Forced upshlft/downshlft¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 228 · Applies to: 450, 451
Automatic shifting is also possible in the "softip mode": • Forced upshift just before reaching the maximum speed of the engine • Forced dcwmshift when approaching the idle speed of the engine • Downshift with kick.down • Engage first gear when vehicle at standstill (clutch open) • Disengaging the gear after 1 s, if a door is opened without the foot brake or accelerator pedal being operated. A warning tone is output, the gear indicator changes to "O" and flashes. Shown with code (V1 1) Softtouch -automatic shift program (FFO) In "softouch mode" the automated manual transmission control unit determines the gear change. The shift operations proceed automatically (depending on a performance map) corresponding to the current load (accelerator pedal position) and the vehicle speed. The following points are taken into account for the shift operations: • Upshifts and downshifts are not tri.ggered at the same operating point in order to avoid repeated shifting between two gears in the critical limits. • When downshiftfng multiple gearshifts (e.g. from 5 to 3) are also conducted. • Manual upshifts and downshifts end the "sottouch mode". • Engaging reverse gear or the neutral position does not end the '"softouch-mode". Backup For backup the gearshift lever must be in position "R": • Operate foot brake, • Move gearshift lever into position "N" • Release foot brake and • Operate accelerator pedal. The vehicle moves off. "R" Is shown in the gear indicator. III It is only possible to engage reverse gear up to a vehicle speed of 5 km/h. Klckdown function The accelerator pedal must be depressed fully in order to trigger an automatic downshift via the kickdown function (overcoming the actuation point). The following processes can be triggered based on a performance map: • Downshift by one to three gears • Subsequent upshift just before reaching the engine's maximum speed III The kick.down function is also available in the "softip mode" and "softouch mode".
Parking the vehicle¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 229 · Applies to: 450, 451
I Parking the vehicle The following steps must be taken to park the vehicle securely: • Operate service brake, • Engage reverse gear, • Apply pa.rking brake, i • Switch off engine and remove transmitter key as well as • Release service brake. In this case the clutch is closed when reverse gear is engaged. ITJ A gear is not engaged when parking the vehicle in neutral. The vehicle can be pushed or towed away. Shift operation The two selector drums are assigned to the gears: • Selector drum 1/3, 5: Gear 1, 3 and5 • Selector drum 2/4, R: gear 2, 4 and reverse gear Through corresponding rotation of the selector drums the sliding blocks running in the grooves are deflected to the left or right. As a result the corresponding shift collars are displaced in turn via the shift forks and thus the gears are shifted. Because when shifting out of a gear and shifting into the next gear different selector drums are used, the gearshift may overlap when it is executed: • While the current gear is disengaged, the next gear is moved up to the synchromesh. • When the shift collar has separated the previous gear, the new gear is then synchronized and engaged. The overlap reduces the time for the gear change significantly, it is shorter than that of gear change with only one selector drum.
Transmission temperature¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 230 · Applies to: 450, 451
The oil temperature influences the viscosity of the transmission oil and thus the shift operation process. As the transmission control takes into account the oil temperature for the actuation of the actuator motors, a consistent shift quality is achieved. The temperature of the transmission is computed. The speed of the shafts and the transmitted torque is drawn on to calculate the friction, which is converted in the transmission into heat. The cooling due to the airstream is determined from the ambient temperature and the vehicle speed and the transmission temperature is established by means of a performance map. Following an extended imm.obilization period the ambient temperature Is adopted for the-transmission temperature. Error reactions The processes in the transmission are monitored by means of the actuation signals and the sensor signals. If events occur in the process which deviate from the normal sequence, these are stored in the automated manual transmission control unit. Stored events can be erased again if they do not occur any more on several trips in sequence. There are three fault categories • Fau It ls stored but no effects on driving are noticeable. No warning message is output in the multifunction display. Such event recordings serve solely analysis of causes. • In the event of basic faults a warning message is output in the multifunction display: The trip is only impaired slightly. The restrictions frequently go unnoticed by the driver. Thus, e.g. overlaps and gear steps are no longer executed. The duration of the shift operations Is extended.
In the event of serious faults a warning message Is 11KewIse¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 231 · Applies to: 450, 451
• In the event of serious faults a warning message Is 11KewIse output in the multifunction display. The transmission changes into limp-home mode. The following reactions are possible: No further gearshifts are performed, the gear engaged is retained. - After stopping and restarting only reverse gear and 1st gear are still actuated, engine power and engine speed are limited. - After stopping and· restarting no further gear is engaged. Clutch actuation During each shift operation a corresponding clutch process is ca.rried out by the automated manual transmission control unit. The automated manual transmission control unit actuates the clutch motor directly for this. I; The load is evaluated in the automated manual transmission control j unit in order to avoid overloading the clutch. 1nma11z1ng The initialization must be performed using STAR DIAGNOSIS after the following activities: • Removal of transmission • Removal of one or both transmission motors • Replacement of automated manual transmission control unit W A transmission teach-in process takes place after the power supply is discontinued. In the process the incremental counter reading of the selector drum system of sensors is read Justed. For this purpose the selector drums arc moved into their end positions when the clutch is open. If the threshold value is exceeded the clutch starts to pulse in order to draw the driver's attention to an overload. The clutch is opened in the event of further overload. For wear adaptation the drag point and transmission characteristic of the clutch are continuously adapted by the automated manual transmission control unit
IGF26.19-P-100:>MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 232 · Applies to: 450, 451
JTransm1ss1on motor selector arum anve component aescnpt1on TRANSMISSION 717.480 /481 /482 /483 in MODELS 451 .3 /4 M17/3 M17/4 Location Transmission motor 1 Transmission motor 2 The tra.nsmission motors are located in the transmission housing. Task Depending on the shift request from the automated manual transmission r.ontrol unit (N15/6) the transmission motors adjust the selector drums via two-stage spur-gear unit. Actuation is pulse-v.idth modulated by two output stages with four electronic switches each. The transmission motor is braked when the specified position is reached. It can, if necessary, be actuated v.ith opposing voltage, if an overshoot beyond the spegified position is to be prevented or reversed. J 22.U.Of P26.19-2128-71 Actuation of the transmission motors is monitored by the incremental sensors, which are located on each motor shaft. These detect the rotation angle and direction of rotation of the respective , transmission motor using an integrated system of Hall sensors. Actuation of transmission motors is only required for carrying out shift operations . Upon reaching a specified position a bolt engages in the locking groove of the selector drum. This suffices to retain the selected gear.
1GF26.19-P-10~3MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 233 · Applies to: 450, 451
jTransmission rpm sensor component description I TRANSMISSION 717.480 /481 /482 /483 in MODEL 451 .3 /4 L2 Transmission rpm sensor I Location I The rpm sensor is mounted to the transmission housing. I Task The rpm sensor determines the rotational speed of the input shaft. The •determined speeds of the crankshaft and input shaft are used to monitor the clutch operation. The speeds of the input shaft and the drive wheels are used to determine the actual gear engaged. III The diagram illustrates the oscilloscope picture of an rpm sensor. 125.1 .07
GF26.00-P-0003-04MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 234 · Applies to: 450, 451
I GF26.00-P-0003-04MCC Automated manual transmission shift lever positions, shift positions I Neutral (N) and reverse gear (R) a Selector drum 113, 5 b Selector drum 214, R c Adjustment of selector drum (1 grid= 40°) d Deflection of sliding block mass (1 grid= 7.5 mm) Neutral position The sliding blocks in the grooves of the selector drum are in the neutral position. No gear is engaged. Reverse gear The selector drum 2/4, R rotates through 120• downwards. This deflects the upper sliding block by 22.5 mm to the left. The sliding gear of reverse gear engages in the external toothing of the shift collar 1/3 The sliding blocks in the selector drum 1 /3, 5 are in the neutral position. t C N
Shift position of 1st gear (11 and 2nd gear (2)¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 235 · Applies to: 450, 451
a Selector drum 1 /3, 5 b Selector drum 214, R c Adjustment of selector drum (1 grid= 40°) d Deflection of sliding block mass (1 grid= 7.5 mm) 1st gear The selector drum 1/3, 5 rotates downwards by 40°. This displaces the upper sliding block by 7.5 mm to the left. The shift collar 1/3 is slid into the idler gear of first gear. The sliding blocks in the selector 1 drum 2/4, R are in the neutral position. 2nd gear When changing from 1st gear to 2nd gear both selector drums are twisted upwards by 40•. This in tum displaces the lower sliding block for the selector drum 2/4, R by 7 .5 mm to the left. The shift collar 2/4 is s~d into the idler gear of second gear. The sliding blocks of the selector drums 1/3, 5 are in the neutral position. t C 1 a d·...,,._ C b a d-- b
Shift position of 3rd gear (3) and 4th gear (4)¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 236 · Applies to: 450, 451
- a
- Selector drum 1/3, 5
- b
- Selector drum 214, R
- c
- Adjustment of selector drom (1 grid= 40°)
- d
- Deflection of sliding block mass (1 grid= 7.5 mm)
- 3rd gear
- When changing from 2nd gear to 3rd gear both selector drums are
- II
- tl!.isted upwards. by 40°. The upper sliding block in the selector
- drum 1/3, 5 is displaced lo the right by 7.5 mm. II presses the shift
- collar 1/3 into the idler gear of third gear. The other sliding blocKs
- are in the neutral position. 4th gear When changing from 3rd gear to 4th gear both selector drums are twisted upwards by 40°. The lower sliding block in the selector drum 2/4, R is displaced to the right by 7.5 mm. It presses the shift collar 2/4 into the idler gear of fourth gear. The other sliding blocks are in the neutral position. r-r --;:;:,.;;:::= _ ==;- __ r--;;;::;;;:~ r-;;:::=:;:::;~---;;;;r =-;:::--::-::=i C C C C 3 a
::.nm position of 5tn. Gang (5)¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 237 · Applies to: 450, 451
a Selector drum 1/3, 5 b Selector drum 214, R c Adjustment of selector drum (1 grid= 4()0) d Deflection of sliding block mass (1 grid= 7.5 mm) 5th gear When changing from 4th gear to 5th gear both s.elector drums are twisted upwards 1/3 5 by 40°. The lower sliding block in the selector drum 1/3, 5 is displaced to the left by 7.5 mm. It presses the shift collar 5 into the idler gear of 5th gear. The selector drum 2/4, R is tv,isted downwards by 40°. The sliding blocks of the selector drum 2/4, R are in lhe neutral position. i C 5 a (.f+-0-+
GF26.00-P-0003-02MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 238 · Applies to: 450, 451
Automated manual transmission shift lev-er-~¶
- - - - - - - - - - --1:· GF position.s, technical data L-------- -~-
-
-
-
-
-
- ~
Technical Data
Transmission 717.480
Transmission 717.481
Transmission 717.483
1:i_ousing
Two piece with bell housing
Two piece with bell housing
Two piece with bell housing
Housing material
AJumim.m alloy
Aluminum alloy
AJ1.minum aloy
Len~
364 mm Ord 75 mm clutch)
364 mm (incl. 75 mm ckAch)
364 mm Qncl. 75 mm dutch)
Max. torque
120 Nm
120 Nm
120 Nm
1st gear ratio
3,071
3,071
3,308
2nd gear ratio
1,913
1,913
1,913
3rd gear ratio
1,258
1,258
1,258
4th gear ratio
0,943
0,943
0,892
-- 5th gear ratio 0,763 0,707 0,643 Gear ratio for reverse gear 3,231 3,231 3,231 Differential ratio 4.529 4,529 4,158 Weight (without oil charge) 33,5 KG 33,5 KG 33,5 KG Oil charge (permanent 1,71 1,71 1,71 charge) Oil Viscosity SAE 75W90 API GL-4 SAE 75W90 API Gl-4 SAE 75W90 API Gl-4
- ~
Technical Data
Transmission 717.480
Transmission 717.481
Transmission 717.483
1:i_ousing
Two piece with bell housing
Two piece with bell housing
Two piece with bell housing
Housing material
AJumim.m alloy
Aluminum alloy
AJ1.minum aloy
Len~
364 mm Ord 75 mm clutch)
364 mm (incl. 75 mm ckAch)
364 mm Qncl. 75 mm dutch)
Max. torque
120 Nm
120 Nm
120 Nm
1st gear ratio
3,071
3,071
3,308
2nd gear ratio
1,913
1,913
1,913
3rd gear ratio
1,258
1,258
1,258
4th gear ratio
0,943
0,943
0,892
-
-
-
-
Component description for the automated manual transmission control unit¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 239 · Applies to: 450, 451
22.8.07 N15/6 Automated manual transmission control unit Location The automated manual transmission control unit is located in the passenger compartment under the driver seat. General The automated manual transmission control unit controls, monitors and coordinates the complete transmission control. For this purpose it exchanges (CAN) data with other control units via the Controller Area Network (data bus/CAN bus). Task The automated manual transmission control unit controls the following functions depending on the initial information: • Engage first gear when vehicle is at a standstill • Gear change • Forced upshift just before reaching the maximum speed of the engine • Forced downshift when approaching the idle speed of the engine • Shift down for kickdown • Disengaging the gear after 1 s, if a door is opened without the foot brake or accelerator pedal being operated. • Clutch operator • Monitoring clutch load N15/6 P26.19-2130-04 Signals from the following components are read in directly by the automated manual transmission control unit: • Transmission. rpm sensor (L2) • Transmission motor 1 (M17/3) • Transmission motor 2 (M17/4) • Clutch motor (M18) • Electronic selector lever module control unit (N 15/5) The following components are actuated directly by the COi control unit: • Transmission motor 1 • Transmission motor 2 • Coupling motor Communication via CAN takes place with the following components: • Instrument cluster (A1) • COi control unit (N3/9) (on engine 660.9) • Motor electronics control unit (N3/10) (on engine 132.9) • SAM control unit (N10/10) • ESP control unit (N47-5)
GF26.00-P-0003-01 MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 241 · Applies to: 450, 451
Shift pattern Shift lever In neutral position Au:omated manual transmission shift lever positions The display "N" appears in the multifunction display (A1p13) of the instrument cluster (A1). The engine can only be started when in this position. Gearshift lever in "softip mode" position The current gear engaged In each case is shown in the multifunction display of the instrument cluster. The gearshift recommendation is shown as an arrow: • Arrow up: Shift up one gear • Arrow down: Shift down one gear [I] The gearshift recommendations are orientated towards a consumption-orientated driving style and do not match with the shift points in the "softouch mode" (with code (V11) Softouch - automatic shift program (FFO)). + P26.60-2361-10 Gearshift lever in "softouch mode" position (with code (V11) Softouch • automatic shift program (FFO)) The automated manual transmission control unit (N15/6) determines the gear change in "Softouch mode". The gear indicator indicates "A'' (Automatic) in the multifunction display of the instrument cluster in all forwards gears. Below that the gear selected by the automated manual transmission control unit is indicated. [I] By actuating the switch in the gearshift lever a change is made between "softouch mode" and "softip mode".
GF26.60.P-1 000MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 242 · Applies to: 450, 451
Shifting mechanism component description 25,1.07 Design 1 Shift fork, shift collar 5 2 Shift fork for sliding gear, reverse gear 3 Shift fork for shift collar 113 4 Shiftfork for shift collar 214 5 Mainshaft 6 Selector drum 113, 5 7 Selector drum 214, R 8 Input shaft Function The shift forks are displaced by the selector drums parallel to the transmission shafts. They in turn slide the shift collars on the input shaft or the main shaft towards the respective idler gears The actuation of the stiift forks is conducted by two independent selector drums. each of which has a groove. The sliding blocks for two shift forks run in each groove: Selector drum 1/3, 5: • Sliding block of shift fork for shift collar 1 /3 • Sliding block of shift fork, shift collar 5 Selector drum 2/4. R; • Sliding block of shift fork for shift collar 2/4 • Slidirig block of shift fork for sliding gear, reverse gear P26.60-2360-8 I The positions of both sliding.blocks in the same groove are offset to each other by 120°. If a sliding block shifts a shift fork out of the center position, the other sliding block is located in the straight area of the groove (in the center position of the assoc I ated shaft fork).
SI00.40-P-0013A¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 243 · Applies to: 450, 451
Service Information: Transmission oil for automated manual transmission 23.4.07 MODEL 450, 451, 452, 454 with TRANSMISSION 717 .4 III The following transmission oil should be us.ed for model 450 (smart fortwo) and model 452 (smart roac!ster) with automated manual transmission (AMT): ESSO, "Dexron 21065" Sourcing alternative: Model 450 (smart fortwo) and model 452 (smart roadster): ATF Dextron D-21065, can be ordered under part number Q0022037V0OO 000000 as 20-liter container. III The following transmission oil should be used for model 451 (smart fortwo) and model 454 (smart forfour) with automated manual transmission (AMT): BP-Castro!, "Bunna BOT 328" Sourcing alternative: Model 451 (smart fortwo) end model 454 (smart forfour): Specification 75W90 API GL4, can be ordered under part number A 00198951 0310 as 1-liter container. Enquiries for larger containers should be made directly at the manufacturer. The assignment to a corresponding sheet number in the Specifications for Operating Fluids takes place in the next supplement N20 in September 2007.
H3/2¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 244 · Applies to: 450, 451
Alarm siren with inclination sensor Location The alarm siren is located on Ille right side of the vehicle at the bottom of the vehicle. Task • Acoustic alarm output for anti-theft alarm (A TA) • Self-alarm output upon loss of supply voltage or communication to SAM control unit (N10/10) • Monitoring vehicle inciination for realizing tow-away protection function [II The status of the alarm siren is polled via the local interconnect network interior compartment 2 by the SAM control un~. Design The alarm siren includes: • Rechargeable battery for ensuring power supply • Inclination sensor for analyzing vehicle inclination e Speaker for acoustic alann output 25.1.07 PS0.50-2613-12 Inclination sensor, function When the tow-away protection function is activated. the ATA inclination sensor determines the reference position wtth which the relative vehicle Inclination is compared during the activated time period. If the maximum vehicle inclination in relation to the reference position is exceeded, an alarm is triggered. at the earliest. 25 s after the ATA is activated.If the vehicle inciination changes very slowly (e.g. leaky tire), the reference position adapts to the current vehicle posnion to prevent inadvertent activation of the inclination sensor.
ENGINE¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 245 · Applies to: 450, 451
10.1.07 .m ENGINE 132.9 in MODEL 451.33 /43 G2 A/temator Location The alternator is located on the suction side on the right on the engine. Task The poly-V bell driven altemator delivers sufficient energy for all rotational speeds which occur whi\e-driving to the on-board electrical system and thus secures the on-board electrical system powerstrpply and charging ofthe battery (G1). Design The alternator is designed as an alternator with integral regulation. Control Regulation of the altemator takes place by Integral electronics depending on the rotational speed and on-board power supply voltage. The alternator is, for engine 660.9, connected via a local intecconnect network CDI (LIN A) with the COi control unit (N319) and for engine 132.9 directly with tile ME-SFI {ME] oontrol unit (N3/10). Functional principle Voltage generation In tile alternator is based on the principle of iriduction. If a magnetic field changes in a conducting loop {coil or winding) an electrical voltage is induced in the conducting loop. P15.40-2-46~03 If a coil is traversed by a rotating, magnetic field with a north and south poJe a sinusoidal alternating voltage is generated. The AC voltage is rectified by diodes. One d"ifferentiates for the alternator between three electric c-ireults: PrEM>xcitation power circuit The pllHlxcitation power circuit builds up the magnetic field in the excitation coil. Once the engine starts the alternator excites itself. If ttle excitation current is flowing the alternator charge monitoring and warning lamp (A 1e5) in the instfument cluster (A 1) switches off. Excitation pow&r circuit The excitation current builds up the magnetic field in the excitation coil of the rotor Charge power circuit The charge power circuit supplies the on-board electrical system wltll electrical energy.
AR01.40-P.S000-01MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 246 · Applies to: 450, 451
Bolt plan for timing case cover A BoltM6 x 25 B BoltM6 x 35 C BoltM6 x 55 D BoltM6 x 65 E Bolt MB x 30 F Bolt MB x 55 G Bolt MB x 65
AR01.00-P-2420-01 MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 248 · Applies to: 450, 451
Detaching/attaching engine wirtng harness on engine Disconnect electrical connector (2) on ad)ustable camshaft liming solenoid (Y 49) 2 Remove electrical coMectors (3) at Injection valves 3 Disconnect electrical connector (4) at camshaft Hall sensor (B6/1) 7 Disconnect electrical connector (9) on pressure regulator valve (Y74} and electrical connector (10) on charge air Ian motor (M44). III For engine 132.930. 8 Lay engine wirtng harness (1) lo the front and fix to a suhabte point using a cable tie. 9 Connect in reverse order. POl .00-.2913-06 4 Unclip holder (5) for engine wiring harness (1) from mounts at cylinder head cover (6). 5 Open retaining clamps (7) using a suitable screwdriver and expose engine wiring harness (1). 6 Unlock connector for 02 sensor upstream of lWC (G312x1 J using a suhable screwdriver at mount on holder (8) and take off.
Ins'trl.lllent cluster¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 251 · Applies to: 450, 451
Instrwaent cluster In.stru:aent cluster Instrwaent cluster Instrwaent cluster Instrwaent cluster Turn rate and lateral acceleration sensor SAl'I control unit Control aodule for autollflted aanual trannission Restraint systeas control •odule Heater/ AC operating unit m:-SFI [IIE) control aodule CDI control aodu.le ESP control aodule Steering angle sen:Jor Steering assist cona ol •odule Valid for diesel vehicles XXX Valid for gasoline engines Valid for AAC [KLA) 1/4 Data link connector Z37/2 Z37/2 Z37/2 Z37/2 237/2 237/3 237/3 237/3 237/3 237/3 Z37/4 237/4.l 37/41 237/41 237/42 237/42 237/42 237/5 CAN engine bus (lov) co.nnector sleeve CAN engine bus (low) connector sleeve CAlJ engine bus (lov) connector sleeve CAN engine bus (low) connector sleeve CAB enqine bus (low) connector sleeve CAR engine bus (high) connector sleeve CAJi engine bus (high) connector s leeve CAil engine bus (high) connector sleeve CAN engine bus (high) connector:: sleeve CAN engine bus (high) connector:: sleeve Pover steering CAN bus connector sleeve CAN databus (high) connector sleeve CAN databus (high) connector sleeve CAN databus (high) connector sleeve Cll bus (lov) connector sleeve CAB bus (lov) connector sleeve CAB bus (low) connector sleeve (low) Power sceerin.g CAN bus connector sleeve (high)
l"'r-..::0.1 ::,...--1 uU'fIvt1.,1.,¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 252 · Applies to: 450, 451
IcIectronic seIector Iever moau1e control unit, component description 125.1.07 TRANSMISSION 71 7.480 /481 /483 in MODEL 451.3 /4 'Shown on model 451 with code (V11 ) Softouch - automatic shift program (FFO) 1 Softouch button (with code {V11) Softouch - automatic shift program (FFO)) N1515 Electronic selector lever module control unit Location The electronic selector lever module control unit is located in the center console. Task The electronic selector lever module control unit records the driver's shift requirements. The shift positions "N", "R", "+", "-" are detected in the electronic selector lever module control unit via Hall sensors. These are read in and evaluated by the electronics within the electronic selector lever module control unit. The signals corresponding to the shift lever positions are passed on directly to the automated.manual transmission control unit (N15/6) (shift-by-wire). P26.19--2127-01 The right-hand backup light (E4e3) is actuated directly by the electronic selector lever module control unit. It is possible to change between "softip mode" and "softouch mode" using the "Softouch" button.
Electric steering control unit, component description¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 253 · Applies to: 450, 451
22.8.07 ower s eenng, N68 Steering assist control unit Location The steering assist control unit is located on the left at the top of the vehicle firewall. Task The power steering control unit takes over control of the power steering motor (M19). The following signals are read in for this: Via Controller Area Network (data bus/CAN bus) (CAN): • Vehicle speed from ESP control unit (N47-5) • Steering angle and steering speed from steering angle sensor (N49) Oin'!r.t signals: • Steering torque from power steering torque sensor (B23) • Resetting request from power steering motor By means of the input signals the steering assist control unit determines the direction of rotation and current intensity of the power steering motor (M19) and permanently checks all input signals for plausibility. P46.35-202S-03 In the event of a faulty signal the electric steering is switched off and the respective fault stored in the internal fault memory.
OIi fiiter¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 254 · Applies to: 450, 451
21.8.07 OIi fiiter 2 OIi drain screw 3 OIi filktr neck cap k>I Removing w Chango Ille engine oil only when the engine is at operating temperature M Remove engine compartment cover ~ AR Remove/install 1nterioc compartment flap AR88.40-P-1100-03MCC above engine 12 Unscrew oil filler neck cap (3) I& Danger! Risk of death caused by vehi-Cle slipping or Align vehicle between columns of vehlcle lift ASOO.OO-Z-0010-0IA loWling off of Ille li1\ing platform and posllion fo<Jr support plates at vehicle lift support points specified by ""hlcle manufacturer. 13 Rajse vehieie with vehicle lift 14 Remove oil drain screw (2) and remove seal ring on U1e oil drain screw (2) IW Coiled englno oil in a suitable container. 5 Remove filter screen on the oil drain screw (2) aoo clean 16 Unscrew oil fitter (1) 119'I •454589060900 llt.,J ln9tall ~ Tighten oil filter (1) IW Replace oil fitter (1), Wet sealing ring of oll filter (1) with engine oll, !3 •BA 18.20-P-1002-0IN ~ "454589060900 8 Position new seal ting on the oil drafn screw (2) 19 lnsef1 filte< screen on Ille od drain scr,rw (2) and Ughten oU drain scr,rw (2) I!!! "BAO! .45-P-1003-01J 10 Lower vehicle with rtftin_g plalfomi 11 Pour in engine oil rttJ "BF18.00-P•1001-01N 12 Tighten oil filler necl< cap (3) & Danger! Ri$k of accident caused by \/ellicle starting secure vehicie to prevent ,t from mo\llng by ASOO 00-Z-0005-0tA off by itself when eng,ne is run.nlng. Risk of itself. Injury caused by contusions aoo bums Wear closed aoo snug-fitting work Clothes. during starting p,ocedure 0< when working Do not touch hot or roultlng parts, near the engine as tt tS running 13 Conduct engine test run and check engine fot leaks whilst - Is running 14 Check engine oil level by means of oil I® The fill level must Ile between "Min." and dipstlek ·Max.* otherwise the engine may be ··-
Number¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 255 · Applies to: 450, 451
BA01.45-P-1003-01J ~Oil filter Number 8At8.20-P-1002-01N Remove/install interior compartment flap above engine Designation Oil drain screw to oil pan Designation Oil filter to timing case cover IIJ Capacities of engine lubrication system Number Designation 8F18,00-P-t 001-01N Engine oil Filling capacity (oll and filter change) Specifications for Operating Fluids 454 589 06 09 00 Wrench socket AR88.40-P-1100-03MCC Engine 132.9 Nm 65 Engine 132.9 Nm 14 Engine 132.9 litetS 3,3 Sheet - Sheet Sheet Shee1 Sheet Sheet BBOO.◄0-P-0229-05 A ShOOt
Dipstick¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 256 · Applies to: 450, 451
21.8.07 Dipstick 2 OIi fitter cover !Id Removal w Change lhe engine oil only when lhe Oflgine 1$ at operating temperature , Remove engine c:ompartmen1 cover ~ AR Remove/install interiof oompartment flap AR88 40-P•I 100-03MCC above engine 2 PUii oil dipsUCk (1) out of oil dipsticl< guide lube 3 Unwew cap for oil filler opening 14 ISUdiOn off engine 011 I® Only insen the oil extraction p,obe when the engine is not running otherwise there is a risk of conislon wilh 11\e crankshal. ~ ·450589286300 15 Insert oil dipsliek (I) in lhe oil dlpsliek guide lube ILl:I Da~r! Risk of death caused by vehicle sl,pping or Align vehicle between columns cf vehicle lirt ASOO OO-Z-0010-01A loppOng off of Ille lifting platform. and posttlon four supPOrt plales at vehicle Oft support poinls specified by vehicle manufacturer. 16 Raise vehicle with vehk:le 1111 7 Unscrew oil fitter cover (2) and remove od filler element I<,! Install 18 Serew on oil filter cover (2) W Replace seal ring and oil filter element Coal seal ring wilh engine o" . The torque value is on lhe oil filter cover (2). " Lowe, vehicle with lifting platfonn 10 Pour in engine or! 11:!l "8F18 oo-P-1001-0lN 11 Screw on cap lot o~ filler opening I& oangert Risk of accident caused by vehicle starting Sealre vehicle to prevent a Item moving by ASOO OO-Z-000>01A off by itse~wt>en engine Is running. Risk of itself. Injury cau,ed by contusions and b-ums Wear Closed and snug-fitting wor1' clothes. during starting procedure o, when worl<ing Do not touch hot or t013tlng parts. near the engine as it i& running 12 Conduct engine test run and cheek engine for teaks whil$1 it is running 13 Cheek engine o,I level by means of oil I~ The oH level must be within Ille area dipstick marl<ed on the oil dlpslld< otherwise there Is the threal of engine damage, [I] Lei engine run for approx. 1 minu1". then
~~AR¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 257 · Applies to: 450, 451
Remove/install interior compartment flap above engine = Capacities of engine lubrication system Number Designation BFt8.00-P-1001--01N Engine oil Filling capacity (oil and filter change} Specifications for Operating Fluids 450 589 28 63 00 Oil suction sensor AR88.40-P-1 100-03MCC Engine 660.950 Liters 2,7 Sheet . Sheet . Sheet . Sheet - Sheet . Sheet BB00 40-P-0229--05 A Sheet BB00.40-P-0229-31 A
BE01.00-P-1000-01 G¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 258 · Applies to: 450, 451
Compression pressure Engine 122, 132, 134, 135, 639,660 Check values for compreMion pressure Number Designation Engine Engine Engine Engine 122 132.910 132.930 134 BE01 .OO-P-1001-0l G Compression pressure new value bar 12.1 15 14 13,2 BED1 .00-P-1002-01G Compression pressure wear limit or limit value bar - 8,3 =11 ~ 10 ~9 BED1.D0-P-100l-01G Compression pressure: permissible difference between bar s0.98 - - s 0.98 individual cylinders Check values for compression pressure Number Designation Engine Engine Engine Engine 135.930 135.950 639 660.940 c=18.5 BE01.00-P-1001-01G Compression pressure new value bar 14.3 15.5 18 18.5 8E01.00-P-1002-01G Compression pressure wear limit or limit value bar - 10 - 11 =10.5 - BE01.00-P-1003-01G Compression pressure: permissible difference between bar s:0.98 s 0.98 s 2.5 - individual cylinders Check values for compression pressure Number Designation Engine 660.950 c~19 8E01.00-P-1001-01 G Compression pressure new value bar 28 BE01.00•P•1002-01G Compression pressure wear limit or limit value bar 18 BE0l.00-P-1003-01 G Compression pressure: permissible difference between bar 3 individual cylinders
AR01 .10-P-1000-01 MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 259 · Applies to: 450, 451
Turn engine into the top dead center position Release expansion clips (1) and remove V-belt cover (2) 2 Transfer marking (arrow A) on the crankshaft belt pulley (3) using a suitable colored pencil to the front side. [I] Turn engine at center bolt (4) for crankshaft belt pulley (3) in direction of engine rotation if necessary. 3 Turn engine in direction of engine rotation until marking (arrow A) on crankshaft belt pulley (3) coincides with the TDC marking (arrow B) on the timing case cover (5). P01.10-2900-06 4 Position V-belt cover (2) and install expansion clip (1). [I] If no further turning of the engine is required.
SI00.00-P-0054O¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 260 · Applies to: 450, 451
Service Information: Parts Identification in EPC 4.5.07 MODEL 451 [I) In the EPC [electronic parts catalog] the major assembly catalog for the transmission of the model 451 (smart forlwo). The folowing parts cannot therefore be determined: Transmission 717.48 for engine 660 A 451 370 01 01 Autom. transmission M660 N 910143008010 Screw M8x80 8.8 M660 Transmission to engine N 910 143 0080 19 Screw M8x00 8.8 N 910 105 0080 19 Screw M8x50 10.9 N 000 000 0011 54 Screw M8x50 8.8 Transmission 717.48 for engine 132 A 451 370 00 01 Autom. transmission A 451 370 03 01 Autom. transmission A 451 370 04 01 Autom. transmission Transmission to engine A 001 990 02 03 Screw A 001 990 03 03 Screw M660 M660 M660 M132 M132+(M002/M017) M132+M002+M014 M132 M132 General parts for engine 132 and 660 A 451 540 27 08 Wiring ha.mess Mounting of clutch actuator A 000 990 26 03 Screw A 451 250 00 62 Ctutch operator Mounting of operator system A 000 990 56 03 Screw A 454 254 00 08 A 451 829 02 01 A 000 990 50 17 A 451 542 06 18 A 007 990 64 04 A 000 998 17 21 A 013 997 61 46 Release lever Transmission motor Bolt (screw plug) Rpm sensor Screw Cap Sealing ring The clearing up of part numbers in the EPC takes place with Output 07/2007
ESP control unit, component description¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 261 · Applies to: 450, 451
22.8.07 1 Hydraulic unit N47-5 ESP control unit Location The ESP control unit is located on the hydraulic unit on the vehicle underfloor. Task The ESP control unit controls the following systems: • Electronic Stability Program (ESP) • Acceleration Slip Regulation (ASR) • Engine braking regulation (EBR) • Antilock brake .system (ABS) • Electronic brake force distribution (EBV) Direct entries • Tml. 15 • Circuit 30 • Circuit 31 • Left front rpm sensor (L6/1) • Right front rpm sensor (L6/2) • Left rear rpm sensor (L6/3) • Right rear rpm sensor (L614) • Stop light switch (S9/1) • Brake fluid indicator switch (S 11) • Parking brake switch (S 12) P42.45-2605-04 Communication and influence of ESP control unit on other systems in the vehicle: • The ESP control unit influences the engine management and power transmission in the case of an ESP control. • For driver Information the control unit actuates the instrument cluster via the Controller Area Network (data bus/CAN bus) (CAN)A 1 ), the instrument cluster actuates the ABS indicator lamp (A1e17) and ESP warning lamp (A1e41). Voltage supply • Yaw rate and lateral acceleration sensor (824115) • Steering angle sensor (N49) CAN signals The ESP control unit is a CAN subscriber and receives signals from the following sensors: • Tum rate and lateral acceleration sensor • Steering angle sensor
GF54 .15-P-1255-21 MCA¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 263 · Applies to: 450, 451
Fuse and relay box relay assignment N10/10 SAM control unit A to C Relay sockets P54.15-3108-02 Position Relay Switched function A . . B K.27 Fuel pump relay (model 451.3## /4## ## up to 014118) cc K.87/1 Rear fog light relay (with code (V54) rain/light sensor)
GF54.15-P-1255-20MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 264 · Applies to: 450, 451
Fuse and rel;Jy box fuse a$$ignment Fuse and relay assignment of SAM control unit (NI0/10) (front side) 11031 Fuse sockets R1 to R9 Fuse $OCkets Fuse a.nd relay- ass.ignment of SAM control unit (NI0/10) (back side) 32 10 35 Fuse sockets N t/J/10.1 Electrical connector Nt/J/10.2 Bectrical connector Nt/J/1().3 ElectricaJ connector N1/J/1().4 Electrical connector N10/10.5 Electrical connector N1/J/1().6 Elec.trfc,a/ connector N10/10.7 Electrical connector N10f1().8 Electrical connector Nt0/1().8 Electrlca/ connector NI/J/1().9 Electrical connector Nl/J/10.10 EJectrlul connector N1/J/10.11 Electrical connector Position Fuse Identification color I N10/t0f1 blue 2 N10110f2 !transparent 3 N10/10f3 Yellow ~ NtO/tOf4 transparent 5 NIO/t0f5 red " NIO/t0f6 brown 7 NI0/10!7 brown 8 Nt0110f8 ransparent 9 NI0/10t9 brown R2 RC R8 NI0/10· 1 NI0/10-2 Fused function Starter Wiper motor Power windows (With code (V43) Power windows) Blower motor Front fog lamps (wllh code (V07) Front fog l;Jmps (FFO)) Righi side light Left side light EGA {ARF) swrtchover vilve, adjustable camshaft t1m1"9 soienoPcl', pressure regulator valve Cvlinder I to 3 fuel inledion valve PS4. 15-3035-06 NI0/10 P-54.15-3041-06 Fuse rating In ampel'H (A) 15 25 20 25 10 7.5 7.5 125 7.5
N10I10f12¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 265 · Applies to: 450, 451
12 N10I10f12 red Starter-alternator control unit (N129) (on mO<lel 451.38/48), cockpit switch panel, 10 combination switch, tum signal indicator, data link connec-tor. automated manual transmission control unit (N15/6), instrument cluster (A1), additional instruments. ATA inclination sensor, rain sensor / light sensor (with code (V54) rain/ light sensor) 13 N10/10f13 vacant 14 N10/10f14 blue Charge air fan motor (on engine 132.930), refrig;,rant compressor (with code 15 (101) Air conditioning Plus) 15 N10/10f15 blue Radio (with code (C57) Smart radio 9 or code (C50) Smart radio 10). subwoofer 15 (with code (C22) Sound pacl<age (FFO)}, Interior lamp 16 NI 0/10f16 vacant 17 N10/10f17 blue Rear .. end door wiper motor {on model 451.3) 15 18 N10/10!18 red Restraint systems control unit (N2/7). Instrument cluster (A 1). ESP control untt 10 (N47-5). Steering assist control untt (N68) (with code (V26) Power steering, EPS (FFO)) 19 N10/t0f19 brown ME-SFI (ME) control unit (N3I1 OJ, automated manual transmission control unit 7.5 (N15/6), starter-allernalor control unit (N129) (on model 451.38148), data link connector 20 N10/10f20 red Air conditioning (with code (101) Air conditioning Plus), window washer fluid 10 pump, outside mirror adjustment (with code (V21) Electrically adjustable and heated outside mirror (FFO)), radio (with code (C57) smart radio 9 or code (C50) smart radio 10), seat heater (with code (S1 7) Seat heater (FFO}}, electronic selector lever module control untt (N1515) ~1 NI 0/10121 blue Cigaret(e lighter (with code (132) Smoking set) 15 22 N10/10f22 brown Left low beam 7.5 23 INI0/10123 brown Right low beam 7.5 24 Nt 0/10124 blue Brake light, rear fog light relay (wtth code (V54) Rain/ light sensor) 15 Q5 Nl 0/10125 brown R.ighl main beam 7.5 Q6 NI 0/10126 brown Left main beam 7.5 ~7 Nt 0/10127 brown ME-SFI (ME] control unit (N3110) 7.5 28 N10/10f28 orange Rear window defroster 40 Q9 N10/10f29 o,een Soft top (with model 451.4) 30 '3o N10/10f30 orange Automated manual transmission control unit (N15/6) 40 31 N10/10f31 Yellow Horn, central locking 20 32 N10/10f32 - vacant 33 N10/10f33 red Ignition/starter switch 50 34 N10/10f34 Orange ESP control uritt (N47-5) 40 35 N10110f35 green Steering assist control unit (N68) (wijh code (V26) Power steering, EPS (FFO)) 30 RI light brown Mirror heater (with code (V21) Electrically adjustable and heated outside mirror 5 (FFO)) R2 blue Fuel pump 15 R3 - vacant - R4 - vacant RS - vacant - R6 - red Electrical components of rear luggage carrier (with code (E14) Basic carrier) 10 R7 - vacan t - RS - vacant R9 Yellow Seat heater (with code (S1 7) Seat heater (FFO)) 20
999cc Fuse Block¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 266 · Applies to: 450, 451
31 30 s 17 18 19 20 21 22 23 24 25 26 27 29 s 28 s s 11 12 13 14 15 16 C C 5 6 7 8 9 10 C 1 2 3 4 C C S = Switched Line C = Constent Line 32 ~3 34 35
GF00.19-P-2000-21MCU¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 267 · Applies to: 450, 451
Location and asslgnment of ground points - rear end
Excerpt¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 268 · Applies to: 450, 451
- --·····-·- - - --····--- -----·---·---··-··-··- -- -
Ground Designation Compo-nent Designation Conn- point ector. Pin W6 Ground (left wheelhouse in luggage compartment) - E3 Left taillamp 5 - E19/1 Left license plate lamp 1 - M14/7 Rear-end door CL [ZV] motor 1 Not convertible - S15 Remote trunk opening switch 2 Convertible - S17/8 Trunk lid rotary tumbler microswitch 2 - S88/9 tailgate handle switch 2 - T1/1 Cylinder 1 ignition coil 3 - T1/2 Cylinder 2 ignition coil 3 - T1/3 Cylinder 3 ignition coil 3 Not convertible (connector 2) - X18/19 Trunk lid connector 2 Convertible (connector 1) - X23/7 Soft top connector 4 W7 Ground (right wheelhouse in luggage compartment) - E4 Right taillamp 2 - M3/3 Fuel pump with fuel tank sensor 4 - N3/10 ME-SFI [ME) control unit 1.58 - N3/10 ME-SFI (ME) control unit 1.59 -, S12 Par1<ing brake indicator switch 2 .... W11/7 Ground (tank neck) Seat heater - X28/5 Front passenger seat heated cushion connector 2 -► X55/4 Front passenger seat connector block 4
GF00.19-P-2000-29MCU¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 269 · Applies to: 450, 451
Location and assignment of ground points- left footwell
Ground¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 270 · Applies to: 450, 451
Designation Compo-nent Designation Conn- point ector. Pin W9 Ground (left front. at lamp unit) ➔ A1 Instrument cluster 1.2 - A15x1 Additional instruments connector 3 ➔ A45x1 Clock spring contact and airbag connector 7 Raini1ight sensor ➔ 838 Rain sensori1ight sensor 3 -> E15/4 Front interior lamp 3 - N10/10 SAM control unit 10.1 ... N10/10 SAM control unit 2.5 Seat heater - N25/5 Front HS (SIH] control unit 2 - N49 Steering angle sensor 3 - N57/2 Power window convenience feature control unit 1.4 ➔ S4 Combination switch 10 ➔ S4/4 Right wiper switch 1.9 W14 Left floor interior compartment ground - B24/15 Tum rate and lateral acceleration sensor 1 Sound system, LHD .... H4/29 Subwoofer 7 ➔ N15/6 Automated manual transmission control unit R.2 ➔ N15/6 Automated manual transmission control unit R.4 Seat heater, LHD ➔ X28/4 Driver seat heated cushion connector 2 W30/2 Ground; power steering pump noise suppression Power steering ➔ Z20ll3 Shielding connector sleeve
GF00.19-P-2000-28MCU¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 271 · Applies to: 450, 451
Location and assignment of ground points- right footwell
Ground¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 272 · Applies to: 450, 451
Designation Compo-nent Designation Conn- point ector. Pin W10 Ground (battery) AT A with siren - 832 Microwave sensor 3 - G1 Battery 2 AT A with siren - H3/2 Alarm siren with inclination sensor 2 - N15/5 Electronic selector lever module control unit 3 - N23 Heater/AC operating unit 1.7 -+ N47-5 ESP control unit 1 - N47-5 ESP control unit 4 - N66 TPM (RDK] control unit 2 - S6/1 Cockpit switch group 3 - S9/1 stop lamp switch 1 Convertible - S84 Power soft top switch 1 - X58/1 Interior socket 1 W26 Ground (transmission tunnel) - A2/1 smart radio 9 A.8 - A2/2 smart radio 10 A.8 - N2/7 Restraint systems control unit A.1 - X11/4 Data link connector 4 -+ X11/4 Data link connector 5 - X85/10 Heating or air conditioning connector 1
GF00.19-P-2000--02MCU¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 273 · Applies to: 450, 451
Location and assignment of ground points. engine compartment, right
Ground¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 274 · Applies to: 450, 451
Designation Compo-oent Designation Conn- point ector. Pin W11 Ground (engine) -+ W11/5 Ground ( engine/bocty) W11/5 Ground (engine/body) -+ M33 Secondary air injection pump 2 - W11 C,rn11nrf IP.nninP.\
GF00.19--P-2000-27MCU¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 275 · Applies to: 450, 451
Ground point Designation Location and assignment of ground points, right rear wheelhouse W11/7 Ground (tank neck) Compo-nent Designation P00.19-3932-06 Conn- ector. Pin - W7 Ground (right wheelhouse in luggage compartment)
GF00.19-P-2000-30MCU¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 276 · Applies to: 450, 451
Location and assignment of ground points - left firewall
Ground¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 277 · Applies to: 450, 451
Designation Compo-nent Designation Conn- point ector. Pin W43 Ground (outside left fire wall) - E1 Left front headlamp unit 1 ..... E1 Left front headlamp unit 5 - E2 Right front headlamp unit 1 - E2 Right front headlamp unit 5 Foglights - E5/1 Left front fog lamp 2 Foglights - E5/2 Right fog lamp 2 .... E6/13 Left side tight 2 .... E6/14 Right side light 2 - E22/1 Left additional tum signal lamp 1 ..... E22/2 Right additional turn signal lamp 1 ..... H2 Hom 1 .... M4/2 Coolant fan motor B .... M6/1 Wiper motor 1 .... N68 Steering assist control unit 1.1 ..... S11 Brake fluid indicator switch 2 .... X35/1 Left door separation point A1
X35/2 Right door separation point A1 - -- Pn\41,:;,r c: :tPP.rinn ... 7~"1[11 ~bi,:.lrljnn rnon,1:1,rfnr c:;(,::a,p.\Jp =
&pans/011 c/1p¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 278 · Applies to: 450, 451
21.8.07 1 &pans/011 c/1p 2 Cover 3 Center boll 4 Crankshaft bell pulley P01.00-2995-06 R4 Sparlc plugs ~I..,] Removelln$tall &Danger! Risk of death caused by vehicle slipping or Align vehi<:le between columns of vehicle lift AS00.00-l-0010-0lA toppling off the liftlng platform. and position four support plates at vehicle lift suppon points specified by vehlcle manufacttJrer. 1 Lift vehicle using the vehiae lift. until the rear wheels can be turned freely 2 Remove expansion dips (1) and remove oover(2) • Kemove $1)8rlt p,ugs \K4) ~AP Replace sparlt plugs AP1510-P-1580MCC 4 Lead a suaable hose through the spark plug threaded hole fn the respedive cytlnder and 1um engine at the center bott (3) or the crankshaft belt pulley (4) in the diredion or engine rotation until the piston stands at the bottom dead center of the cylinder to be
BB00.40-P-0229--0SA¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 279 · Applies to: 450, 451
Mulllgrade engine oils (Sheet 229.5) Product name OW-30 OW-40 5W-30 IAddinol Super power MV 0537 X !ALPINE Long!~e SAE 5W-30 X IALJ'INE RSOW30 X ""'I SuperSynlh X JAra! SuperTronlc G X IAvlatlcon Unique OC 5W/30 X BP Visco 7000 GM X BP Visco 7000 M X ICaslrol OCu I uPUP X Castro! Edge OW-30 X astrol Edge OW-40 X K:astrol Formula SlX X K:astrot Formula SlX longTec X C&strol SlX Longtec OW-30 X "astro! SlX Professional Longtec OW-30 X Castro! SLX Professional Long Tee OW-40 X Castro! Synlec OW-30 European Formula X Cepsa Star Mega Syntetic OW30 X Chevron Supreme Synthetic Motot 011 Owinol SYNTHOlight MB SAE 5W-30 X Elf Excellium OW-30 X Elf Excellium 229.5 5W-30 X Ell Exceu,um Full Tech OW-30 X EUROLUB Multitec M SW/30 X Ina First 600 OW-30 X otmulaShell Ultra AB X Fuchs TrTAN Supersyn Longfife SAE X 15W-30 IG,Jax Sy,,tee, SAE SW-30 X i<,alp Formula XLO, SAE 5W-40 Gulf Avan\garde K SW-30 X Gulf Fotmula Ex,treme OW-30 X Gulf Formula GX, SAE 5W-30 X lgol Process Compact P X INA Futura MB X ll,abo M8229.5 X IM&(cedes-Benz passenge, car $Y,,thelic X 1&ngine oil sheet 229.5 !Midland Cryplo 5W-30 X IMOOi 1 OW-40 X IMOb" 1 Aretlc OW-40 X Mobil I Formula C OW-40 X Mobil 1 Fo,mula M 5W-30 X Mobil I Fotmula M 5W-40 Mobil I New Life OW-40 X Mobil 1 TurbO Diesel OW-40 X MODI! SHC Formula MB 5W-30 X MOtOrex Profile M-XL 5W-30 X "'°tul 8100X-rnax 5W-30 ~ul Specific MB 229.5 5W-30 X l()JS Econ~Ventas OM Extra CNV30 X 10MV BIXXOL special BM X IUMV 1\111 syn MB X Panolin Exclusive BO X Pennzoil Platinum European Fonnula X Uhra Pentospeed OW-30 vs· X 5W-40 X X X X For use In vehicles/engines refer to Sheel223.2 Customer. town/country St>eel229.5 BBOO 40-P-022~2A !Addinol Lube Oil GmbH, Leuna, Germany Mitan MineralOI GmbH, Ankum. Germany Mitan Mine.ralOI GmbH, Ankum, Germany IAtal AktiengesellscllaJt, Hamburg, Gem1<1ny 1Ata1Akt~llsd1aft, Hamburg, Gem1<1ny Finke Mineralotwefk GmbH. VissethOvede./Germany BP pJ,c., London/Great Britain BP p.l.c., Londoo/Great Britain 11.,aslrol Limile<I, GB Rea<IJng RG6 ,,....,..,real Brlialn Castrol Umtted, GB Reading RG8 7QR/Greal Brilaln Castrol Limited, GB Reading RG8 7QR/Great Brilain Casltol Limited, GB Readu,g RG8 7QR/Great Britail1 Cas1tol Limited, GB Reading RG8 7QR/Great Britain Castro! Limited, GB Reading RG8 7QR/Great Britain C.strol Limited, GB Reading RG8 7QR/Great Britain Castro! Limited, GB Reading RG8 7QR/Great Britain !Castro! Limited, GB Reading RG8 70R/Great Britain Cepsa Lubrlcantes, SA, Madrid, Spain !Chevron Global Lubricants, Ghent/ZWijnaarde/Belgium IZeuer+Gmelin GmbH & Co. KG, Eislingen/Geml<lny Total Lubrifiants. Paris la Oefense Cedex. France Tot.al Lubtlflants. Paris la Defense Cedex. France Total Luoonants, Pa.ns la Oeiense Cedex. France Hunold Scllmlerstolfe GmbH, Eching, Ge,many ITolal Lubliflants. Pans la Defense Cedex, France Shell lntemational Petroleum Company. LCH'ldonlGreat Bfitajn Fuchs Petrolub AG, Mannheim, Gennany Ralinerija Na~e 000 Beograd, Belgrade/Serbia Peltogal S.A .• Lisbon. Portugal S.A. Espanola de Lubrificantes, Madrid. Spain S.A. Espanola de Lubrfficantes, Madrid, Spain Gulf oa tntemational, London, England lgol France, Amiens • Cedex/France INA Ralinerija na~e Rijeka, Rijeka/Croatia Fuchs Labo Auto S.A.. Ruei~Matmaison, France Daimler AG, Stuttgart/Germany Oel-Brack AG, Hunzensehwil. Switzerland Exxon MobO COfJ)Oralloo, Fairfax, Virginia, USA Exxon Mobil COfJ)Ofatlon, Fairfax, Virginia, USA Exxon Mobil COfJ)Oration, Fairfax, Virginia, USA Exxon Mobil CO<Potalion, Fairfax, Virginia, USA Exxon Mobil Corporation, Fairla., Virginia, USA Exxon Mobil Corpo,ation, Faimlx, Virginia, USA Exxon Mobil Corporation, Fairfax, Virginia, USA Exxon Mobil Corporation. Fairfax. Virginia, USA Bucller AG Langenthal, LangentMVSWittertand Motul, Aubervilliers/France Motul, Aubervilllers/France Oelwefke Julius :,cnindler GmbH, Hamburg, Gennany OMV Refining & Marl<eting GmbH. Vienna, Austria OMV Refining & Marl<eUng GmbH, Vienna, Auslria Panolin AG, Madetswil, SWitterland Pennzoil.Quaker Stale Canada Company, Burlinglon, Ontario/ Canada Deutsche Pentosin-Werl<e GmbH, Wedel, Germany I I I I I I
Ravenol HCL 5W-30¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 280 · Applies to: 450, 451
X Ravensberger Schmierstoffvertrieb GmbH, Werther, Germany REPSOL ELITE COMMON RAIL 5W30 X Repsol YPF Lubricantes Especialidades, S.A., Mostoles - Madrid/ Spain Shell Helix Diesel Ultra X X X Shell lntemational Petroleum Company, London/Great Britain Shell Helix Ultec X Shell lntemational Petroleum Company, London/Great Britain Shell Helix Ultra X X X Shell lntemational Petroleum Company, London/Great Britain Shell Helix Ultra AB X Shell lntemational Petroleum Company, London/Great Britain Shell Helix Ultra Extra Polar X Shell lntemational Petroleum Company, London/Great Britain Statoil LazerWay B 5W-30 X Svenska Statoil AB, Stockholm, Sweden !Texaco Havoline Synthetic Motor Oil X Chevron Global Lubricants, Ghent/Zwijnaarde/Belgium IT or Synthetic LL X De Oliebron, Zwijndrecht/Netherlands Total Activa Energy 9000 0W-30 X Total Lubrifiants, Paris la Defense Cedex, France Total Quartz 229.5 5W-30 X Total Lubrifiants, Paris la Defense Cedex, France Total Quartz Energy 9000 0W-30 X Total Lubrifiants, Paris la Defense Cedex, France Valvoline SynPower HST X The Valvoline Company, Lexington, Kentucky, USA Valvoline SynPower MXL X The Valvoline Company, Lexington, Kentucky, USA Veritas Syntolube 0W-40 X Oelwerke Julius Schindler GmbH, Hamburg, Germany Wintershall ViVA 1 Longlife X SRS Schmierstoffe Vertrieb GmbH, Salzbergen, Germany Yacco VX 1600 X Yacco SAS, Saint-Pierre-les-Elbuf/France
S'-'1 on model 451.!131 w1th Of19{ne¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 281 · Applies to: 450, 451
132.t and cod4I (101) air condltloniOIJ Plus
Expansion clip
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Restraint systems control unit, component description¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 284 · Applies to: 450, 451
22.8.07 N217 Restraint systems control unit Location The restraint systems control un~ is in tile center on tile underside of the cockpit crossmember. Task The restraint systems control unit is used to control the suppfiemental restraint system.If an accident occurs. the restraint systems control unit specifically deploys the restraint units. This Includes the airbag units and the emergency tensioning retractor units. The restraint systems control unit has self.monitoring and fault monitoring features. Frontal. side-on and rear-end collislons and a rollover along lhe longitudinal vehicle axis are detected and differentiated. Scope of tasks • Sell-test and continliOus monitoring of supplemental restraint system • Storage of faults that have occurred • Status signanng lo the instrument cluster (A 1) • Fault output via the diagnosis communication Direct entries • Circuit31 • Cireult30 • Tml. 15 • Driver head/thoraxbag sensor • Front passenger head/thoraxbag sensor P1l1.60-3378-0S • Capacitor for the event of a batte,y disconnectJon In the event of a collision • Power supply for - Driver head/thoraxbag sensor (A53) (with code (153) Headlthoraxbag) -Front passenger head/thora.><bag sensor (A54) (wtth code (153) Head/thoraxbag) • Evaluation of integrated sensor • Accident detection and ignition time determination • Activation of tile -left emergency tensioning retractor squib (R12/1) - Right emergency tensioning retractor squib (R1212) - Driver airbag squib 1 (R12/13) - Front passenger airbag squib 1 (R1214) - Driver head/thoraxbag squib (R12/20) (with code (153) Head/thoraxbag) -Front passenger head/thoral<bag squib (R12/21) (with code (153) Head/thoraxbag) • Storing of non-votatfle crash telegrams Direct outpuls • Front passenger airbag squib 1 • Driver airbag Ignition squib 1 • Driver head/thora)(bag squib • Front passenger hea<l/\horaxbag squib • Left emergency tensioning retractor squib • Right emergency tensioning retractor squlb
Expansion clip¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 285 · Applies to: 450, 451
10.3.08 Expansion clip 2 Belt drive cover P13.22•2145-11 P13.22°2149-07 3 Belt tensioner 5 Poly-V•belt 7 Coolant pump bolt pulley 4 Screw 6 nmlng case coYer 8 Bott& Modification notes p3o8 !Removal of COOiant pump belt pulley Inserted !Steps 6, 7, 9. I~ Remove &oanger1 Risk of death caused by vehicle slipping or Align ve!ilcle between columns of vehlc:le lift ASOO.OO·Z.0010-01 A toppling off ol th• lilllng platform. and pos~lon four support plates at vehicle lift suppart points specified by vehicle manufacturer. 1 Raise vehicle with vehicle lift 2 Remove expansion dips (1) and ta Ke otf lhe bell dnve cover (2) 13 Counterhold bell tensioner (3) with an opei, IW Unscrew bolt (4) only unbl the stud end wrench as shown, loosen boll (4) and (arrow A) or lhe belt tensiooer (3) is exposed carefully loosen belt tensioner (3) from timing ~om the timing case cover (6). case cover (6) using a suitable saewdriver ~ Ralax lhe belt tensioner (3) by twisting lhe open end wrench $ Remove paly-V belt (5) " Counterhold coolant pump belt pulley (7) and 100 •451559000900 unsaew bolts (8) ~ '451589004000 [I) Counterllolder must be adapled lo lhe version. Angle grinder hllr>:l/oobs aftorsales.daomlerch""'ler com ii3'WF Countemolder WF58 50-P•2850-05MCC
Place poly-V belt (5) on the alternator belt¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 286 · Applies to: 450, 451
8 Place poly-V belt (5) on the alternator belt W Note the installation position of poty-V pulley and pass around the crankshaft belt bell (5). pulley ~ Mount the coolant pump belt pulley (7) and W Note the installation position of poly-V fasten with b<>lts (8) belt(S). [3'.I • 451589000900 ~ '451589004000 ~ 'BA20.10•P- l001-01J 10 Tighten belt tensioner (3) In the direction of ~) Installation: Ensure that the stud (arrow tile arrow up to the att.achment (arrow C), A) gets lod<ed In the bore i.n the timing case using an open end wrench as shown, and cover (6) properly. otherwise, the timing tighten bolt (4) case cover (6) can be damaged. 8 'BA13.2S-P-1001-01V 11 Place belt drive cover (2) and install expansion clips (1) 12 Lower vehicle with vehicle lift ~ Belttensloning device Number Designation Model '451,3801 480 with engine 132.9 BA13.25,P,1001-01V Bolt of belt tensioner to timing case cover Nm 45 ~ Coolant pump, coolant thermostat Number Designation Engine 132.9 8A20.10.P-1001-01J Belt pulley on coolant pump Nm 10 f ' ' ~ ~ '- 4515890040 00 / .. 451 589 00 09 00 / Coontemok:ler $()di.el wrend1
Component description for the SAM control unit¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 287 · Applies to: 450, 451
22.8.07 N10/10 SAM control unit Location The SAM control unh Is localed In the driver footwell Task The SAM control untt suppl>es control units and electrical components with voltage via r.mil switclles. The lndMdual control units and electrical compcnents are fused vi,i the fuse and relay bl«l<s conlained in the SAM control unll The SAM control untt controls the lollowfng functions; • Drive authorization • Central loddng • Ex.terior lighting • Interior lighting • Wiper system • Rear window defroster • Heated outside mirror (with code (V21) Electrically S<ljustable and heated outside minor (FFO)) • And-theft alarm system (with code (VOi) Anti-theft alarm system (FFO)) • Soft top (on model 451.4) Requests are cooveyed to the SAM control unit via data bus s-,.ste-ms or via read--in switehes and sensors. The SAM control untt Is a subscriber on the Controller Are.I Networ1< (data bus/CAN bus) (CAN). Cornpcnents read In d,cectly: • Transmll\er key • Transpcnder ooll(ll 1) • Wiper motor (M6/1) • Rear-end door wiper motor (M6/4) (on model 451.3) • Heated rear window switch (N23s1) • lgnttlonlstart01 switch ($2/1) • Combination switch (S4) • Fanfare horns switcll (S412) (except code (175) Leather sport steering wheel incl. steecing wheel rod<er switcll system) • Right wiper switch (54/4) • Hazard flasher switch (S6/1s1) • Rear fog !,imp switcll (S6/1s7) (with COde (V54) rain/ llghl sensor) • Front fog lamp switch (S611s8) (with code (V07) Front log tamp (FFO)) The lollowfng eompcnents are actuated directly to carry out the functions: • Refrigerant compressor (A9) (wfth code (101) Air condilioni119 P54. 1~17.03 The lollowlng compcnents ace read In to control the functions: Via local interconnect networ1< interior 1 (UN B): • Rain sensor/ light sensor (B38) (wfth code (V54) Rain/light sensor) • Tact,ometer(A15p4) (with code (V31) Cockpit clock and cachorneter package) \Ila local Interconnect networ1< Interior 2 (LIN C): • Alarm siren with lnciination sensor (H3/2) (With COde (V01) Vehicle theft alarm (FFO)) • Microwave senSOI (832) (with code (V01) Vehicle theft ai,i1m (FFO)) • Tow.-away protection /Interior protectlon swttch (S611s10) (with code (V01) Vehicle theft 8.larm (FFO)) • Inside unlocl< Cl (ZV) switch (S611 s11) • Inside loci< CL (ZV) switch (S6/1s12) • Step light switch (S9/1) • Remote trunk epening switch (S15) (on model 451.3) • Trunk lid rotary tumbler mlcroswitch (S17/8) (on model 451.4) • Soft top ope,ation (S84) (on model451.4) • Solt top mlcroswitch (S84/37) (on model 451.4) • Left roof cassette microswitch (S84/38) (on model 451.4) • Right roof cassette microswitch (584/40) (on model 451 A) • Right door rotary tumbler microswitch (S8716) • Left door rotary tumbler microswilch (S87/7) • Right rear soft tOP mlcroswitch (584/39) (on model 451.4) • Left rear soft top microswitch (S84141) (on model 451.4) • Tailgate handle switch (S8819) • Left rear log light (E3e5) (on left-hand drive vehicle) • Right taillamp (E4) • Right tum signal lights (E4e1)
Left front lamp unit (E1)¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 288 · Applies to: 450, 451
• Left front lamp unit (E1) - Left high beam (E1e1) - Left low beam (E1e2) - Left turn signal lights (E1e5) - Left standing lights (E6/13) • Right front lamp unit (E2) - Right high beam (E2e1) - Right low beam (E2e2) - Right turn signal lights (E2e5) - Right standing lights (E6/14) • Left taillamp (E3) - Left tum signal lights (E3e1) • Left taillight (E3e2) • Left brake light (E3e4) • Fuel pump relay (1<27) • Open soft top relay (K66/1) (model 451.4) • Close soft top relay (K66/2) (model 451.4) • Rear fog light relay (K87/1) (with code (V54) rain/ light sensor) • Blower motor (M2) • Fuel pump with fuel gauge sensor (M3/3) • Wiper motor (M6/1) • Rear-end door wiper motor (M6/4) (model 451.3) • Electrical soft top motor (M12/6) (model 451.4) • Left soft top drive (M12/7) (model 451.4) - ~,gnc ca1111gnr \C.4eLJ • Right brake light (E4e4) • Right rear fog light (E4e5) (on right-hand drive vehicle) • Left front fog lamp (E5/1) (with code (V07) front fog lamp (FFO)) • Right front fog lamp (E5/2) (with code (V07) Front fog lamp (FFO)) • Front interior lamp (E15/4) • Left license plate lamp (E 19/1) • Right license plate lamp (E19/2) • Center high-mounted stop lamp (E21) • Left auxiliary turn signal lamp (E22/1) • Right auxiliary turn signal lamp (E22/2) • Horn (H2) • Right soft top drive (M12/8) (model 451 .4) • Right door CL motor (M14/5) • Left front door central locking motor (M14/6) • Rear-end door CL [ZVJ motor (M14/7) • Fuel filler flap CL [ZVJ motor (M14/10) • Mirror heater (M21/1 r1) (with code (V21) Electrically adjustable and heated outside mirror (FFO)) • Mirror heater (M21/2r1) (with code (V21) Electrically adjustable and heated outside mirror (FFO)) • Charge air fan motor (M44) (except engine 132.910) • Heated rear window (R1)
Intake umshaft¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 289 · Applies to: 450, 451
21.8.07
Intake umshaft
2
Exhaust camshaft
POS.30-2155-11
,l,.;I
Removing
,
Remove cylinder head cover
r.rAR
Remove, instaQ cylinder head cover
AR01 20-P-501.WCC
,!
Deta<:11 right rear wheel
I-TAR
Remove/install W'heels
AR•0 10-P•IIOOMCC
~
Che<:klng
~
Tum engine into the TDC PoSitk>n
I-TAR
Tum engine into tile TOC posttion
AR0l 10-P-l~IMCC
14
Lower vehicle with lining plauonn
IS
Cheel< whether the valves of the 1st cylinder
are relieved of toad. if necessary continue
turning engine o.ne revolution in direction of
engine rotation at the central bolt of the
cranksllaft pulley
~
Chedt valve clearance of the Intake valves ol W It must be possible to insert the feeler
the 1st and 2nd cylinder as well as the
gauge making smooth contact all round
exhaust valves of the 1st and 3rd cylinder
between the cam of the Intake camshaft (1)
or exhaust camshaft (2) and the valve tappe~
if necessary determine and note the
deviation.
Inlet valve
"BE05,30-P• I 001-06C
OuUetvalve
"BE05.3o-P-1002-06C
7
Continue turning englne at the center bolt of
the crankshaft belt l)
ENGINE¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 291 · Applies to: 450, 451
10.1.07 n ENGINE 132.9 in MODEL 451.33 /43 G2 Altemator Location The alternator is located on the suction side on the right on the engine. Task The poly-V belt driven alternator delivers sufficient energy for all rotational speeds which occur while driving to the on-board electrical system and thus secures the on-board electrical system power supply and charging of the battery (G1). Design The alternator Is designed as an alternator with integral regulation. Conttol Regulation of the alternator lakes place by integral eleclronics depending on the rotational speed and on-board power supply voltage. The alternator is, for engine 660.9. connected via a local interconnect network COi (LIN A) with tile COi control untt (N319) and for engine 132.9 directly wtth tile ME-SFI [ME] control unii (N3/10). Functional principle Voltage generation in the alternator is based on the principle of ir'lduclion. If a magnetic field changes In a conducting loop (coil or winding) an eledrical voltage is induced ln tile conducting loop. P15 40-2Mi6-03 If a coil is traversed by a rotating, magnetic field wtth a north and south pole a sinusoidal alternating voltage is generated. The AC voltage is rectified by diodes. One differentiates for the alternator between three electric circuits: Pre~xclta11on power circuit The pre-excitation power circuit builds up the magnetic field in the excttation coil. Once the engine slllrts the altemator excites ttself. If the excitation current is flowing the alternator charge monitoring and warning lamp (A 1e5) in the Instrument cluster (A 1) switches off. Excitation power circuit The excitation current builds up the magneUc freld in the excitation coll of tile rotor. Charge power circuit The charge power circuit supplies the on--0oard electrical system wtth electrical energy.
Code¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 292 · Applies to: 450, 451
Designation Cable colors Cable colors Noles M21/1x1 Left electrically adjustable and heated exterior mirror connector 1 )-BKBU 2 BN 3
- VTBK LHD 3 -VT RL 4 )- BKVT 5
- BUSK LHD 5
- su RL M21/2x1 Right electrically adjustable and heated exterior mirror connector 1 )-BKBU 2 -BN 3 )-VT LHD 3 )-VTBK RL 4 )- BKVT 5 -su LHD 5 ) - BUBK RL
X35/1¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 293 · Applies to: 450, 451
Left door separation point BN - A1
-BN Not UK GY - A1 -BN UK GYYE- A2 )-GYYE Not UK GY- A2 )-GYYE UK YEWH - A3 >- YEWH LHD YEWH- A3 -YEBK RHO, not UK GY- A3 -YEBK UK PK - A4 >- PK Not UK GY- A4 >-PK UK WHGN - AS )-WHGN Not UK GY- AS )-WHGN UK GN - A6 )-GN BNGN- A7 -BNGN WH - 81 -WH LHD WH - B1 -WHBK RL BKYE- 82 >-BKYE LHD GYBU - 83 )-GYBU PKBU- 84 >-PKBU LHD PKBU - B4 >-vreu RL PKWH- 85 >-PKWH LHD PKWH - 85 >-VTWH RL GY- 86 )-BUBK UK WHYE - 87 WHYE LHD YE - 88 )-YE LHD YE- 88 )-YEBK RL 8KBU - C1 -BKBU BKGY- C2 -BKGY LHD BU - C3 ) - BU VT- C4 >-vr BKVT- cs ) - BKVT
X3S/2¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 294 · Applies to: 450, 451
Right door separation point BN - A1 )- BN Not UK GY - A1
--BN UK GYYE- A2 ) - GYYE Not UK GY - A2 )- GYYE UK YEBK - A3 YEBK LHD YEBK - A3 -- YEWH RHO, not UK GY - A3 )- YEWH UK PK - A4 -PK Not UK GY - A4 )-PK UK GY - AS --WHGN UK orange - A6 )- OG BNOG - A7 )-BNOG WHBK - B1 -- WHBK LHD WHBK - B1 -WH RL BKYE- B2 )- SKYE RL GYBU - B3 )- GYBU VTBU - B4 >-- VTBU LHD VTBU- B4 --PKBU RL VTWH - BS -- VTWH LHD VTWH - BS --PKWH RL GY- B6 BUSK UK WHYE - B7 --WHYE RL YEBK - B8 )-YEBK LHD YEBK - B8 >- YE RL BKBU - C1 --BKBU BKGY - C2 --BKGY RL BU - C3 ) - BU VT- C4 )- VT BKY.I~.Qg_~
ENGINE¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 295 · Applies to: 450, 451
10.1.07 .m ENGINE 132.9 in MODEL 451.33 /43 G2 A/temator Location The alternator is located on the suction side on the right on the engine. Task The poly-V bell driven altemator delivers sufficient energy for all rotational speeds which occur whi\e-driving to the on-board electrical system and thus secures the on-board electrical system powerstrpply and charging ofthe battery (G1). Design The alternator is designed as an alternator with integral regulation. Control Regulation of the altemator takes place by Integral electronics depending on the rotational speed and on-board power supply voltage. The alternator is, for engine 660.9, connected via a local intecconnect network CDI (LIN A) with the COi control unit (N319) and for engine 132.9 directly with tile ME-SFI {ME] oontrol unit (N3/10). Functional principle Voltage generation In tile alternator is based on the principle of iriduction. If a magnetic field changes in a conducting loop {coil or winding) an electrical voltage is induced in the conducting loop. P15.40-2-46~03 If a coil is traversed by a rotating, magnetic field with a north and south poJe a sinusoidal alternating voltage is generated. The AC voltage is rectified by diodes. One d"ifferentiates for the alternator between three electric c-ireults: PrEM>xcitation power circuit The pllHlxcitation power circuit builds up the magnetic field in the excitation coil. Once the engine starts the alternator excites itself. If ttle excitation current is flowing the alternator charge monitoring and warning lamp (A 1e5) in the instfument cluster (A 1) switches off. Excitation pow&r circuit The excitation current builds up the magnetic field in the excitation coil of the rotor Charge power circuit The charge power circuit supplies the on-board electrical system wltll electrical energy.
AR01.40-P.S000-01MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 296 · Applies to: 450, 451
Bolt plan for timing case cover A BoltM6 x 25 B BoltM6 x 35 C BoltM6 x 55 D BoltM6 x 65 E Bolt MB x 30 F Bolt MB x 55 G Bolt MB x 65
AR01.00-P-2420-01 MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 298 · Applies to: 450, 451
Detaching/attaching engine wirtng harness on engine Disconnect electrical connector (2) on ad)ustable camshaft liming solenoid (Y 49) 2 Remove electrical coMectors (3) at Injection valves 3 Disconnect electrical connector (4) at camshaft Hall sensor (B6/1) 7 Disconnect electrical connector (9) on pressure regulator valve (Y74} and electrical connector (10) on charge air Ian motor (M44). III For engine 132.930. 8 Lay engine wirtng harness (1) lo the front and fix to a suhabte point using a cable tie. 9 Connect in reverse order. POl .00-.2913-06 4 Unclip holder (5) for engine wiring harness (1) from mounts at cylinder head cover (6). 5 Open retaining clamps (7) using a suitable screwdriver and expose engine wiring harness (1). 6 Unlock connector for 02 sensor upstream of lWC (G312x1 J using a suhable screwdriver at mount on holder (8) and take off.
OIi fiiter¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 299 · Applies to: 450, 451
21.8.07 OIi fiiter 2 OIi drain screw 3 OIi filktr neck cap k>I Removing w Chango Ille engine oil only when the engine is at operating temperature M Remove engine compartment cover ~ AR Remove/install 1nterioc compartment flap AR88.40-P-1100-03MCC above engine 12 Unscrew oil filler neck cap (3) I& Danger! Risk of death caused by vehi-Cle slipping or Align vehicle between columns of vehlcle lift ASOO.OO-Z-0010-0IA loWling off of Ille li1\ing platform and posllion fo<Jr support plates at vehicle lift support points specified by ""hlcle manufacturer. 13 Rajse vehieie with vehicle lift 14 Remove oil drain screw (2) and remove seal ring on U1e oil drain screw (2) IW Coiled englno oil in a suitable container. 5 Remove filter screen on the oil drain screw (2) aoo clean 16 Unscrew oil fitter (1) 119'I •454589060900 llt.,J ln9tall ~ Tighten oil filter (1) IW Replace oil fitter (1), Wet sealing ring of oll filter (1) with engine oll, !3 •BA 18.20-P-1002-0IN ~ "454589060900 8 Position new seal ting on the oil drafn screw (2) 19 lnsef1 filte< screen on Ille od drain scr,rw (2) and Ughten oU drain scr,rw (2) I!!! "BAO! .45-P-1003-01J 10 Lower vehicle with rtftin_g plalfomi 11 Pour in engine oil rttJ "BF18.00-P•1001-01N 12 Tighten oil filler necl< cap (3) & Danger! Ri$k of accident caused by \/ellicle starting secure vehicie to prevent ,t from mo\llng by ASOO 00-Z-0005-0tA off by itself when eng,ne is run.nlng. Risk of itself. Injury caused by contusions aoo bums Wear closed aoo snug-fitting work Clothes. during starting p,ocedure 0< when working Do not touch hot or roultlng parts, near the engine as tt tS running 13 Conduct engine test run and check engine fot leaks whilst - Is running 14 Check engine oil level by means of oil I® The fill level must Ile between "Min." and dipstlek ·Max.* otherwise the engine may be ··-
Number¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 300 · Applies to: 450, 451
BA01.45-P-1003-01J ~Oil filter Number 8At8.20-P-1002-01N Remove/install interior compartment flap above engine Designation Oil drain screw to oil pan Designation Oil filter to timing case cover IIJ Capacities of engine lubrication system Number Designation 8F18,00-P-t 001-01N Engine oil Filling capacity (oll and filter change) Specifications for Operating Fluids 454 589 06 09 00 Wrench socket AR88.40-P-1100-03MCC Engine 132.9 Nm 65 Engine 132.9 Nm 14 Engine 132.9 litetS 3,3 Sheet - Sheet Sheet Shee1 Sheet Sheet BBOO.◄0-P-0229-05 A ShOOt
Dipstick¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 301 · Applies to: 450, 451
21.8.07 Dipstick 2 OIi fitter cover !Id Removal w Change lhe engine oil only when lhe Oflgine 1$ at operating temperature , Remove engine c:ompartmen1 cover ~ AR Remove/install interiof oompartment flap AR88 40-P•I 100-03MCC above engine 2 PUii oil dipsUCk (1) out of oil dipsticl< guide lube 3 Unwew cap for oil filler opening 14 ISUdiOn off engine 011 I® Only insen the oil extraction p,obe when the engine is not running otherwise there is a risk of conislon wilh 11\e crankshal. ~ ·450589286300 15 Insert oil dipsliek (I) in lhe oil dlpsliek guide lube ILl:I Da~r! Risk of death caused by vehicle sl,pping or Align vehicle between columns cf vehicle lirt ASOO OO-Z-0010-01A loppOng off of Ille lifting platform. and posttlon four supPOrt plales at vehicle Oft support poinls specified by vehicle manufacturer. 16 Raise vehicle with vehk:le 1111 7 Unscrew oil fitter cover (2) and remove od filler element I<,! Install 18 Serew on oil filter cover (2) W Replace seal ring and oil filter element Coal seal ring wilh engine o" . The torque value is on lhe oil filter cover (2). " Lowe, vehicle with lifting platfonn 10 Pour in engine or! 11:!l "8F18 oo-P-1001-0lN 11 Screw on cap lot o~ filler opening I& oangert Risk of accident caused by vehicle starting Sealre vehicle to prevent a Item moving by ASOO OO-Z-000>01A off by itse~wt>en engine Is running. Risk of itself. Injury cau,ed by contusions and b-ums Wear Closed and snug-fitting wor1' clothes. during starting procedure o, when worl<ing Do not touch hot or t013tlng parts. near the engine as it i& running 12 Conduct engine test run and cheek engine for teaks whil$1 it is running 13 Cheek engine o,I level by means of oil I~ The oH level must be within Ille area dipstick marl<ed on the oil dlpslld< otherwise there Is the threal of engine damage, [I] Lei engine run for approx. 1 minu1". then
~~AR¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 302 · Applies to: 450, 451
Remove/install interior compartment flap above engine = Capacities of engine lubrication system Number Designation BFt8.00-P-1001--01N Engine oil Filling capacity (oil and filter change} Specifications for Operating Fluids 450 589 28 63 00 Oil suction sensor AR88.40-P-1 100-03MCC Engine 660.950 Liters 2,7 Sheet . Sheet . Sheet . Sheet - Sheet . Sheet BB00 40-P-0229--05 A Sheet BB00.40-P-0229-31 A
BE01.00-P-1000-01 G¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 303 · Applies to: 450, 451
Compression pressure Engine 122, 132, 134, 135, 639,660 Check values for compreMion pressure Number Designation Engine Engine Engine Engine 122 132.910 132.930 134 BE01 .OO-P-1001-0l G Compression pressure new value bar 12.1 15 14 13,2 BED1 .00-P-1002-01G Compression pressure wear limit or limit value bar - 8,3 =11 ~ 10 ~9 BED1.D0-P-100l-01G Compression pressure: permissible difference between bar s0.98 - - s 0.98 individual cylinders Check values for compression pressure Number Designation Engine Engine Engine Engine 135.930 135.950 639 660.940 c=18.5 BE01.00-P-1001-01G Compression pressure new value bar 14.3 15.5 18 18.5 8E01.00-P-1002-01G Compression pressure wear limit or limit value bar - 10 - 11 =10.5 - BE01.00-P-1003-01G Compression pressure: permissible difference between bar s:0.98 s 0.98 s 2.5 - individual cylinders Check values for compression pressure Number Designation Engine 660.950 c~19 8E01.00-P-1001-01 G Compression pressure new value bar 28 BE01.00•P•1002-01G Compression pressure wear limit or limit value bar 18 BE0l.00-P-1003-01 G Compression pressure: permissible difference between bar 3 individual cylinders
AR01 .10-P-1000-01 MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 304 · Applies to: 450, 451
Turn engine into the top dead center position Release expansion clips (1) and remove V-belt cover (2) 2 Transfer marking (arrow A) on the crankshaft belt pulley (3) using a suitable colored pencil to the front side. [I] Turn engine at center bolt (4) for crankshaft belt pulley (3) in direction of engine rotation if necessary. 3 Turn engine in direction of engine rotation until marking (arrow A) on crankshaft belt pulley (3) coincides with the TDC marking (arrow B) on the timing case cover (5). P01.10-2900-06 4 Position V-belt cover (2) and install expansion clip (1). [I] If no further turning of the engine is required.
&pans/011 c/1p¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 305 · Applies to: 450, 451
21.8.07 1 &pans/011 c/1p 2 Cover 3 Center boll 4 Crankshaft bell pulley P01.00-2995-06 R4 Sparlc plugs ~I..,] Removelln$tall &Danger! Risk of death caused by vehicle slipping or Align vehi<:le between columns of vehicle lift AS00.00-l-0010-0lA toppling off the liftlng platform. and position four support plates at vehicle lift suppon points specified by vehlcle manufacttJrer. 1 Lift vehicle using the vehiae lift. until the rear wheels can be turned freely 2 Remove expansion dips (1) and remove oover(2) • Kemove $1)8rlt p,ugs \K4) ~AP Replace sparlt plugs AP1510-P-1580MCC 4 Lead a suaable hose through the spark plug threaded hole fn the respedive cytlnder and 1um engine at the center bott (3) or the crankshaft belt pulley (4) in the diredion or engine rotation until the piston stands at the bottom dead center of the cylinder to be
BB00.40-P-0229--0SA¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 306 · Applies to: 450, 451
Mulllgrade engine oils (Sheet 229.5) Product name OW-30 OW-40 5W-30 IAddinol Super power MV 0537 X !ALPINE Long!~e SAE 5W-30 X IALJ'INE RSOW30 X ""'I SuperSynlh X JAra! SuperTronlc G X IAvlatlcon Unique OC 5W/30 X BP Visco 7000 GM X BP Visco 7000 M X ICaslrol OCu I uPUP X Castro! Edge OW-30 X astrol Edge OW-40 X K:astrol Formula SlX X K:astrot Formula SlX longTec X C&strol SlX Longtec OW-30 X "astro! SlX Professional Longtec OW-30 X Castro! SLX Professional Long Tee OW-40 X Castro! Synlec OW-30 European Formula X Cepsa Star Mega Syntetic OW30 X Chevron Supreme Synthetic Motot 011 Owinol SYNTHOlight MB SAE 5W-30 X Elf Excellium OW-30 X Elf Excellium 229.5 5W-30 X Ell Exceu,um Full Tech OW-30 X EUROLUB Multitec M SW/30 X Ina First 600 OW-30 X otmulaShell Ultra AB X Fuchs TrTAN Supersyn Longfife SAE X 15W-30 IG,Jax Sy,,tee, SAE SW-30 X i<,alp Formula XLO, SAE 5W-40 Gulf Avan\garde K SW-30 X Gulf Fotmula Ex,treme OW-30 X Gulf Formula GX, SAE 5W-30 X lgol Process Compact P X INA Futura MB X ll,abo M8229.5 X IM&(cedes-Benz passenge, car $Y,,thelic X 1&ngine oil sheet 229.5 !Midland Cryplo 5W-30 X IMOOi 1 OW-40 X IMOb" 1 Aretlc OW-40 X Mobil I Formula C OW-40 X Mobil 1 Fo,mula M 5W-30 X Mobil I Fotmula M 5W-40 Mobil I New Life OW-40 X Mobil 1 TurbO Diesel OW-40 X MODI! SHC Formula MB 5W-30 X MOtOrex Profile M-XL 5W-30 X "'°tul 8100X-rnax 5W-30 ~ul Specific MB 229.5 5W-30 X l()JS Econ~Ventas OM Extra CNV30 X 10MV BIXXOL special BM X IUMV 1\111 syn MB X Panolin Exclusive BO X Pennzoil Platinum European Fonnula X Uhra Pentospeed OW-30 vs· X 5W-40 X X X X For use In vehicles/engines refer to Sheel223.2 Customer. town/country St>eel229.5 BBOO 40-P-022~2A !Addinol Lube Oil GmbH, Leuna, Germany Mitan MineralOI GmbH, Ankum. Germany Mitan Mine.ralOI GmbH, Ankum, Germany IAtal AktiengesellscllaJt, Hamburg, Gem1<1ny 1Ata1Akt~llsd1aft, Hamburg, Gem1<1ny Finke Mineralotwefk GmbH. VissethOvede./Germany BP pJ,c., London/Great Britain BP p.l.c., Londoo/Great Britain 11.,aslrol Limile<I, GB Rea<IJng RG6 ,,....,..,real Brlialn Castrol Umtted, GB Reading RG8 7QR/Greal Brilaln Castrol Limited, GB Reading RG8 7QR/Great Brilain Casltol Limited, GB Readu,g RG8 7QR/Great Britail1 Cas1tol Limited, GB Reading RG8 7QR/Great Britain Castro! Limited, GB Reading RG8 7QR/Great Britain C.strol Limited, GB Reading RG8 7QR/Great Britain Castro! Limited, GB Reading RG8 7QR/Great Britain !Castro! Limited, GB Reading RG8 70R/Great Britain Cepsa Lubrlcantes, SA, Madrid, Spain !Chevron Global Lubricants, Ghent/ZWijnaarde/Belgium IZeuer+Gmelin GmbH & Co. KG, Eislingen/Geml<lny Total Lubrifiants. Paris la Oefense Cedex. France Tot.al Lubtlflants. Paris la Defense Cedex. France Total Luoonants, Pa.ns la Oeiense Cedex. France Hunold Scllmlerstolfe GmbH, Eching, Ge,many ITolal Lubliflants. Pans la Defense Cedex, France Shell lntemational Petroleum Company. LCH'ldonlGreat Bfitajn Fuchs Petrolub AG, Mannheim, Gennany Ralinerija Na~e 000 Beograd, Belgrade/Serbia Peltogal S.A .• Lisbon. Portugal S.A. Espanola de Lubrificantes, Madrid. Spain S.A. Espanola de Lubrfficantes, Madrid, Spain Gulf oa tntemational, London, England lgol France, Amiens • Cedex/France INA Ralinerija na~e Rijeka, Rijeka/Croatia Fuchs Labo Auto S.A.. Ruei~Matmaison, France Daimler AG, Stuttgart/Germany Oel-Brack AG, Hunzensehwil. Switzerland Exxon MobO COfJ)Oralloo, Fairfax, Virginia, USA Exxon Mobil COfJ)Ofatlon, Fairfax, Virginia, USA Exxon Mobil COfJ)Oration, Fairfax, Virginia, USA Exxon Mobil CO<Potalion, Fairfax, Virginia, USA Exxon Mobil Corporation, Fairla., Virginia, USA Exxon Mobil Corpo,ation, Faimlx, Virginia, USA Exxon Mobil Corporation, Fairfax, Virginia, USA Exxon Mobil Corporation. Fairfax. Virginia, USA Bucller AG Langenthal, LangentMVSWittertand Motul, Aubervilliers/France Motul, Aubervilllers/France Oelwefke Julius :,cnindler GmbH, Hamburg, Gennany OMV Refining & Marl<eting GmbH. Vienna, Austria OMV Refining & Marl<eUng GmbH, Vienna, Auslria Panolin AG, Madetswil, SWitterland Pennzoil.Quaker Stale Canada Company, Burlinglon, Ontario/ Canada Deutsche Pentosin-Werl<e GmbH, Wedel, Germany I I I I I I
Ravenol HCL 5W-30¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 307 · Applies to: 450, 451
X Ravensberger Schmierstoffvertrieb GmbH, Werther, Germany REPSOL ELITE COMMON RAIL 5W30 X Repsol YPF Lubricantes Especialidades, S.A., Mostoles - Madrid/ Spain Shell Helix Diesel Ultra X X X Shell lntemational Petroleum Company, London/Great Britain Shell Helix Ultec X Shell lntemational Petroleum Company, London/Great Britain Shell Helix Ultra X X X Shell lntemational Petroleum Company, London/Great Britain Shell Helix Ultra AB X Shell lntemational Petroleum Company, London/Great Britain Shell Helix Ultra Extra Polar X Shell lntemational Petroleum Company, London/Great Britain Statoil LazerWay B 5W-30 X Svenska Statoil AB, Stockholm, Sweden !Texaco Havoline Synthetic Motor Oil X Chevron Global Lubricants, Ghent/Zwijnaarde/Belgium IT or Synthetic LL X De Oliebron, Zwijndrecht/Netherlands Total Activa Energy 9000 0W-30 X Total Lubrifiants, Paris la Defense Cedex, France Total Quartz 229.5 5W-30 X Total Lubrifiants, Paris la Defense Cedex, France Total Quartz Energy 9000 0W-30 X Total Lubrifiants, Paris la Defense Cedex, France Valvoline SynPower HST X The Valvoline Company, Lexington, Kentucky, USA Valvoline SynPower MXL X The Valvoline Company, Lexington, Kentucky, USA Veritas Syntolube 0W-40 X Oelwerke Julius Schindler GmbH, Hamburg, Germany Wintershall ViVA 1 Longlife X SRS Schmierstoffe Vertrieb GmbH, Salzbergen, Germany Yacco VX 1600 X Yacco SAS, Saint-Pierre-les-Elbuf/France
S'-'1 on model 451.!131 w1th Of19{ne¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 308 · Applies to: 450, 451
132.t and cod4I (101) air condltloniOIJ Plus
Expansion clip
2
Pin
J
eov.r
4
Poly.V-ofrolrlgorMt
.,(with code (101) Air
conditioning PIii$}
S
Poly-V•be/1
8
CMtor bolt
~p,olll0$
A
N-po/)'-V
8
W- to /Jang: Poly-V,,,. pointed
(n-: trapa,otd-1)
C
Cord• are vi.$lble a, tht base of
1M po/)'-V (Hglltw points).
D
Trannwsecnda-.llNl>adr
E
Poly-V_from_ofthe
21.8.07
i i ·• i
po/)'-V _
(.,,}
F
Fraying of outer corchl
G
Corri tom out at tht t/dt
H
Ttansverse cracl
Expansion clip¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 311 · Applies to: 450, 451
10.3.08 Expansion clip 2 Belt drive cover P13.22•2145-11 P13.22°2149-07 3 Belt tensioner 5 Poly-V•belt 7 Coolant pump bolt pulley 4 Screw 6 nmlng case coYer 8 Bott& Modification notes p3o8 !Removal of COOiant pump belt pulley Inserted !Steps 6, 7, 9. I~ Remove &oanger1 Risk of death caused by vehicle slipping or Align ve!ilcle between columns of vehlc:le lift ASOO.OO·Z.0010-01 A toppling off ol th• lilllng platform. and pos~lon four support plates at vehicle lift suppart points specified by vehicle manufacturer. 1 Raise vehicle with vehicle lift 2 Remove expansion dips (1) and ta Ke otf lhe bell dnve cover (2) 13 Counterhold bell tensioner (3) with an opei, IW Unscrew bolt (4) only unbl the stud end wrench as shown, loosen boll (4) and (arrow A) or lhe belt tensiooer (3) is exposed carefully loosen belt tensioner (3) from timing ~om the timing case cover (6). case cover (6) using a suitable saewdriver ~ Ralax lhe belt tensioner (3) by twisting lhe open end wrench $ Remove paly-V belt (5) " Counterhold coolant pump belt pulley (7) and 100 •451559000900 unsaew bolts (8) ~ '451589004000 [I) Counterllolder must be adapled lo lhe version. Angle grinder hllr>:l/oobs aftorsales.daomlerch""'ler com ii3'WF Countemolder WF58 50-P•2850-05MCC
Place poly-V belt (5) on the alternator belt¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 312 · Applies to: 450, 451
8 Place poly-V belt (5) on the alternator belt W Note the installation position of poty-V pulley and pass around the crankshaft belt bell (5). pulley ~ Mount the coolant pump belt pulley (7) and W Note the installation position of poly-V fasten with b<>lts (8) belt(S). [3'.I • 451589000900 ~ '451589004000 ~ 'BA20.10•P- l001-01J 10 Tighten belt tensioner (3) In the direction of ~) Installation: Ensure that the stud (arrow tile arrow up to the att.achment (arrow C), A) gets lod<ed In the bore i.n the timing case using an open end wrench as shown, and cover (6) properly. otherwise, the timing tighten bolt (4) case cover (6) can be damaged. 8 'BA13.2S-P-1001-01V 11 Place belt drive cover (2) and install expansion clips (1) 12 Lower vehicle with vehicle lift ~ Belttensloning device Number Designation Model '451,3801 480 with engine 132.9 BA13.25,P,1001-01V Bolt of belt tensioner to timing case cover Nm 45 ~ Coolant pump, coolant thermostat Number Designation Engine 132.9 8A20.10.P-1001-01J Belt pulley on coolant pump Nm 10 f ' ' ~ ~ '- 4515890040 00 / .. 451 589 00 09 00 / Coontemok:ler $()di.el wrend1
Intake umshaft¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 313 · Applies to: 450, 451
21.8.07
Intake umshaft
2
Exhaust camshaft
POS.30-2155-11
,l,.;I
Removing
,
Remove cylinder head cover
r.rAR
Remove, instaQ cylinder head cover
AR01 20-P-501.WCC
,!
Deta<:11 right rear wheel
I-TAR
Remove/install W'heels
AR•0 10-P•IIOOMCC
~
Che<:klng
~
Tum engine into the TDC PoSitk>n
I-TAR
Tum engine into tile TOC posttion
AR0l 10-P-l~IMCC
14
Lower vehicle with lining plauonn
IS
Cheel< whether the valves of the 1st cylinder
are relieved of toad. if necessary continue
turning engine o.ne revolution in direction of
engine rotation at the central bolt of the
cranksllaft pulley
~
Chedt valve clearance of the Intake valves ol W It must be possible to insert the feeler
the 1st and 2nd cylinder as well as the
gauge making smooth contact all round
exhaust valves of the 1st and 3rd cylinder
between the cam of the Intake camshaft (1)
or exhaust camshaft (2) and the valve tappe~
if necessary determine and note the
deviation.
Inlet valve
"BE05,30-P• I 001-06C
OuUetvalve
"BE05.3o-P-1002-06C
7
Continue turning englne at the center bolt of
the crankshaft belt l)
ENGINE¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 315 · Applies to: 450, 451
10.1.07 n ENGINE 132.9 in MODEL 451.33 /43 G2 Altemator Location The alternator is located on the suction side on the right on the engine. Task The poly-V belt driven alternator delivers sufficient energy for all rotational speeds which occur while driving to the on-board electrical system and thus secures the on-board electrical system power supply and charging of the battery (G1). Design The alternator Is designed as an alternator with integral regulation. Conttol Regulation of the alternator lakes place by integral eleclronics depending on the rotational speed and on-board power supply voltage. The alternator is, for engine 660.9. connected via a local interconnect network COi (LIN A) with tile COi control untt (N319) and for engine 132.9 directly wtth tile ME-SFI [ME] control unii (N3/10). Functional principle Voltage generation in the alternator is based on the principle of ir'lduclion. If a magnetic field changes In a conducting loop (coil or winding) an eledrical voltage is induced ln tile conducting loop. P15 40-2Mi6-03 If a coil is traversed by a rotating, magnetic field wtth a north and south pole a sinusoidal alternating voltage is generated. The AC voltage is rectified by diodes. One differentiates for the alternator between three electric circuits: Pre~xclta11on power circuit The pre-excitation power circuit builds up the magnetic field in the excttation coil. Once the engine slllrts the altemator excites ttself. If the excitation current is flowing the alternator charge monitoring and warning lamp (A 1e5) in the Instrument cluster (A 1) switches off. Excitation power circuit The excitation current builds up the magneUc freld in the excitation coll of tile rotor. Charge power circuit The charge power circuit supplies the on--0oard electrical system wtth electrical energy.
Overall network (GVN) function¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 316 · Applies to: 450, 451
A 1
Instrument cluster
Af~
Tachomelftr
(for code (V31) Coc.l<plt clock
and tachometer package
824115
Tum rate and lateral
ttCCeleraUon sensor
B32
Microwave sensor
(for code (V01) An/I-theft
a/8rm system (FFO)J
838
Rain sensor/light sensor (for
code (V!U) Rain/light sensor)
895
Battery sensor
/for rn<XHI '51.38148)
G2
Generator (with engine 6$().9/
H3/2
Alarm signal siren with Incl/nation sensor (for
code (V01) Anti-theft alarm system (FFO)I
N2fl
R&stralnt systems control unit
N319
CD/ control unit (witfl engine 66Q.9/
NJ/10
ME-SF/ {ME] control unit (With engine 132.9)
N10M0
SAM control un/1
N1412
Glow output st_ (on engine 66Q.9)
N1516
Automated manual transmission control unit
N23
Heater/air conditioning operating unit
/for code (/01) Air conditioning Plus)
N47-5
ESP control unit
N49
Steering angle sensor
N68
Steering assist control unit
/(or code (V26) Power steering, EPS (FFO)J
Data bus systems
The following data bus SY$tems are Involved in !he overall nelWOtk:
•
Controller Area NelWOrl< (data bus/CAN bus) (CAN)
•
1.0c81 Interconnect NelWOtk (LIN)
CAN
When transferring data, Ille connected comJ)Onen1s are not
addressed. but rather the content of a message (e.g. rpm or engine
temperature) is marl
GF00.19-P-0001-01MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 318 · Applies to: 450, 451
Overall network (GVN), location of components A15p4 838 A1 N-49 • ' ,--: .· N23 X11/4 - A 1 Instrument cluster A15p4 Tachometer (with code (V31) Ccclcpit clock and tachometer package) 824115 Tum rate and lateral acceleration sensor 832 Microwave sensor (with code (V01) Ant/theft a/am, system (FFO)) 838 Rain sensor/tight sensor (for code (V54) Rain/tight sensor) 895 Battel}' sensor (with model 451.38/48) G2 Generator (with engine 660.9) H3/2 Alam, siren with inclination simsor (for code (V01) Ant/- theft ala.rm system (FFO)) N2/1 Restraint systems control unit N3/9 CD/ conlrof unit (with engine 660.9) N3/10 ME-SF/ (ME] control unit (for engine 132.9) N10/10 SAM control unit N1412 Glow output stage (on engine 660.9) P00.19-4313-09 N15/6 Automated manual transmission control unit N23 Heater/air conditioning operating unit (for code (101) Air conditioning Plus) N47-5 ESP control unit N49 Steering angle sensor N68 Steering assist control unit (for code (V26) Power steering, EPS (FFO)) N129 Starter-alternator control unit (w1th model 451.38/48) X11/4 Data link connector
22JS,07¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 319 · Applies to: 450, 451
Temperature preseloction slider
mrett
N23
HHWIAC op,,-Ung unit
Pl3.40-S?e&-07
N23$2 Air conditioning ,witch
2
Air dfstribution fOtaty awltch
H23b1 Interior temperature sensor
N2l$1 Healed rNrwlndow switch
N23$3 Afr reeircu.latlon switch
S98/1
Blower switch
Loc:adon
The heater/AC operaoog unit is located in lhe center console.
TIM hotter/AC operating unit permits She following operations:
•
SMtming 1he air e:ondiboning &)'$tern on end off
•
Interior tempe,atu,e se)edion cokttwarm
•
Ma.null blower oontrot
•
ManuaJ air cf'ISttibutlon
• Recirculated air mode
• DefrO&tfunctlo<I
• Re., window heater
n,. heator/AC openJtlng unit reads In the foUowfng sensor
slgnal5:
• Direct:
• Interior temperature sensor
(lntog,ated In heater/AC oporoting uni!)
- E~porator tcrnperatute sensor (B 1016)
• 81encS arr ft.Ip actuator
•
'{1a C~N:
• Outside temperature via the instrument cluster (A 1 )
~ Coolant temperature -Aa the COi control unit
(with engine 660.9) or via the ME-sFI (ME] oontJOI unft (N3/I0)
(..;it! engine 132.9)
Air dlsttfbulion rotary s-wftch
The air cflstributlon rotary $witch is used to adjust which aJr outlet
no,zles Ille air supplied by the blower mota< (M2) Is routed throogh
hito the interior.
For U.S purpose. 12 position$ of the air ctl$tribution rotery .switch
are available, which are a.rre.ng,ed in the following 3 main directions.
• Oe~t wind.s.hlold
• Footwell
•
Pas.s.e~er compartment
[I) If the air dislributlon rotary $Witch is turned to "Oofmt
wlnclsNeld'"'. the automatic air condilloning is &W!lehed on
automatically without lhll being ind'aeated by tho ltght-emirting diode
In the air cond~ning switch. As long as the air d.lstrlbutfon rotary
swttch is in this position, the automatic
Temperature preS<tlectJon slider¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 320 · Applies to: 450, 451
22.8.07
1
Temperature preS
order to close the air recirculation flap. When the air recirculation¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 321 · Applies to: 450, 451
flap is closed, air supply from the outside is prevented. The LED in the air recirculation switch lights up during operation. Blower switch The 4-stage blower switch is used to define the intensity of the air the blower motor delivers into the vehicle interior. unit, which energizes the heated rear window (R1). Simultaneously, the LED in the rear window heater switch is switched on. If the heated rear window switch is pressed again, the actuation of the heated rear window is terminated.
Engine cooling system • check fluid level, adjust to correct level. Inspect¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 322 · Applies to: 450, 451
1 cap Engine cooling system • check fluid level, adjust to correct level. Inspect anticorr0$ion/antifreeze protection, adjust to correct concentration 2 Expansion reservo;, ~ Removal I& Danger! Risk of Injury to skin and eyes caused by Do not open cootjng system unless coolant scalding from cont8ct with hot coolant Sl)ray, temperature is below 90"C. Open cap slowly Risk of poisoning ca~ by swallowing and re-tease the pressure. Oo not pour coolanL coolant into beverage containers.. Wear protective gloves, protective clolhfng and safety glasses. 1 Remove m.ajntenance ftap 12 Tum cooling system cap (1) on the engine radiator (2) a haff tum CO<JnterclockWise. relieve the pte»ure and then unscrew the COOiing system cap (1) 11!:!1 I Check 3 Check corrosion/antifreeze in eootant and 11.it.J enter tn the maintenance $heet ~BB Coolant speciflcatfons Sheet 310.1 ~ BB Anticom,$ion/anlilr-e agents (Sheet 32.5.0 Sheet 325.0 If necessa,y: t Correct lhe coolant composition. - subjed to separate repair order, Replace coolant Engine 132.9 Engine 660.9 ® Notes on coolant 14 Chedt coolant leffl In the expansion W The engine coolant level at coolant reservoir (2) and oorreet if necessary expansion reservoir (2) must be positioned at the max. marking. ~ BB COOiant specifications Sheet 310.1 i;;i'"BB Anlieorrosion/anlilreeze agents (Sheet 325.0) Sheol 325.0 In the event or fluid Joss not caused by consumption or wflen the COOiant circuit has been opened, the coolant system must be checked for leaks. • subject to separate ,epair ocder. r.---A R lnspeel cooling system for teaks Engine 660.9 Engine 132.9 ® Notes on cool.ant i<;J Install 5 Seal expansion reservoir (2) witl1 cap (1) 25.1.07 P20.00-2327•11 AS20 OO-UI001.01A "450589012100 8800 40.P.0310.01.0. 8800 40-P.0325-00A AP2.0.00-P-2080MCC AP20 0O.P-2080MCO AH20 OQ.N-2080.01.0. 8800 40.P.0310.QIA 8800 40.P.0325-00A AR20OQ.P-1010MCC AH20 OQ.N•2080.01A
IBB00.40-P-0310-01A¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 323 · Applies to: 450, 451
jCoolanl speciflC81ioOS
Note: Th<lse regulations apply to the Mercedes-Sen,, Mayt,a<:h and
smart brancts.
1. Coolant
1.1 CoolantcomposttJon
1.1.1 Passenger car and comtnercjaJ vehlcte engfnes (normal
case)
50 vol.-% Water
50 vot.•% AnticoNOSionlantif~• agents ($80 Sheet 325.0 or
325.2. 325.3) antifroe,e protection down to approx.
.37 •c
Pre..mlxed p<od·ucts rn aceotdance with Sheets 326.x can also be
used.
1.1.2 Commercial vehicle engines (without antifreeze
opecificaUon)
Blend of water and coo'ant acklitive in aocordance with Sheet
312.0. forpresaibed mixture ratio refer to Slleet 312.0.
Scope:
With oonslant ambient temperatures above
free
Total chlorides and sulfat .. :¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 324 · Applies to: 450, 451
max.160mgn
If k1 doubt, contact Daimler AG, ~nment EPIMOR (operating
fluids), C 405, 0-70546 SMtgall, Germany.
1.3 Premixed coolant
Several provide!$ have water with premixed coolant In their produd
range. Provided lhey are approved (see below), lhey can also be
used; lhe regulations relating to al'l)lieation, comPQsltlon, c,,ange
lnte,vats, etc. or these coolant specifications also apply. ll is
Imperative !hat lhe correct aoocentration (50/50) is used in lhelr
application and, of cou~. ru.rther dilution Is not permitted I
Approval status:
COolants ror aJI vehicle and engffles
Sheet 326.0
Coolants for commercial vehrcle
and iOOustrial engines
(Basis 32.5.2)
Sheet 326.2
Coolants f<X OOf'l\merclal vehfcie
and industrial engines
(Basis 325.3)
Sheet 326.3
(Basis 325.0)
2. Coolant additives (General lnfonnaUon)
Nonnally, coolant consists of water and antieorroslonlantifreeze
agen~ The antlcorrosloNantttreeze .agents (ethylene gl'ycol with
eorrosions inhibil0l$) in the cooling system have
to fulfill, among olher lhings. tile following functions:
-
to provide sufficient corrosion and cavitation ptotection tot
aJI cooling system components
freezing point depression (anllfreeze)
-
ineteaslng bolling poJnt
Fo< corrosion protection purposes lhe coolant
approx. 50 vol.-% Antieorrosionlant~ze agents are added if the
expected ambient temperatures do not require an even higher
concentration. This conoentratlon
(50 vol%) offers frost protection up to approx. -37 •c. A higher
concentration is onty nece,ssary if the ambient temperatures are
even lower.
Even with extremely k>w ambient temperatures. not more than 55
vol.-% antioorrosion/antifreeze agent should be used, because at
this tevel the max'amum a.ntifreeze protection is reached and a
greater conoentratlon reduees the antifreeze protection again alld
d~ases the heat dissipation (55 vol.•% corresponds to antifreeze
protection down to approx. -45 •C).
2.1
Anticorroslon/antlfreeze agent for pasaenger..car engines
Alongside the com,ct constitution ol lhe coo~ng water (POlnt 1.2.2),
care must be taken to ensure that only anUcorrosion/antifreeze
agents as approved !Of all engines In aceottlance with Sheet 325.0
ar.e u$ed. These p,oducts serve to guarantee that, in particular. an
effective protection against corrosion Is provided for all light-altoy
pallS in the cooling system end tlley are also specified for all
passenger-car engines..
The regulations for each respective Sheet 325.x. are to be
tr.1nsferred correspondingly to Sheet 326.x.
At the time of compiling these regulations it is pcssible that not all
the Sheets 326.x are represented wilh approved products,
Should these coolant 1119ulaUons fall to be obS
outside temperatures this is al$o important In terms of raising the¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 325 · Applies to: 450, 451
boiting point. In the event that these regulations are not observed
the cooling system may S\Jffer from damage by corrosion. As a
consequence of OOITO$lon deposits there is a danger that dud.$ l:n
lhe radiators (engine overheating) and heal exeh.lrigers (poo< heat
O<Jlpul) get plugged up thus causing damage to lhe engine.
As a result of the optimizations we have carried out on the system
of enginelcootantlcooting system, in the majority of our newer
passenger cars, a replacement of coolant is not ne<:e$$ary until
reaching 15 operating years 0< 250,000 km (whichever comes first),
This may not apply to some models: in these cases the
maintenance b<>OJ(let will stipulate another regulation.
2.3 Coolant addltJves for commercial-vehlcle engines without
an-z• specifications (Nlferto Item 1.1.2)
(not: BR 600. BR 100 and BR 200)
In those app(jcation cases where no antjfreeze Is necessary,
coolant for commercial-vehicle engt.nes as under rtem 1.1.2 can be
mixed to suit. It is itnpossible to cite genen10zed ml~ proponions
because the application eoneentrallon$ of p,odudll included in
Sheet 312.0 may bedifferenL If the tolerances exceed or "'11 belOw
lhose given in Sheet 312.0, lhen appropriate adjustments must be
made. The eoolanrs bolling point is only insignificantly increased by
lh&se addaives- The •ta rung-off water underlies lhe m0<0 atringenl
regulations as under point 1.2.3. The usage period for this coolant
i:s shorter than usual (see position 3). If it is necessary to refill, the
same product must be used and at the same concentration Jevel.
The blending of differenl plOdudll ls not pennitled as •tated In
Sheet 312.0.
3. Monitoring coota_nt operation
It is very important to monitC>f' the ooolant constantly if ttie engine is
to run trouble free.
The concentration level should be checked f!/Very $ix months.
The lnspeclio/l should be conducted with suitable apparatus. tf,
when monitoring the concentration of the ooolant. it is determined
that the concentration of anticorrosionlantifreeze agent has reached
40 vol.% or less or an an1ifreexe p,otectlon of -28 •c is no longer
guaranteed. the ooncenttatlon musl be inaeased to the reguJatk>n
filling of 50 vol.% (-37 "CJ. When topping up (after coolant loss), an
antlcorrosicwantifreez.e a.gent content in lhe coolant of at least 50
vol % (antifreeze protection down to .J7 •c) must be ensured. or
the concentration regulations according 10 point 2.312.4.1 must be
ob$et\'ed. In dosing an example is given In Overview Section 5.
& Non observance of these regulations or the use of non
4
approved products will result in serious damage.
Products that are not listed in Sheets 325.0 and 326.0, or 325.2
and 326.2, or 325.3 and 326.3 are not approved and are 1heref0
The coolants are blologicallY.,egradable material.¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 326 · Applies to: 450, 451
All statutory regulations or waste water regulations in each Individual countty with regard to the disposal of used coolant must be observed. It is recommended to have the possibilities available for disposing of materials explained by the local responsible water authorities. 5. Ov&n1iew Which coolant additive, what change interval for which engines? Passenger cars engin,s Sheet No. Engine series M100/M200 OM600 325.0 or 326.0 • • Commercial vehicles engines !Sheet No. CurrenUy In Germany methods are being compiled tor the purification of used coolanL The separate collection of all used operating fluids is highly recommended. However. as a consequence of the complex tasks aSked of a modem 0001.ant. it is on no account advisable to use an improperly "recycled" coolanL which has only undergone a mechanical pre- purification process. Change interval years/km 15/250.000 [I] Whichever occurs first must be observed; Exception: in the vehicle's maintenance booklet.shorter change intervals are stipulated EI\Qlne series Change interval Years OM300 OM457/460 OM400 OM500 OM900 311.0 • 312.0 • 325.0 or 326.0 • 325.2 or 326.2 • 325.3 or 326,3 • Calculation of the antifreeze quantity to be r&fillad with a concentration that is too low (specified: 50 vol. %) • • • • Coolant capacity (total) = I ··············"'\ers I~ • • • • • • • • • Measured concentration• ~Vol , % ~ 0- ................. [dxCJ.[d· ~ - • •••••••••••••••• = c=J~ Example of calculation: Coolant capacity (total)= I ..... ll. .•..•... ~i!ers. Measured concentration-= 36 _ Vol.% -10 -14 -20 ·23 -25 •27 -30 vol 111. 20 25 30 32 35 37 40 42 0,5 • 1 • 3 • 3 • 5 Refilling quantity Antlcorroslon/antifreeze agent j ............. Ltters I This quantity should normally be drained off Refilling quantity Anticorrosionlantifreeie agent 1 ... 1,1s •••••• mars 33 35 -40 5 50
Adjust headlamps¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 328 · Applies to: 450, 451
Cap 2 Control lever Et I.ell front headlamp unit E2 Right front headlamp unit ~ ' Removal 1 I,.;neck settings 01 ""' rront ,amp unit \t:.1) and right front lamp unit (E2) ~AP Check and coned the adjustment of the UJ headlamps Adjusting headlamps When driving abroad 2 Remove left front lamp unit (E1) and right front lamp untt (E2) 3 Remove cap (1) from left front lamp untt (E1) and from right front lamp unit (E2) AdjUSl ~ Adjust left front lamp unit (E1) and right front lamp unit (E2) at adjustment lever (2) lor right-hand/left-hand trafflo (arrow) l!,;l ' lnatall ~ lnstaU cap (1) at lefl front lamp unit (E1) and at right front lamp unit (E2) 16 Install left front lamp unit (E1) and nght front lamp unit (E2) 7 Check settings of left tront lamp unit (E1) and ~AP right front lamp unit (E2) Check and correct the adjustment of the ITT headlamps AdJusting headlampe when driving ab<Oad 21.8.07 P82.10o4507-0e AP82 10.P-8260MCC AH82 IQ.P.(l()()H)IMCC AR82 1O-P-'173OMCC W Adjustment lever (2) must latch in the relevant end position. AR82 l~-'1730MCC AP82 10-P~260MCC AH8210-P.(1()()1-01MCC
AP82.10-P-8260-04MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 329 · Applies to: 450, 451
Adjust or check front fog lights Shown on vehicle with code (V07) Front fog lamps (FFO) II] The light-dark boundary must run as horizontal as possible at the height of the corresponding division mark (4), if necessary correct with the adjustment screw {arrow). 4 P82.10-0205-01 P82.10-4593-01
Check and correct the adjustment of the headlamps¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 330 · Applies to: 450, 451
Shown on vehicle with code {V07) Foglamps (FFOJ Adjustment scn,w (vertical) 2 Adjustment screw {horizontal) E1e1 Leh mitln beam E1e2 Leh low ,,...m E2e1 Right main - E2e2 Right low beam E5l1 Leh front fog lamp (with code (V07) Front fog lamps (FFO)} EM Right front fog lamp (with code (V01) Front fog lamps (FFO)) Stiow n on vehlela with BRABUS addftional headlamps Modific.etion notes 3 Additional headlamp surround ,2.08 I!!! , ii 3 14 5 6 7 "Cheek adjustmenl of daytime running lights, correct if necessa,y" added Checking Drive vehicle onto level surface. lt;orrect tire lnRation pressure Place 75 kg or one person on driver seat and set headlamp height adjustment to V Remove maintenance Rap Align the headlamp aimer with the vehlcie and perform height adjustment to the center or the headlamps Switch on lelt high beam (E1e1) and right high beam (E2e1) Check the adjustment of the left high beam Step11 W The vehicle must be in the ready-to-drive condition (curb weight, fuel tank full or corresponding additional weight). Front wheel$ in straight-ahead position. I W Observe operat()(s manual of the headlamp aimer. Headlamp aimer httn.l,....is.aft-_..... dalmiefch""'ief com 19.2.08 P82.1o.5192..07 AP'lJ l!i-l>-406tMCC AP82 IO-P-8280-02MCC
Switch on left low beam (E 1 e2) and right low¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 331 · Applies to: 450, 451
8 Switch on left low beam (E 1 e2) and right low beam (E2e2) 9 Check the adjustment of the left low beam ill If a light-dark boundary is not displayed AP82.1 0-P-8260-05MCC (E1e2) and right low beam (E2e2), if on the headlamp aimer, the cause may be necessary adjust the left low beam (E1e2) or that the left front lamp unit or right front lamp right low beam (E2e2) at the adjustment unit is converted for right-hand/ left-hand screws (1 , 2) traffic, if necessary convert the left front lamp unit or right front lamp unit. See: i ~ AR Adjust headlamps AR82.1 0-P-4735MCC 10 Switch on left front fog lamp (ES/1) and right On vehicles with code (1/07) Front foglamps AP82.1 0-P-8260-04MCC front fog lamp (ES/2) and check adjustment, (FFO) orwith BRABUS additional headlamps if necessary through the opening (arrow A) of the additional headlamp surround (3) 11 Switch on the left daytime running light and On vehicles with BRABUS additional AP82.1 O-P-8260-0BMCC right daytime running light and check headlamps adjustment, if necessary through the opening (arrow B) of 11:le surround (3) of the additional headlamp
P82.1 O-P-8260-02MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 332 · Applies to: 450, 451
Check setting of high beam IIl The center of the luminous be.am must be the corresponding central marks (6). If this is not the case: adjust high beam. i P82.10-0204-01
f P82.1 0-P-8260-0SMCC j Check low beam¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 333 · Applies to: 450, 451
(D The lighHlark boundary must be on the horizontal division marl\ (4) of the device. The kink line (5) must start below the central mark (6) on the horizontal division mark (4) and rise to the right. 6 5 P82.10-0203-01
Electrical connector¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 334 · Applies to: 450, 451
21.8.07 us 1 Electrical connector 2 Screw 3 Refrigerant 1/ne 4 Screw A9 Refrigerant compressor P83.5S--215&-08 l~l,,,J Remove/install I& Danger! IRlSk of npIoslon caused by weld Ing Of Never penonn we1eung wutl\ on or near a A!>6300-~~1~1A SOidering wor$<. on dosed air conditioning closed atr conditioning system. No smojcjng system. Risk of Poisoning caused by Ot open flames. Wear safety glasses and inhaling overtiealed refrigerant vapors Risk pcotectlve gloves. Wori< ooly in well ventilated of Injury to skin and eyes caused by contact areas. Carry out repair work on the air with liquid refrigerant. condltJonlng system circuit ooty after the system has been discharge<!. 1\21 Procedure tor a damaged°' ~aky air AH83.30-N~1A conditioning syste('n 112l Protect air conditioni('l9 circul.t and IAH8330-N-000!>-01A components from moisture when carrying oul repalrwor1< 1W Noles oo han<lling relrlge1anl R134a AH83 30-N-0003-01 A 1 Discharge air conditioning system W lnstallaUon: Evacua.te a.ir eond!Uoning AR83.30-P-t760MCC and then fill 2 Disconnect tully automatic air condrtion,ng Fully automatic air eondftioning set"Vioe service station station t,1to'.J•-... •- -•-•,ga1A-.A,:iim1--J.--1er-- ~ I Release rear ctrtve mooule IAKU1 .OO.P-3050MCU ~ Remove pofy-V bett ror refrigerant ARl3.21.P-1202MCU compressor (A9) 5 Detach electrical connector ( t) ror refrigerant compresso, (A9) "' I Remove bolls (2), ploee ,orrIgerant llnes (3) I W Close off relrlge11m1 lines (3) and to one side and remove seal rings or refrigerant compressor (A9) using appcopriat, refrigerant I,nes (3) stop plugs. as othetwise any pene,radng dirt and moisture damages components that are connected to the refrigerant circuit. [iJ Installation; Replace sealing rings at relrlgerant fines (3) and coal with compressor fluid When Inserting. 13 "BA83 5S.P-1003-01V 7 unscrew SCtews (4) from refrigerant I~ "BA83.5S.P•I001-01V compresSO< (A9) ~ •BA83 SS.P-1002-0tV
pnstall in the reverse order¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 335 · Applies to: 450, 451
110 pnstall in the reverse order 8 Refrigerant compressor Number Designation Engine 132.9 BA83.55-P-1001-01V Bolt, AC compressor to crankcase Nm 20 BA83.55-P-1002-Q1V Bolt, AC compressor to oil pan Nm 20 BA83.55-P-1003-01V Bott, refrigerant line to refrigerant Nm 20 compressor
ll.illlSJ¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 336 · Applies to: 450, 451
21.8.07 ll.illlSJ Removo/lnstall ~ Dongo,! Risk of ••-Ion -bywolding O< ,""""'"' welding -1< on or..,.,• AS8300.Z 01 '" soldemg -1< on dosed wc:ondibO<q ____ .,. No~ - Rlsk of poisoning ca..sed by or open- Wear ute,yglnses lfld inhaJlng oveffiNted refr,go~nl vapors Rls.k protectivo gloYos. Work onl)' In well venlilllecl of Injury IO •~In and eyu cauMd by <OIIIOCI areas, c.,ry OUI rep.air wotk on the eir - liquid relngeran. oond....,lng system citcull only after Ille ·---cfiscNrgod ~ -,.....,,1111JOrav.1,o-v-Of-1M ,-.., ~-OlA oond«ionor,g aysrem 1121 Protad ai, conchtionlng c.rcu11 and AH83 30-f<.0005.01A ~nta from molltUrt 'Nhen carrying OUI repaw-1< L1J -onhendlr,v~Rl3"" AH8330-k-6u,.• -01A 1 ~ .. cancfotionlng aymm IW tnstJ.ll•tJon; Evacuate air c:onditionlng AA83JO.p.116Q"4CC and then fill 2 o.cc.,,- ru.1y au,ornatlc: o,r oondilaonlng Fully outornttlc: •• oondllloning - -- - i--. J- afletl.aNls com 3 Release ,ear dnve module AROI OO-P·30~C • Remove pcly~V belt for rerrtgerant AR1321-l'-120.?MCC comoreuor (119) 5 --121---1w-., ""1-101ne- -..(3)ol~-(/lll) Mot of lhe reto,n,ng- (2) 8 Remow bolls (4, 5), p- refrige"'nt linet Ill!/ C'°" off refrigeran1 Moes (6, 7) and (6, 7) IO one •Ide and remove Mal rings of relrige18nl compresso< (/Ill) u,rr,g app,oprio14 refrivo<al,I hr,es (6. 7) ou,p~ ... --ao,,gdlrtlfld ., ____ connec:led 10 the refrigeranl orcul. III lnstallollon: Replace ... , nogs at refrigerant lints (6, 7) and coal wtth -oll-lnsenor,g 8 •BA13S5-P.1003,41V 17 Remowbob(8) 1; •BAl!J S5-P, 1001-0IV ' 8"83 55-P-1002-0I V ~ R..,,..... 11frlgeran1 oomp<essor (119) ~ Removeillle<d,ye< IW-..,. 111UOO lhe-drier- NwlJ0-1'-~ -ll>O~CIICUII 1'0 , ....... u,o.......,., 8 Refrlger.tnt corn-•0< I Numb«
Remove/install front CBS¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 337 · Applies to: 450, 451
30.11.06 PSS.00-2340-09 1 FrontCBS 4 Expansion clip 6 Bolt 2 Bolt 5 Edgeguard 7 Bolt 3 Fender cover PBS.00-2341,09 1 FrontCBS 9 Expansion clip 10 Bolt 8 LJ>ngitudinal member paneling
Removennstall seat belt buckle (front seat)¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 339 · Applies to: 450, 451
23.4.07 Driver seat P91.40-2786-07 f Seat belt buclde 3 Bolt 4 Seat belt buckle w;rlng harness 2 Backrest frame ll<il 1Remova1 I& Danger! Risk of Injury caused by backrest suddenly When working on the seat. be careM not to AS91 CJO.Z-0005-0IV folding foiward if release lever is accidentally accidentally release lhe backrest mechanism operated during inspection and repai1 work allowing the seal to fold rorward. Keep body parts dear or the backrest travel area. 1 Remove seat AR91.10-P• 1 OOOMCC 12 Check routing of wiring harness for seat belt IW If the wiring harness for the seat beft buckle (4) buckle (4) ls routed as shown m picture A. then Ille seat belt buckle (1) and the backrest fnlme (2) must be replaced and the wiring harness fo, the seat bell buckle (4) routed as shown in picture B. 3 Rem°"" buckle (1 ) When Ille wiring harness for the seat bell AR91 •O-P•1515-01MCC buckle (4) is routed as shown in picture A (eMy type of fastening for seal bell buckle (1)). When the wiring harness for the seat belt AR91 40-P•l515-01MCE buckle (4) is routed as shown in picture B (new type or fastening for seal be~ buckle (1)). ~ Remove backrest frame (2) When the wiring harness ror lhe seat bett AR9t 10-P-3331MCC buckle (4) ls routed as shown in picture A. ll<,J Install 5 Install backrest frame (2) When the wiring harness for the seat belt AR91 10-P-.3331MCC buckle (4) was routed as shown in picture A. ill Screw In the bolls (3) of Ille backrest frame (2) In lhe area or the seat belt buckle (1) up to the contact surface only. 16 Install bett buckle (1) AR91.40-P-1515-02MCC ~ 0BA9110-P-1002-01P ~ •BA91 40-P.1003-0IG 7 lnsta.11 seat AR91 10-P-IOOOMCC I:!!!! Front seats Number Designation Model 451.3/4 8A91~10-P-1002-01P Bott of backrest rrame 10 &eat fnlme Nm 45 ~ Seatbelts/emergency le11$ionlng retractors I Number I Designation 451 .3/4 I Model
Fw.l di$trlbutor¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 340 · Applies to: 450, 451
Engine wifing hameu
5
E./«ultal COOtteetOI#
8
Fuo/pl~
6
HosecJamp
3
Ret•lnlng cl/p
FuolhO#t
4
Rttalnlng clip
i.;ii;..
Remove/ins.tall
ILU Olinger!
Risk of e,cploslon caused by fuel lgnielng.
risk of Poisoning caused by 1nha1ing end
SW91lowing fuel and risk of Injury to eye.$
and skin causec1 by contact 'Mlh fuei
I
Remove interior flap above eAgine
12
Unclip engin,e wiring l\lmess (2) from
"'taining clfp5 (3. 4)
p
{)ig(;QM&ct eJectrk:a.l conneet04'$ (5)
~
Uncl,p fuel line (8) llOm mounts (9)
15
Oetacl> dam;, (8) and remove fuel hose {7)
from fuel dls
Passenger-side paneling¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 341 · Applies to: 450, 451
1 Passenger-side paneling 3 C~mping ring 2 Connector 4 Expander l~i.W Remove/install 1 Remove radio 2 Disconnect connector (2) of external audio source separatjon point (X39/45) from slot (arrow A) of communication control unit (N4) 3 Route connector (2) of external audio .source separation point ()(39/45) into radio recess 4 Undip expander (4) of external audio source separation point ()(39/45) from clamping ring (3) with a suitable SW!Wdriver 5 Press clamping ring (3) together and push out external audio source separation point (X39145) towards the rear and oul of passenger-side paneling (1) ~ Take out external audio source separation paint (X39/45) through radio recess 7 Install in the reverse order " l"erfo,m function test or external audio source separation poinl (X39/45) 22.3.07 P82.60-5949-09 N4 Communication control unit (with code (C41) Bluetoolh or code (19Z) Personal navigation device) X39145 External audio source separation point AR82.60·P•7502MCC On vehicles wtth eode· (C47) Bluetooth or code (192) Personal navigation device On vehicles with code (C47) Bluetoolh or code (19Z) Personal navigation device W Carefully press passenger-side paneling (1) into direction of arrow.
Remove/install front module¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 342 · Applies to: 450, 451
Shown on model 451.3 with code (101) Air conditioning Plus 1 Electrical connector 2 Electrical connector 3 Screw Shown on model 451.3 with code (101) Air conditioning Plus 6 Front Module 7 Screw 8 Screw 9 Scrnw 4 Clip 5 Screw B14 Outside temp.,.,,turn display temperature sensor El Left front headlamp unit E2 Right front he;,dlamp unit 21.8.07 P62.30-2930-09 E1 Left front hu.dlamp unit E2 Right front headlamp unit P62.30-2931-09 E511 Left front fog lamp (with code (V07) Front fog lamps /FFOJ) E512 Right front fog lamp (with code (Vfl7) Front fog lamps (FFO)) H? U.-.rn
Shown on model 451.3 with eode (101) Air conditioning Plus¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 343 · Applies to: 450, 451
10 ~ Supports 11 Radiator unit 12 Bracket /1,14/1 Wiper motor P62.30-2932·11 ~l..;J Remove/install ~ RemoYe lront CBS AR88 00-P-101 OMCC 2 Remove paneling on center piece in front of AR88 OO-P-2792MCC the windshield 3 Remove wiper arms AR82 30-P-61 OOMCC 4 o;sconnect electrical connecto,s from horn W On vehicles wilh code (V55) Twin-tone (H2) hOm, a secono nom (tfl), WhOSe eledrical connecl0<$ must also be separated, is also installed in the marked area (arrow B). 5 Disconnect eleclrical connectors (1, 2) frl)ffl Jell front lamp untt (E1) and tight front lamp unij (E2) 6 Unclip outside temperature Indicator temperature sensor (814) and lay down to side With l!ne connected 7 Disconnect electrical connector rrom left front On vehicle• wtth code (V07) fr<>nt fog lamps tog lamp (ES/1) and right front tog lamp (FFO) (ES/2) 8 Remove clip (4) from left and tight fender liner, 9 Unscrew bOII$ (5) at side on front module (6). 1U Unscrew uun t8) 11 Unsaew bOlt (9) rrom br8cl<et (12) on w,pe, motor (M6/1) 12 Loosen boll$ (3) 13 Unscrew boll$ (7) frl)ffl front module (6). 14 Lift front module (6) In area of wiper linl<age W Aid of he'Per required. (arrows A). remove wilh aid of helper and insert mounts (10) into radiator unit (1 1). [TI Installation: Ensure that the rubber guides In the area of the wiper linkage (arrows A) and lhe bracket (12) are posllioned cooectly. l:ll •451589013100 15 lnstaH In the reverse Older
Remove/install radio¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 344 · Applies to: 450, 451
with CODE (C50) smart radio 1 O with CODE (C57) smart radio 9 Shown on vehicle with code (C57) smart radio 9 21.8.07 PS:2.60-5795-07 1 Cover 3 Electrical connector.; A211 smart radio 9 2 Screw 4 Antenna plug (with code (C57} smart radio 9) AV:2 smart radio 10 (with code (C50) smart radio 10) ~Ill! Remove/Install , Remove cover (1) on center console AR68 20-P-2350MCC 2 Remove bolls (2) from smart radio 9 (A211) Rechargeable drill/ screwdriver or from smart radio 1 o (A2/2) hllD.//aolis aftersales daimlereh=ler.com 3 Pull smart radio 9 (A2/1) or smart radio 10 (A2/2} out of radio recess until electrical connectors (3) and anlenna plug (4) are accessible 4 Disconneci -elecidcal connectors (3) and W The actual number of connectors (3) will antenna plug (4) from smart radio 9 (A2/1) or depend on the amount of equipment rrom smart radio 1 o (A2/2) installed. 5 Remove smart tadio 9 (A2/1) or smart radio 10 (A212) 6 Install in the reverse order 7 Read out fault memory, ·erase if necessary ~ AD Connect STAR DIAGNOSIS and read out ADOO.OO-P-2000-04MCC fault memory a Perform function test of sma.11 radio 9 (A2/1) or smart radio 10 (A2/2)
AR91.40-P-1515-01MCE¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 346 · Applies to: 450, 451
Remove seat belt buckle Fold backrest of seat forwards. 2 Place seat with backrest onto a suitable base. 3 Unclip plug (4) of seat belt buckle wiring harness (3) from seat. 4 Detach seat belt buckle wiring harness (3) from brackets (2) and expose. 5 Remove bolt (7) at belt buckle (5). 6 Remove bolts (6) and raise seat console slightly off the backrest frame (1 ). 7 Expose seat belt buckle wiring harness (3) in the direction of the seat belt buckle (5). P91.40-2787-06 8 Pull grommet (8) of wiring harness for seat belt buckle (3) out of backrest frame (1 ). 9 Remove bolt (7) and remove seat belt buckle (5) with seat belt buckle wiring harness (3).
fR91.40-P-1515-01MCC¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 347 · Applies to: 450, 451
!Remove seat belt buckle P91.40-2795-09 Fold backrest of seat (1) forwards 7 Remove bolts (4) on seat console (10) and raise seat console (10) slightly. 2 Place seat (1) with backrest onto a suitable base. 8 Expose seat belt buckle wiring harness (6) in the direction of 3 Unclip plug (7) of seat belt buckle wiring harness (6) from the seat belt buckle (2). seat (1). 9 Remove bolt (5) and remove seat belt buckle (2) with seat 4 Detach s.eat belt buckle wiring harness (6) from brackets (8) belt buckle wiring harness (6). and expose. 10 Remove edge guards (9, 11). 5 Remove bolt (5) at belt buckle (2). 11 Screw in bolts (4) on seat console (10) up to the contact 6 Remove cable ties (3) from seat belt buckle (2) surface.
Install, remove automatic brake adjuster¶
1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 348 · Applies to: 450, 451
21.8.07 1 Fixing spring 2 Adjuster 3 Brake shoes 4 Retumsprlng 5 Spring 6 Threaded tool 7 Angled piece 8 Thumbwhee/ 9 Heat protection P42. I0.2659--06 rni,i Remove/Install 1 Remove left or right brake shoes (3) on the AR42.10.P-0165MCC rear axle 2 Unhook fastening spring (1) on brake adjusler (2) and on brake shoes (3) 3 Unhook relurn spring (4) on brake shoes (3) 4 Unhook spring (5) on brake shoes (3) lj Installation: Observe curvature of teeth on adjusting wheel (8), They must curve away in the direction of adjustment (arrow). 5 Pull threaded union (6), spring (5) and (2) The heat shield (9) must be located in adjustment wheel (8) out of the angle (7) in the center of the angle cutout (7), as the brake adjuster (2) ot/lerwise the dnim brake function may be impaired. ill Installation: Cheel< the direction of the brake adjustment. in the process pressing against the elbow (7) and relieving tile load again. Observe the installation position of the brake adjuster (2): . Right side = Le!Hand thread on brake adjuster (2) - Left side = Right-hand thread on brake adjuster (2) The designations on the brake adiusters (2) are•invalid. p Install in the reverse order ~ Adjust drum brake AR42. IO.P-1010· 11SM