2008 smart fortwo (451) - US Introduction into Service Manual.pdf

122 excerpts.

Introduction of the smart fortwo

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 1 · Applies to: 451

, Introduction of the smart fortwo Model series 451 Introduction into Service Manual Introduction of the smart fortwo
Model series 451 www.smartusa.com _J L C►smart 7 I I

smart USA

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 2 · Applies to: 451

Introduction of the smart fortwo Model Series 451 Introduction into Service Manual SN_Typ 451_us.book Seite 1 Freitag, 30. November 2007 1:56 13 4---- -4 - - -t C►smart r -+ +-

Copyright

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 3 · Applies to: 451

© smart USA, 2007 All rights reserved. Reproduction by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from the publisher. Published by smart USA, 2007 Printed in U.S.A. www.smartusa.com SN_Typ 451_us.book Seite 2 Freitag, 30. November 2007 1:56 13 4---- -4 - - -t r -+ t --t-

Content

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 4 · Applies to: 451

3 Introduction of the smart fortwo, Model Series 451 Preface 7 Complete vehicle Overview 8 Technical data 10 Maintenance 13 Safety concept 17 Electrical system On
board electrical system/power supply 20 Complete networking 22 Wiring harnesses 24 Diagnosis 26 SAM control unit 28 Engine M132 Engine description 30 Performance graph 30 Engine data 32 Valve assembly 33 Valve timing 34 Gasoline injection and ignition system 35 Belt drive 38 Cooling system 39 Engine mount 41 SN_Typ 451_us.book Seite 3 Freitag, 30. November 2007 1:56 13 4---- -4 - - -t r -+ +-

Content

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 5 · Applies to: 451

4 Introduction of the smart fortwo, Model Series 451 Fuel system Fuel supply 42 Exhaust system Overview 45 Secondary air injection 46 Automated manual transmission Transmission description 47 Transmission data 48 Shift mechanism 49 Synchronization 54 Transmission control 55 Park pawl 61 Clutch 62 Chassis Front axle 64 Rear axle 65 Rear module 66 Tire pressure monitor 67 Brakes 69 Steering 75 SN_Typ 451_us.book Seite 4 Freitag, 30. November 2007 1:56 13 4---- -4 - - -t r -+ +-

Content

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 6 · Applies to: 451

5 Introduction of the smart fortwo, Model Series 451 Body Interior 82 Doors/flaps 86 Roof systems 90 Central locking 96 Anti
theft alarm system (ATA [EDW]) 99 Exterior lights 101 Audio system 102 Climate control 104 Customized Bodypanel System (CBS) 106 Seats 108 Supplemental restraint system 109 Body 113 Accessories smart accessories 116 Index 120 SN_Typ 451_us.book Seite 5 Freitag, 30. November 2007 1:56 13 4---- -4 - - -t r -+ +-

Content

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 7 · Applies to: 451

6 Introduction of the smart fortwo, Model Series 451 SN_Typ 451_us.book Seite 6 Freitag, 30. November 2007 1:56 13 4---- -4 - - -t r -+ t --t-

Preface

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 8 · Applies to: 451

7 Introduction of the smart fortwo, Model Series 451 Dear reader, This Introduction into Service Manual presents the new smart fortwo in model series 451. The purpose of this manual is to inform you of the technical features of this new vehicle. This brochure is intended to provide information for people employed in service, maintenance and repair as well as for aftersales staff. In terms of the contents, the emphasis in this Intro
duction into Service manual is on presenting the major assemblies and systems. This Introduction into Service manual is not intended as an aid for repairs or for the diagnosis of technical problems. For such needs, more extensive information is available in the Workshop Information System (WIS) and in the Diagnosis Assistance System (DAS). WIS is updated monthly. Therefore, the information available there reflects the latest technical status. This Introduction into Service Manual presents initial information relating to the new smart fortwo in model series 451 and, as such, is not stored in WIS. The contents of this brochure are not updated. No provi
sion is made for supplements. We will publicize modifications and new features in the relevant WIS documents. The information presented in this Introduction into Service Manual may therefore differ from the more up
to
date information found in WIS. All information relating to technical data, equipment and options is valid as of the copy deadline in September 2007 and may therefore differ from the current production configuration. smart USA aftersales SN_Typ 451_us.book Seite 7 Freitag, 30. November 2007 1:56 13 4---- -4 - - -t r -+ t --t-

Overview

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 9 · Applies to: 451

8 Complete vehicle Introduction of the smart fortwo, Model Series 451 P00.10-4192-00 P00.10-4198-00 smart fortwo coupé smart fortwo cabrio SN_Typ 451_us.book Seite 8 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Overview

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 10 · Applies to: 451

Complete vehicle 9 Introduction of the smart fortwo, Model Series 451 Vehicle concept Externally, the smart fortwo is immediately distin
guishable by its compactness with the tridion safety cell and its two
tone design. The smart fortwo is avail
able in a variety of colors. The tridion safety cell in black or silver can be combined with six different basic colors. The model series can be ordered as the smart fortwo coupé or the smart fortwo cabrio. Despite its compact appearance, the smart fortwo provides the occupants with a generous amount of legroom and sufficient trunk capacity. The interior compartment has a classic design. The instrument panel was designed with straight lines and the colors have been kept refined. Repeated aluminum accent trim on the air vents and the inside door handles gives the interior design a harmonic yet modern aspect. Vehicle characteristics • Overall vehicle exterior External dimensions to suitably accommodate the occupants and provide sufficient the trunk capacity. Plastic panoramic sunroof or full roof on the smart fortwo coupé. Tritop soft top on the smart fortwo cabrio. • Overall vehicle interior Numerous color and pattern variants in the interior. Ergonomic instrument cluster in the instrument panel. Clearly arranged and user
friendly center console. Rear
end door with integral stowage compartment for the smart fortwo coupé or tight
fitting stowage areas without retaining straps for the roof side supports in the smart fortwo cabrio. • Engine/injection system 3
cylinder gasoline engine with 52 kW. Fuel injection system with Bosch Multi
Point
Injection. • Transmission 5
speed automated manual transmission AMT 2 (2nd generation). • Suspension MacPherson front suspension with torsion stabilizer bars. DeDion rear axle. • Brake Hydraulic 2
circuit brake system with ESP and TT (front/rear) split, version 8.1 from Bosch. • Steering Equipped with rack
and
pinion steering as standard. Electromechanical power steering with active steering centering and adaptation of the steering forces available as special equipment. • Maintenance Maintenance concept: Maintenance service only every two years, with only the Oil Service Plus once a year in between. Service flap at front for easy access to the maintenance points. • Safety Restraint system with airbags and emergency tensioning retractors. Bodyshell made of high
strength steels. Door reinforcements made of high
strength steels. Full
length knee guard for driver and passenger. SN_Typ 451_us.book Seite 9 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Technical data

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 11 · Applies to: 451

10 Complete vehicle Introduction of the smart fortwo, Model Series 451 P00.10-4259-00 Dimensions
smart fortwo coupé 48.0 50.0 27.7 28.7 106.1 15.9 73.5 16.7 24.4 19.7 39.7 21.0 11.5 21.0 54.5 61.4 69.0 50.5 60.7 Dimensions Unit smart fortwo coupé (model 451) Vehicle length in (mm) 106.1 (2695) Vehicle width in (mm) 61.4 (1559) Vehicle height in (mm) 60.7 (1542) Wheelbase in (mm) 73.5 (1867) Front track width in (mm) 50.5 (1283) Rear track width in (mm) 54.5 (1385) SN_Typ 451_us.book Seite 10 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Technical data

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 12 · Applies to: 451

Complete vehicle 11 Introduction of the smart fortwo, Model Series 451 P00.10-4260-00 Dimensions
smart fortwo cabrio 48.0 50.0 27.7 28.7 106.1 15.9 73.5 16.7 24.4 19.7 39.7 21.0 11.5 21.0 54.5 61.4 69.0 50.5 60.7 Dimensions Unit smart fortwo cabrio (model 451) Vehicle length in (mm) 106.1 (2695) Vehicle width in (mm) 61.3 (1559) Vehicle height in (mm) 60.7 (1542) Wheelbase in (mm) 73.5 (1867) Front track width in (mm) 50.5 (1283) Rear track width in (mm) 54.5 (1385) SN_Typ 451_us.book Seite 11 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Technical data

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 13 · Applies to: 451

12 Complete vehicle Introduction of the smart fortwo, Model Series 451 Models and major assemblies Loads, weights and other data smart fortwo Model Engine Transmission smart fortwo coupé 451.331 132.910 (52 kW) 717.482 smart fortwo cabrio 451.431 Unit smart fortwo coupé smart fortwo cabrio Powerplant kW 52 52 Permissible front axle load lb (kg) 969 (440) Permissible rear axle load lb (kg) 1458 (660) Curb weight as per DIN lb (kg) 1652 (820) 1740 (840) Permissible gross vehicle weight lb (kg) 2247 (1050) 2247 (1050) Payload lb (kg) 595 (230) 507 (210) of which max. in luggage compart
ment lb (kg) 110 (50) Max. seating capacity 2 Luggage compartment volume up to belt line up to roof in3 (l) in3 (l) 7.8 (220) 12 (340) Turning circle yd (m) 9.57 (8.75) Tank capacity/including reserve US gal (l) 8.72/1.32 33/5 SN_Typ 451_us.book Seite 12 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Maintenance

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 14 · Applies to: 451

Complete vehicle 13 Introduction of the smart fortwo, Model Series 451 Ma xintenance concept Consistent product development has enabled a future
oriented servicing concept to be implemented in model series 451. The servicing concept of the smart fortwo has allowed the service intervals to be extended significantly, as shown below. Maintenance intervals * depending on first occurrence smart fortwo kW Interval Gasoline engine 52 Every 2 years or 20,000 miles* Oil Service Plus In combustion engines with a high engine output per unit of displacement, the engine oil is subjected to extreme loads. With 3.7 US qt (3.5 liters), the smart fortwo has a relatively small quantity of engine oil, meaning that it has to be replaced at regular time/mileage intervals. To help optimize operating costs, the "Oil Service Plus" has been introduced, which is due every 10 000 miles or once per year. It comprises merely an engine oil change and inspection of the safety
relevant components and functions. This servicing concept has benefits for both the workshops and the customers: • Customers have lower vehicle operating costs due to the reduced maintenance costs as a whole. This improves customer satisfaction. • The workshops improve their competitiveness in the servicing business especially. Longer
lasting customer loyalty and better chances of follow
up business are possible with this concept. SN_Typ 451_us.book Seite 13 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Maintenance

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 15 · Applies to: 451

14 Complete vehicle Introduction of the smart fortwo, Model Series 451 Maintenance interval display (WIA) The maintenance interval display is located in the multifunction display of the instrument cluster. The maintenance intervals are indicated by the lighting of one or two wrench symbols. In addition, approximately one month in advance of a scheduled service date the multifunction display shows the remaining time (in days) until it is due. After engine start the range (in miles) is displayed for about ten seconds. P54.32-5676-00 Instrument cluster A1 Instrument cluster A1p13 Multifunction display i Note When the Oil Service Plus or a maintenance service has been performed, the maintenance interval display can be reset to the starting distance on the instrument cluster itself or via STAR DIAGNOSIS. (See WIS for a detailed description.) Meaning of wrench symbols: • 1 wrench means Oil Service Plus • 2 wrenches mean maintenance service P54.32-5677-00 Multifunction display with maintenance interval display SN_Typ 451_us.book Seite 14 Freitag, 30. November 2007 1:56 13 -+ A1p13 so□ mllN ,t ~08.2 0 1200am 3 I -w: 1 +-

Maintenance

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 16 · Applies to: 451

Complete vehicle 15 Introduction of the smart fortwo, Model Series 451 Service flap The smart fortwo is equipped with a detachable service flap which allows convenient access to all maintenance points in the front section. Customer
relevant maintenance items can be performed by the customer accordingly. To remove the service flap, levers located in the air grille on each side must be operated to unlock the service flap. The service flap can then be removed and suspended by two brackets on the front of the vehicle. A check strap prevents the service flap from falling down. Maintenance points at front end The most important maintenance points at the front of the car are: • Brake fluid reservoir • Windshield washer fluid reservoir • Coolant expansion reservoir • Lamp units for bulb replacement P00.20-2629-00 Maintenance points at front end 1 Brake fluid reservoir 2 Windshield washer fluid reservoir 3 Coolant expansion reservoir 4 Lamp unit for bulb replacement 5 Service flap 6 Check strap SN_Typ 451_us.book Seite 15 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Maintenance

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 17 · Applies to: 451

16 Complete vehicle Introduction of the smart fortwo, Model Series 451 Maintenance points in engine compartment The maintenance points in the engine compartment can be accessed once the engine compartment cover in the luggage compartment floor has been removed. The most important maintenance points in the engine compartment are: • Oil filler neck • Oil dipstick • Air filter housing • Spark plugs P00.20-2630-00 Maintenance points in engine compartment 7 Oil filler neck 8 Oil dipstick 9 Air filter housing 10 Ignition coils (spark plugs) SN_Typ 451_us.book Seite 16 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Safety concept

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 18 · Applies to: 451

Complete vehicle 17 Introduction of the smart fortwo, Model Series 451 In the smart fortwo, high levels of active safety are provided by both tried
and
tested and newly devel
oped systems and components. Active safety Active safety includes measures and equipment that help to prevent detected dangers from occurring in the first place, or that warn the driver of dangers in advance, or that assist him in critical driving situa
tions: A distinction is drawn between the following safety aspects: • Driving safety • Stress
reducing safety • Perceptual safety • Operating safety The components responsible for maintaining driving safety include: • Electromechanical power steering (SA) • 5
speed automated manual transmission • Vehicle dynamics systems: ABS (antilock brake system) ASR (acceleration skid control) ESP (electronic stability program) High levels of stress
reducing safety are due to: • Comfortable seats with integral head restraints • Temperature
regulated air conditioning High levels of perceptual safety are assured by the following components: • Auto on/off headlamps (SA) • Center high
mounted brake lamp in the roof spoiler Operating safety is provided by: • Ergonomically designed driver area • Clearly arranged and easily reachable controls SN_Typ 451_us.book Seite 17 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Safety concept

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 19 · Applies to: 451

18 Complete vehicle Introduction of the smart fortwo, Model Series 451 Passive safety The goal of a vehicle's passive safety is to minimize as much as possible the effects of an accident on the people involved. Some of the most important aspects of this are the preservation of the survival space (rigid passenger cell), high energy dissipation in the event of an accident thanks to exploitable crumple zones at the front and rear, and energy
absorbing restraint systems in the interior. The passive safety concept includes: • tridion safety cell consisting of 50% high
strength steel • Crash management system (CMS) at the front and rear, which absorbs energy at low vehicle speeds and prevents expensive bodyshell damage • Front end with no major assemblies, for effective exploitation of the short overhang as a crumple zone • Inclusion of the wheels and axles/frame
type integral support in the crumple zone and for force application • Front and rear structures with several impact planes and large cross sections to transfer and disperse the crash energy that is generated • Long forward displacement area for the driver and passenger with restraint systems adapted to compensate for the "short" crumple zone • Sturdy steel seat structures for effective protection against shifting cargo and for specific deformation in rear
end collisions • Side doors made of solid steel frame profiles including side impact protection • Safe positioning of the fuel tank in the underfloor area between the axles • Deformable steering column to dissipate energy, prevent intrusion and lengthen the forward displacement distance in a frontal collision • Full interior lining to reduce head injuries The occupant restraint systems comprise: • 2
stage driver airbag in steering wheel • 2
stage top
mounted passenger airbag with deployment opening on the top surface of the instrument panel • Head/thoraxbags in the backrests • Three
point seat belts with emergency tensioning retractors, belt force limiters and belt guides on the backrests • Seat belt reminders for driver and passenger • Belt tension sensor on passenger side • Passenger seat with Weight Sensing System (WSS) with automatic passenger airbag deactivation for the corresponding weight classes and airbag OFF indicator lamp • Full
length knee guard • Two frontal acceleration sensors on front crossmember • Two satellite sensors on inner side wall in area of left and right B
pillar • Restraint systems control unit P91.60-3663-00 1 Driver airbag 2 Passenger airbag 3 Head/thoraxbag SN_Typ 451_us.book Seite 18 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Safety concept

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 20 · Applies to: 451

Complete vehicle 19 Introduction of the smart fortwo, Model Series 451 Protective measures for pedestrians and cyclists comprise: • Single
piece front end module • Main headlamps with predetermined fracture point • Concealed and retracting windshield wiper shafts • Energy
absorbing covering on the center piece in front of the windshield • Large, soft plastic surfaces at the front The extended range of functions following an accident includes: • Automatic engine off feature • Interruption of the fuel supply • Unlocking of the doors • Activation of the hazard warning system SN_Typ 451_us.book Seite 19 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

On
board electrical system/power supply

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 21 · Applies to: 451

20 Electrical system Introduction of the smart fortwo, Model Series 451 General The on
board electrical system ensures that the power supply to all the electrical consumers and components in the vehicle is appropriate for the requirements and the situation. The on
board electrical system consists of the following main components: • Starter • Battery • Alternator • ME
SFI [ME] control unit • Instrument cluster Starter The starter has an output of 0.95 kW and supplies the torque necessary to start the engine. It takes the necessary energy from the adequately charged battery. Battery The battery (42 Ah) supplies the consumers when the engine is off, the starter while the engine is being started, and the on
board electrical system when the alternator is unable to provide the required consumer current. The battery is located in the passenger footwell under the carpeting. There are three fuses located in the area of the battery: F36 Secondary air injection pump fuse F58 Starter/alternator fuse F91 SAM prefuse P54.10-2890-00 G1 Battery F36 Secondary air injection pump fuse F58 Starter/alternator fuse F91 SAM prefuse SN_Typ 451_us.book Seite 20 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

On
board electrical system/power supply

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 22 · Applies to: 451

Electrical system 21 Introduction of the smart fortwo, Model Series 451 Alternator The alternator supplies the electrical consumers while the engine is running and recharges the battery so that a subsequent engine start is possible. The alternator is equipped with an overvoltage protection function that limits the on
board power supply voltage in the event of a defect in the governor. The alternator is monitored by the ME
SFI [ME] control unit. The alternator is pre
excited via a direct line. The alternator load is reported back to the ME
SFI [ME] control unit over a separate line and monitored. Instrument cluster The on
board power supply voltage is monitored by the engine control. If the voltage is < 11.5 V for a period of over 3 min, a signal is sent over CAN to the instrument cluster and the alternator charge moni
toring and warning lamp (A1e5) lights up. P54.10-2891-00 G2 Alternator P54.32-5684-00 A1 Instrument cluster A1e5 Alternator charge monitoring and warning lamp SN_Typ 451_us.book Seite 21 Freitag, 30. November 2007 1:56 13 4---- --t -+ +- A1e5

Complete networking

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 23 · Applies to: 451

22 Electrical system Introduction of the smart fortwo, Model Series 451 Overall network
location of components P00.19-4338-00 Overall network
full equipment A1 Instrument cluster on the left side of the instrument panel A15p4 Tachometer (with code (V31) Cockpit clock and tachome
ter package) in the center of the instrument panel B24/15 Yaw rate, lateral and longitudinal accelera
tion sensor under the floor covering near the driver seat B32 ATA [EDW] microwave sensor (with code (V01) Anti
theft alarm system (FFO)) under the center console near the handbrake lever B38 Rain sensor/light sensor (with code (V54) Rain/light sensor) in the middle of the windshield near the in
side rearview mirror H3/2 Alarm siren with inclination sensor (with code (V01) Anti
theft alarm system (FFO)) on the right in front of the fuel tank N2/7 Restraint systems control unit in the center under the instrument panel N3/10 ME
SFI [ME] control unit behind the right side paneling in the rear N10/10 SAM control unit on the left under the instrument panel N15/5 Electronic selector lever module control unit (Legend continued on the next page) SN_Typ 451_us.book Seite 22 Freitag, 30. November 2007 1:56 13 N3/10 A15p4 -+ N57/2 +-

Complete networking

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 24 · Applies to: 451

Electrical system 23 Introduction of the smart fortwo, Model Series 451 Overall network
CAN bus/LIN bus P00.19-4339-00 Block diagram
Full equipment N15/6 Automated manual transmission control unit under the floor covering near the driver seat N23 Heater/AC operating unit (with code (I01) Air conditioning Plus and code (V30) Outside temperature sensor (FFO)) in the center of the instrument panel N25/5 Front HS [SIH] control unit (with code (S17) Seat heaters (FFO)) in the center under the instrument panel N47
5 ESP control unit on ESP hydraulic unit N49 Steering angle sensor in steering wheel N57/2 Power window convenience feature control unit (with code (V43) Power windows) on the left under the instrument panel N68 Power steering control unit (with code (V26) Power steering, EPS (FFO)) in interior compartment on left of firewall N88 TPM [RDK] control unit on left below instrument panel N110 Weight Sensing System (WSS) control unit on underside of passenger seat X11/4 Data link connector on the bottom of the instrument panel on the driver side CAN Controller Area Network bus (data bus/CAN bus) CAN
B Controller Area Network bus class B (interior compartment) LIN B Interior Local Interconnect Network 1 LIN C Interior Local Interconnect Network 2 SN_Typ 451_us.book Seite 23 Freitag, 30. November 2007 1:56 13 4---- fr N3/10 N23 X11/4 N2/7 N68 N47-5 N15/6 CAN A1 N49 B24/15 N88 N15/5 LINC LIN B CAN-B 838 I N57/2 I -+ IA15p4 I I N25/5 I +-

Wiring harnesses

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 25 · Applies to: 451

24 Electrical system Introduction of the smart fortwo, Model Series 451 P54.18-4507-00 Wiring harness groups The wiring harness is divided into the following groups: 1 Main wiring harness 2 Engine wiring harness 3 Transmission wiring harness 4 Battery wiring harness Not illustrated:
Door wiring harness
Soft top wiring harness (in smart fortwo cabrio)
Rear
end door wiring harness SN_Typ 451_us.book Seite 24 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Wiring harnesses

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 26 · Applies to: 451

Electrical system 25 Introduction of the smart fortwo, Model Series 451 General The wiring harness variants result from the basic standard equipment, the special equipment items and the national versions. Repair capability A basic wiring harness repair kit in a case is available for repairing individual lines, wiring harnesses and connectors without sealed plugs. All the above repairs can be carried out using this kit. It is also possible to expand the kit with a supple
mental repair set to allow wiring harnesses with sealed plugs to be repaired. i Note W000 589 13 99 00 Basic wiring harness repair kit. Tools for repairing individual lines, wiring harnesses and connectors in combination with the wiring harness repair kit supplement for passenger cars (W220 589 04 99 00). W220 589 04 99 00 Wiring harness repair kit supplement for passenger cars Tools for repairing individual lines, wiring harnesses and connectors in combination with the basic wiring harness repair kit (W000 589 13 99 00). P54.18-4140-00 Wiring harness repair kit SN_Typ 451_us.book Seite 25 Freitag, 30. November 2007 1:56 13 4---- --t -+ +- I --

Diagnosis

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 27 · Applies to: 451

26 Electrical system Introduction of the smart fortwo, Model Series 451 General The network architecture in model 451 allows external access to individual control units in the CAN bus system. Data link connector The CAN bus is accessed by means of a diagnostic tester that is connected to the vehicle via the data link connector. The data link connector is linked directly to the CAN bus and can therefore access all the control units that have diagnostic or programming capability. The data link connector is located in the vehicle interior on the underside of the instrument panel on the driver side. Diagnostic tester By connecting the diagnostic tester, the vehicle with all its equipment variants can be precisely identified. This enables accurate fault evaluation and rectifica
tion and the analysis of vehicle
specific values and parameters. P54.22-2048-00 Location of data link connector (X11/4) SN_Typ 451_us.book Seite 26 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Diagnosis

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 28 · Applies to: 451

Electrical system 27 Introduction of the smart fortwo, Model Series 451 Diagnosis capability The following control units have diagnosis capability: • Instrument cluster • Restraint systems control unit • WSS control unit • ME
SFI [ME] control unit • SAM control unit • Automated manual transmission control unit • Heater/AC operating unit • ESP control unit • Steering assist control unit • TPM [RDK] control unit • Electronic selector lever module control unit Fault memory Each of the control units listed above has a fault memory that provides information about the associ
ated systems. The stored faults are displayed by the diagnostic tester and must be rectified. When all the faults have been eliminates, the fault memory must be erased and read out again. There should be no fault entries left afterwards. Maintenance intervals The diagnostic tester is used to reset the mainte
nance interval in the instrument cluster following an Oil Service Plus or a maintenance service. Programming control units The following control units can be programmed: • ME
SFI [ME] control unit • SAM control unit • Automated manual transmission control unit • ESP control unit TAN generator For the following applications a TAN (transaction number) must be generated: • Retrofitting the steering wheel gearshift (SAL) • Replacing the ME
SFI [ME] control unit • Replacing the SAM control unit • Teach
in of transmitter keys (after loss or detection of additional transmitter keys) SCN (Software Calibration Number) coding The following control units can be coded via the SCN coding process: • ME
SFI [ME] control unit) • SAM control unit • ESP control unit • Automated manual transmission control unit) • Restraint systems control unit • Instrument cluster *) The control unit is relevant to exhaust emissions, i.e. the SCN is written in the control unit and can be interrogated. For the other control units a virtual SCN is generated during the coding process, but this is not written to the control unit. i Note Up to six transmitter keys in total can be taught in at the same time. SN_Typ 451_us.book Seite 27 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

SAM control unit

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 29 · Applies to: 451

28 Electrical system Introduction of the smart fortwo, Model Series 451 Almost all of the fuses in model 451 are accommodated on the SAM control unit. Slots 1
31 are located on the front of the SAM control unit; slots 32
35 are located on the rear. The following fuses are not accommodated on the SAM control unit: • Secondary air injection pump fuse (F36) • Starter/alternator fuse (F58) • SAM prefuse (F91) The SAM control unit is installed in the vehicle interior on the left side near the A
pillar under the instrument panel. The SAM control unit is linked with the CAN in order to exchange data. It communicates with the following components: • Instrument cluster • ESP control unit • Restraint systems control unit • ME
SFI [ME] control unit • Heater/AC operating unit • Steering assist control unit • TPM [RDK] control unit • Weight Sensing System (WSS) control unit • Yaw rate, lateral and longitudinal acceleration sensor • Steering angle sensor • Data link connector P54.21-2702-00 SAM control unit (front) SN_Typ 451_us.book Seite 28 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

SAM control unit

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 30 · Applies to: 451

Electrical system 29 Introduction of the smart fortwo, Model Series 451 The SAM control unit also communicates over: • LIN B with the tachometer and the rain sensor/light sensor • LIN C with the ATA [EDW] microwave sensor and the alarm siren with inclination sensor. The fuse and relay box is integrated in the SAM control unit. The following relays are not accommodated on the SAM control unit: • Left turn signal/brake light relay (K52/11) • Right turn signal/brake light relay (K52/12) • Secondary air injection pump relay (K64) • Soft top opening relay (K66/1) (only cabrio) • Soft top closing relay (K66/2) (only cabrio) P54.21-2703-00 SAM control unit (rear) i Note Up to six transmitter keys can be stored in the SAM control unit. SN_Typ 451_us.book Seite 29 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Engine description

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 31 · Applies to: 451

30 Engine M132 Introduction of the smart fortwo, Model Series 451 Engine M132 At market launch, the smart fortwo is available with a 3
cylinder gasoline engine with 61 in3 (999 cm3) displacement and 52 kW P01.10-2942-00 3
cylinder gasoline engine (M132) SN_Typ 451_us.book Seite 30 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Performance graph

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 32 · Applies to: 451

Engine M132 31 Introduction of the smart fortwo, Model Series 451 Power and torque graph The red characteristic represents the power curve (P) in relation to the engine speed (n). The blue characteristic represents the torque curve (M) in relation to the engine speed (n). P01.00-2999-00 Power and torque graph M132 M Torque (lb
ft) P Engine power (kW) n Engine speed (rpm) 0 0 1000 2000 3000 4000 5000 6000 7000 20 40 60 80 100 120 140 160 180 M (lb-ft) P (kW) n (1/min) 0 10 20 30 40 50 60 70 SN_Typ 451_us.book Seite 31 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Engine data

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 33 · Applies to: 451

32 Engine M132 Introduction of the smart fortwo, Model Series 451 * Fuel requirements: Only unleaded premium fuel may be used. The octane number (shown on the gasoline pump) should be at least 91. This is an average value based on tests of the octane number (RON) and motor octane number (MON) (RON+MON/2). It is also known as the anti
knock index. M132 Engine model designation 132.910 Rated output kW at rpm 52 5800 Rated torque lb
ft (Nm) at rpm 68 (92) 4500 Compression ratio e 10.0:1 Engine configuration/no. of cylinders Inline/3 Camshaft configuration/number Overhead/2 Displacement in3 (cm3) 61 (999) Bore in (mm) 2.83 (72) Stroke in (mm) 3.22 81.8 Cylinder angle ° 45 Fuel * Premium gasoline unleaded Emission regulations ULEV SN_Typ 451_us.book Seite 32 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Valve assembly

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 34 · Applies to: 451

Engine M132 33 Introduction of the smart fortwo, Model Series 451 Valve assembly The timing chain is driven by the crankshaft via the crankshaft gear and thus drives the intake camshaft via the camshaft adjuster and the exhaust camshaft via the exhaust camshaft sprocket. The timing chain is guided by a slide rail. A tensioning rail and chain tensioner ensure that the chain is at the right tension to prevent wear and noises. The intake and exhaust camshafts control the gas exchange in the engine via the intake and exhaust valves. Variable camshaft adjustment allows for greater torque at low engine speeds and better response time in the idle and partial
load ranges. At the same time, the camshaft adjustment helps to achieve the stipulated exhaust emissions limits. P05.00-2082-00 Valve assembly 1 Exhaust camshaft sprocket 2 Exhaust camshaft 3 Camshaft adjuster 4 Intake camshaft 5 Crankshaft gear 6 Crankshaft 7 Timing chain 8 Intake valve 9 Exhaust valve 10 Valve spring 11 Cup tappet SN_Typ 451_us.book Seite 33 Freitag, 30. November 2007 1:56 13 4---- --t 2 4 -+ 1 +- 7 6

Valve timing

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 35 · Applies to: 451

34 Engine M132 Introduction of the smart fortwo, Model Series 451 General Engine M132 is equipped with mechanical cup tappets. The mechanical stress on the cams and cup tappets makes it necessary to check and adjust the valve clea
rance. The cup tappets must be measured using a micro
meter. Find and insert the appropriate cup tappet by refer
ence to its markings. The valve clearance is adjusted by exchanging the cup tappets. These are available in various thicknesses. P05.30-2151-00 1 Cylinder head 2 Camshaft bearing cap 3 Intake camshaft 4 Exhaust camshaft 5 Cup tappet 6 Intake valve 7 Exhaust valve 8 Valve spring retainer 9 Valve locks 10 Valve spring 11 Valve stem seal 12 Valve seat SN_Typ 451_us.book Seite 34 Freitag, 30. November 2007 1:56 13 -+ +-

Gasoline injection and ignition system

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 36 · Applies to: 451

Engine M132 35 Introduction of the smart fortwo, Model Series 451 Injection control Engine M132 features an ME (motor electronics) gasoline injection and ignition system. The central control unit of this system is the ME
SFI [ME] control unit. It is networked over CAN with the following components: • Instrument cluster • SAM control unit • Automated manual transmission control unit • Heater/AC operating unit • ESP control unit • Steering assist control unit • Data link connector The ME
SFI [ME] control unit puts its information on the CAN, making it accessible to all the other networked components on the CAN. The information from other components reaches the ME
SFI [ME] control unit in the same way. For example, the signal from the clutch motor, which is read directly by the automated manual transmission control unit, reaches the ME
SFI [ME] control unit in this way. Direct input signals come from: • Knock sensor • Fuel tank pressure sensor • Camshaft Hall sensor • Coolant temperature sensor • Accelerator pedal sensor • O2 sensor downstream of TWC [KAT] • O2 sensor upstream of TWC [KAT] • Crankshaft position sensor • Throttle valve actuator • Oil pressure switch Direct output signals go to: • Fuel pump relay • Fuel pump with fuel level sensor • Secondary air injection pump relay • Secondary air injection pump • Secondary air injection pump switchover valve • Throttle valve actuator • Cylinder 1 ignition coil • Cylinder 2 ignition coil • Cylinder 3 ignition coil • Outside air shutoff valve • Adjustable camshaft timing solenoid • Cylinder 1 fuel injection valve • Cylinder 2 fuel injection valve • Cylinder 3 fuel injection valve • Fuel tank vent valve There are also the following inputs on the ME
SFI [ME] control unit: • Circuit 15 • Circuit 30 • Circuit 31 Function The engine is controlled according to load by the performance map based on the signals arriving either directly or over CAN. The actuators are actuated via direct lines in accordance with the values computed by the ME
SFI [ME] control unit. Information intended for other components is put on the CAN. The ME
SFI [ME] control unit has an integral fault memory and can exchange information with STAR DIAGNOSIS via a data link connector that is connected to the CAN. SN_Typ 451_us.book Seite 35 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Gasoline injection and ignition system

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 37 · Applies to: 451

36 Engine M132 Introduction of the smart fortwo, Model Series 451 P07.61-3578-00 Data flow chart of M132 injection system SN_Typ 451_us.book Seite 36 Freitag, 30. November 2007 1:56 13 i: A16 B4/3 ....... B6/1 -+ S41/1 ....... 115/30/311---..- - N10/10 A1 N15/6 M16/6 C A N N23 G3/1 G3/2 N47-5 K64 Y49 ....... Y58 Y32 N68 M3/3 M33 Y50 Y62/1 Y62/2 Y62/3 T1/1 T1/2 T1/3 X11/4 +-

Gasoline injection and ignition system

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 38 · Applies to: 451

Engine M132 37 Introduction of the smart fortwo, Model Series 451 15/30/31 Circuit status A1 Instrument cluster A16 Knock sensor B4/3 Fuel tank pressure sensor B6/1 Camshaft Hall sensor B11/4 Coolant temperature sensor B28 Intake manifold pressure sensor B37 Accelerator pedal sensor G3/1 O2 sensor downstream of TWC [KAT] G3/2 O2 sensor upstream of TWC [KAT] K27 Fuel pump relay K64 Secondary air injection pump relay L5 Crankshaft position sensor M3/3 Fuel pump with fuel level sensor M16/6 Throttle valve actuator M33 Secondary air injection pump N3/10 ME
SFI [ME] control unit N10/10 SAM control unit N15/6 Automated manual transmission control unit N23 Heater/AC operating unit N47
5 ESP control unit N68 Steering assist control unit S41/1 Oil pressure switch T1/1 Cylinder 1 ignition coil T1/2 Cylinder 2 ignition coil T1/3 Cylinder 3 ignition coil X11/4 Data link connector Y32 Secondary air injection pump switchover valve Y49 Adjustable camshaft timing solenoid Y50 Outside air shutoff valve Y58 Tank vent valve Y62/1 Cylinder 1 fuel injection valve Y62/2 Cylinder 2 fuel injection valve Y62/3 Cylinder 3 fuel injection valve CAN Controller Area Network (data bus/CAN bus) SN_Typ 451_us.book Seite 37 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Belt drive

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 39 · Applies to: 451

38 Engine M132 Introduction of the smart fortwo, Model Series 451 Belt adjustment and description of stretch belt Self
tensioning belt drive The alternator and coolant pump are driven by a poly
V belt with tensioning device. The poly
V belt is tensioned via a new spring
loaded tensioning device. To install and remove the poly
V belt the tensioning device must be rotated clockwise using a special tool to slacken the tension in the belt drive. The tensioning device can then be locked in place and the poly
V belt removed. Stretch belt The refrigerant compressor is driven by a stretch belt. The stretch belt does not need a tensioning device, but it must be replaced after a specified mileage. It is removed and installed with the aid of a special tool that guides the stretch belt over the belt pulley of the refrigerant compressor. The stretch belt can be pulled on or off the belt pulley by cranking the engine in its normal direction of rotation. P13.20-2055-00 Belt drive 1 Alternator belt pulley 2 Poly
V belt 3 Coolant pump belt pulley 4 Refrigerant compressor belt pulley 5 Crankshaft pulley 6 Tensioning device 7 Tensioning device belt pulley 8 Stretch belt SN_Typ 451_us.book Seite 38 Freitag, 30. November 2007 1:56 13 -4 -r 1 -+ 3 +- 8

Cooling system

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 40 · Applies to: 451

Engine M132 39 Introduction of the smart fortwo, Model Series 451 Coolant circuit In the small cooling circuit, the coolant is pumped through the engine, the heater heat exchanger and back to the engine via the expansion reservoir by the coolant recirculation pump. In the large coolant circuit, the coolant flows from the thermostat straight to the radiator and on to the coolant recirculation pump. The switchover between the small and large coolant circuit is performed by the thermostat depending on the coolant temperature. In the expansion reservoir the circuit is split again, with one stream flowing direct to the coolant recircu
lation pump and the other passing through the radi
ator. The coolant fan motor is switched on or off depending on the engine temperature recorded by the coolant temperature sensor and cools the coolant. P20.00-2339-00 1 Radiator 2 Expansion reservoir 3 Coolant return line 4 Coolant feed line (large circuit) 5 Coolant pump 6 Coolant pump belt pulley 7 Thermostat 8 Coolant feed line (small circuit) 9 Heater heat exchanger 10 Coolant pipe B11/4 Coolant temperature sensor M4/2 Coolant fan motor SN_Typ 451_us.book Seite 39 Freitag, 30. November 2007 1:56 13 4---- --t -+ +- 4 1 M4/2

Cooling system

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 41 · Applies to: 451

40 Engine M132 Introduction of the smart fortwo, Model Series 451 Bleeding cooling system General If some or all of the coolant has been drained, the cooling system must be bled after refilling. Fill Unscrew the cooling system cap and fill the cooling system up to the "MAX" mark in the expansion reser
voir. Bleeding Unfasten the clamp, pull off the coolant hose and wait until coolant emerges from the coolant hose and the cylinder head. Then reconnect the coolant hose and fasten it with the clamp. Top up the expansion reservoir to the "MAX" mark again and screw on the cooling system cap. Warm up the engine until the thermostat opens. Switch off the engine and check the coolant level in the expansion reservoir. P20.00-2340-00 1 Cooling system cap 2 Expansion reservoir 3 Coolant hose 4 Clamp i Note The cooling system must be filled and bled only when the engine is cold. SN_Typ 451_us.book Seite 40 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Engine mount

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 42 · Applies to: 451

Engine M132 41 Introduction of the smart fortwo, Model Series 451 Engine mount/torque support The engine with transmission is mounted on two mounts and a torque support. They were designed to dampen inherent engine vibrations. They also consid
erably reduce the rocking of the drive assemblies during load changes. The reduction in vibrations and in the tendency to rock provides a higher level of driving safety and ride comfort. P22.10-2299-00 Engine mount, transmission mount and torque support 1 Frame
type integral support 2 Engine mount 3 Transmission mount 4 Torque support SN_Typ 451_us.book Seite 41 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Fuel supply

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 43 · Applies to: 451

42 Fuel system Introduction of the smart fortwo, Model Series 451 Fuel supply A non
return fuel system is used for the fuel supply. The fuel is pumped by a flow pump via the fuel filter in the fuel tank into the fuel distributor rail according to requirements. Any surplus fuel is pumped via the fuel pressure regulator straight into the buffer of the fuel pump. The fuel pressure regulator is designed to ensure that there is always a pressure of 46 psi (3.24 bar) at the fuel distributor rail. The fuel tank fill level is measured by a float
and
lever sensor. Fuel tank The fuel tank is located in front of the rear axle under the seats. It is made of polyethylene and is formed such that the available installation space is used to an optimum. The capacity of the fuel tank is 8.72 gallons (33 liters), including a 1.32 gallon (5 liter) reserve. The intank fuel supply system consists of a fuel pump with fuel level sensor, fuel pressure regulator and an integrated fuel filter. Evaporative emission control system (purging) The evaporative emission control system prevents fuel vapors escaping to the atmosphere. The fuel vapors are stored in the activated charcoal filter and then sent later to the engine for combustion. Leak test The leak test for the fuel evaporation control system must detect leaks with a diameter as of 0.02 in (0.5 mm) and must take place in three stages (function chain): • Test for gross leaks (equal to or greater than 0.12 in (3 mm)) • Test for fine leaks (equal to or greater than 0.04 in (1 mm)) • Test for very fine leaks (equal to or greater than 0.02 in (0.5 mm)) Test for gross leaks The outside air shutoff valve is closed and the tank vent valve is opened. Intake manifold vacuum present in fuel tank. This vacuum is measured by the tank pressure sensor. If no vacuum is built up in the fuel tank (approx.
0.1 psi (
6 mbar) within approx. 12 seconds) there is a major leak (e.g. tank cap open, hose line loose). The test will be interrupted and the "gross leak" fault will be registered. If the ME
SFI [ME] control unit detects a system with a gross leak, the fuel reserve warning lamp in the instrument cluster flashes and the message "CHECK FILLER CAP" appears in the multifunction display. Test for fine leaks The tank vent valve is closed at a vacuum of around
0.1 psi (
6 mbar). The system is closed and thereby airproof. The vacuum is then measured for approx. 30 seconds. The vacuum must not reduce more rapidly than 0.004 to 0.007 psi/s (0.3 to 0.5 mbar/s) (depends on fuel level). If the vacuum drops more rapidly, there is a fine leak. The test will be interrupted and the "fine leak" fault will be registered. SN_Typ 451_us.book Seite 42 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Fuel supply

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 44 · Applies to: 451

Fuel system 43 Introduction of the smart fortwo, Model Series 451 Check for very fine leaks If no fine leak is recognized then purging is briefly enabled and then the vacuum of about
0.1 psi (
6 mbar) is built up again. The vacuum must not reduce more rapidly than 0.0014 to 0.002 psi/s (0.1 to 0.15 mbar/s) in the closed system (depends on fuel level). If the vacuum drops more rapidly, the fault "very fine leak" will be registered. The reduction in vacuum depends on the fuel level in the fuel tank and on outgassing of the fuel. The outgassing of the fuel is measured just before the test by the fuel tank pressure sensor and is allowed for during fault determination. The test for fine and very fine leaks is aborted if an excessive lean correction of the lambda control takes place during the build
up of the vacuum. The function of the tank vent valve is checked at the same time by the actuation. If the closed tank vent valve jams, the fault "gross leak" is stored. Test requirements • Engine at idle • Vehicle stationary • Drive position "D" or "R" is engaged • Off
period after engine start elapsed (approx. 16 minutes) or mixture adaptation performed • Lambda control enabled • Intake air temperature <113° F (<45 °C) • Coolant temperature at engine start <212° F (<100 °C) • Air injection not active • Air pressure >1.12 psi (>780 hPa) (i.e. no tests performed above approx. 2735 yd (2500 m) altitude) • Low loading of activated charcoal canister • Fuel level in fuel tank between approx. ¼ and ¾ • No fault in outside air shutoff valve • No fault in the fuel tank pressure sensor • No fault in tank vent valve • Battery voltage > 11 V The outside air shutoff valve is reopened after the tests. SN_Typ 451_us.book Seite 43 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Fuel supply

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 45 · Applies to: 451

44 Fuel system Introduction of the smart fortwo, Model Series 451 P47.-10-2433-00 Fuel system 1 Fuel tank 2 Activated charcoal filter 3 Vent line 4 Filler neck 5 Filler neck hose connection 6 Purge line 7 Fuel distributor rail B4/3 Fuel tank pressure sensor M3/3 Fuel pump with fuel level sensor Y50 Outside air shutoff valve Y58 Tank vent valve SN_Typ 451_us.book Seite 44 Freitag, 30. November 2007 1:56 13 -4 -r 5 M B4/3 6 -+ 1 +- 2 Y50

Overview

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 46 · Applies to: 451

Exhaust system 45 Introduction of the smart fortwo, Model Series 451 Design The exhaust system is made of stainless steel and consists of the following components: • Exhaust manifold • Catalytic converter • Main muffler Muffler system When designing the muffler systems, it was important both to minimize the exhaust back pressure and achieve optimum acoustic tuning. The muffler system is rigidly fixed to the vehicle body. Exhaust aftertreatment A control sensor and a diagnostic sensor are installed for exhaust aftertreatment. Aftertreatment of the exhaust gases is performed by a catalytic converter with monolithic coating. P49.00-2109-00 Exhaust system 1 Exhaust manifold 2 Catalytic converter 3 Main muffler G3/1 O2 sensor downstream of TWC [KAT] G3/2 O2 sensor upstream of TWC [KAT] SN_Typ 451_us.book Seite 45 Freitag, 30. November 2007 1:56 13 4---- --t -+ +- 3

Secondary air injection

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 47 · Applies to: 451

46 Exhaust system Introduction of the smart fortwo, Model Series 451 Secondary air injection Engine 132 is fitted with a secondary air injection pump (electric air pump), which injects additional fresh air in order to reduce exhaust gas emissions after a cold start and to accelerate the warming of the catalytic converter to its reaction temperature. The necessary air is injected into the exhaust ports in the cylinder head by the secondary air injection pump via the combination valve. The secondary air injection pump is actuated by the ME
SFI [ME] control unit via a relay. The secondary air injection pump switchover valve is supplied with vacuum from the vacuum reservoir at the intake manifold via a check valve. When actuated, the secondary air injection pump switchover valve releases vacuum to the combination valve. This opens and the air injected by the secondary air injection pump passes through to the exhaust ports in the cylinder head. The injected air reacts with the hot exhaust gases in the outlet port. The carbon monoxide (CO) and hydro
carbon (HC) are oxidized. This "afterburning" process increases the exhaust temperature and reduces pollutants. The duration of secondary air injection is dependent on the coolant temperature. The secondary air injection pump is only actuated at a coolant temperature of 45 °F to 97 °F (7 °C to 36 °C) and for a maximum duration of 33 seconds. P14.30-2183-00 Secondary air injection 1 Cylinder head 2 Combination valve 3 Air hose 4 Vacuum hose M33 Secondary air injection pump Y32 Secondary air injection pump switchover valve SN_Typ 451_us.book Seite 46 Freitag, 30. November 2007 1:56 13 -4 -r -+ 4 3 2 Y32 +- 1

Transmission description

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 48 · Applies to: 451

Automated manual transmission 47 Introduction of the smart fortwo, Model Series 451 5
speed automated manual transmission (AMT 2) The smart fortwo is fitted with the newly developed 2nd generation 5
speed automated manual transmis
sion (AMT 2). Advantages of the 5
speed automated manual trans
mission: • Greater shift comfort • Reduced fuel consumption Features: • 5
speed transmission • Two
drum control • Potentiometer
free position sensor system • Mechanical park pawl The driver can choose between two operating modes: • Automatic mode (selector lever in position “D“) • Manual mode (selector lever in position M “+/
“) with operation via the selector lever or paddle shifts on the steering wheel (SAL) P26.10-2167-00 5
speed manual transmission (AMT 2) SN_Typ 451_us.book Seite 47 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Transmission description

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 49 · Applies to: 451

48 Automated manual transmission Introduction of the smart fortwo, Model Series 451 AMT 2 in model 451 Unit Transmission model G 717.482 Number of forward/reverse gears 5/1 Max. transferable torque lb
ft (Nm) 88 (120) Clutch Single
plate dry clutch Overall length (including 3 in (75 mm) for clutch) in (mm) 14.3 (364) Housing material Aluminum alloy Weight (without oil charge) lb (kg) Approx. 74.9 (34) Oil charge (permanent charge) US qt (l) 2.4 (2.3) Housing Two
piece with bell housing SN_Typ 451_us.book Seite 48 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Shift mechanism

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 50 · Applies to: 451

Automated manual transmission 49 Introduction of the smart fortwo, Model Series 451 Shift mechanism The central components of the shift mechanism are two selector drums for moving the shift forks. Each selector drum is driven by a separate electric motor via two sintered spur gear sets. One selector drum shifts the odd gears, while the other shifts the even gears and reverse gear. The position of the selector drum, and thus the current shift position, is determined by two incre
mental sensors in each electric motor. Both electric motors and the spur gears are located in a common aluminum housing, the actuator unit, which is mounted on the transmission. The two selector drums are arranged to allow over
lapping shift operations to minimize shift times. It is possible to skip gears (e.g. double downshifts). P26.60-2320-00 Design of shift mechanism 1 Shift fork for shift collar 5 2 Shift fork for reverse gear sliding gear 3 Shift fork for shift collar 1/3 4 Shift fork for shift collar 2/4 5 Main shaft 6 Selector drum 1/3, 5 7 Selector drum 2/4, R 8 Input shaft M17/3 Transmission motor 1 M17/4 Transmission motor 2 SN_Typ 451_us.book Seite 49 Freitag, 30. November 2007 1:56 13 4---- --t M17/3 M17/4 -+ 7 +- 5 4 3 2 1

Shift mechanism

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 51 · Applies to: 451

50 Automated manual transmission Introduction of the smart fortwo, Model Series 451 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 shift 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 for shift collar 5 Selector drum 2/4, R: • Sliding block of shift fork for shift collar 2/4 • Sliding block of shift fork for sliding gear, reverse gear The positions of both sliding blocks in the same groove are offset to each other by 120°. If a sliding block displaces a shift fork from the center position, the other sliding block is in the straight area of the groove (in center position of respective shift fork). Shift positions Neutral (N) and reverse gear (R) a Selector drum 1/3, 5 b Selector drum 2/4, R c Selector drum adjustment (1 grid square = 40°) d Sliding block deflection (1 grid square = 0.3 in (7.5 mm)) Neutral position (N) The sliding blocks in the grooves of the selector drum are in the neutral position. No gear is engaged. Reverse gear (R) The selector drum 2/4, R rotates through 120° downwards. This displaces the upper sliding block by 0.89 in (22.5 mm) to the left. The reverse gear sliding gear engages in the outer teeth of shift collar 1/3. The sliding blocks in the selector drum 1/3, 5 are in the neutral position. P26.60-2356-00 SN_Typ 451_us.book Seite 50 Freitag, 30. November 2007 1:56 13 -4 -r -+ +- t t C C Na ! b ' Ra I b I d ~ d +-----0--+ d~ d • ~

Shift mechanism

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 52 · Applies to: 451

Automated manual transmission

51

Introduction of the smart fortwo, Model Series 451

Shift positions

1st gear (1) and 2nd gear (2)

a

Selector drum 1/3, 5

b

Selector drum 2/4, R

c

Selector drum adjustment (1 grid square =

40°)

d

Sliding block deflection (1 grid square = 0.3 in

(7.5 mm))

1st gear (1)

The selector drum 1/3, 5 rotates through 40° down

wards. This displaces the upper sliding block by 0.3

in (7.5 mm) to the left. The shift collar 1/3 is slid into

the idler gear of the first gear. The sliding blocks in

the selector drum 2/4, R are in the neutral position.

2nd gear (2)

For the change from 1st gear to 2nd gear, the two

selector drums rotate through 40° upwards. This in

turn displaces the lower sliding block in the

selector drum 2/4, R by 0.3 in (7.5 mm) to the left.

The shift collar 2/4 is slid into the idler gear of the

second gear. The sliding blocks in the selector

drum 1/3, 5 are in the neutral position.,

P26.60-2357-00

SN_Typ 451_us.book Seite 51 Freitag, 30. November 2007 1:56 13

4----

fr

-+

+-

t

C

1 a .

i

b

2 a

b · i ._..cc... d +-o--+- __ _cd'-- ~ --,.---=-- d +-o---t,, __ _cdc_ ~ __ ,

Shift mechanism

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 53 · Applies to: 451

52 Automated manual transmission Introduction of the smart fortwo, Model Series 451 Shift positions 3rd gear (3) and 4th gear (4) a Selector drum 1/3, 5 b Selector drum 2/4, R c Selector drum adjustment (1 grid square = 40°) d Sliding block deflection (1 grid square = 0.3 in (7.5 mm)) 3rd gear (3) For the change from 2nd gear to 3rd gear, the two selector drums rotate through 40° upwards. The upper sliding block in the selector drum 1/3, 5 is displaced by 0.3 in (7.5 mm) to the right. It presses the shift collar 1/3 into the idler gear of the third gear. The other sliding blocks are in the neutral position. 4th gear (4) For the change from 3rd gear to 4th gear, the two selector drums rotate through 40° upwards. The lower sliding block in the selector drum 2/4, R is displaced by 0.3 in (7.5 mm) to the right. It presses the shift collar 2/4 into the idler gear of the fourth gear. The other sliding blocks are in the neutral position. P26.60-2358-00 SN_Typ 451_us.book Seite 52 Freitag, 30. November 2007 1:56 13 -+ +- 3 a ; 4 a ' b ' j ' ; d<lf-o--+ d~ d~ -4 I ~ ~ -t-- ---t- --t

Shift mechanism

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 54 · Applies to: 451

Automated manual transmission 53 Introduction of the smart fortwo, Model Series 451 Shift positions 5th gear (5) a Selector drum 1/3, 5 b Selector drum 2/4, R c Selector drum adjustment (1 grid square = 40°) d Sliding block deflection (1 grid square = 0.3 in (7.5 mm)) 5th gear (5) For the change from 4th gear to 5th gear, the selector drum 1/3, 5 rotates through 40° upwards. The lower sliding block in the selector drum 1/3, 5 is displaced by 0.3 in (7.5 mm) to the left. It presses shift collar 5 into the idler gear of the fifth gear. The selector drum 2/4, R is rotated through 40° downwards. The sliding blocks in the selector drum 2/4, R are in the neutral position. P26.60-2362-00 SN_Typ 451_us.book Seite 53 Freitag, 30. November 2007 1:56 13 4---- --t -+ +- i C ; f i • •••• T 5 a . : b l d ~ d ~

Synchronization

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 55 · Applies to: 451

54 Automated manual transmission Introduction of the smart fortwo, Model Series 451 Borg
Warner synchronization All forward gears are equipped with a Borg
Warner synchronization. Reverse gear is not synchronized. Function Before the shift collar (3) positively connects the sleeve carrier with the corresponding idler gear, the tapered pairs of faces contact the clutch body (1), synchronizer ring (2) and, where applicable, an intermediate ring. The engine's gear is run at the speed of the corresponding drive
side gear; only then do the locking splines (4) release the remaining travel of the shift collar. The shift collar travel from neutral to complete engagement in the relevant idler gear is approx. 0.3 in (7.7 mm). P26.50-2173-00 1 Clutch body 2 Synchronizer ring 3 Shift collar 4 Locking splines SN_Typ 451_us.book Seite 54 Freitag, 30. November 2007 1:56 13 -4 -r 2 1 1 2 3 4 -+ +-

Transmission control

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 56 · Applies to: 451

Automated manual transmission 55 Introduction of the smart fortwo, Model Series 451 Transmission rpm sensor (L2) Location The transmission rpm sensor is mounted to the transmission housing. Task The rpm sensor determines the rotational speed of the input shaft. The recorded speeds of the crank
shaft 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. The diagram illustrates the oscilloscope picture of an rpm sensor. P26.19-2104-00 1 Input shaft L2 Transmission rpm sensor SN_Typ 451_us.book Seite 55 Freitag, 30. November 2007 1:56 13 4---- --t 1 L2 -+ +-

Transmission control

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 57 · Applies to: 451

56 Automated manual transmission Introduction of the smart fortwo, Model Series 451 Transmission motors 1 and 2 (M17/3 and M17/4) Location The transmission motors are located on the trans
mission housing. Task Depending on the shift request from the automated manual transmission control unit (N15/6), the transmission motors adjust the selector drums via a two
stage spur gear transmission. Actuation is pulse
width modulated by two output stages with four electronic switches each. Upon reaching the specified position the transmission motor is braked. It can, if necessary, be actuated with opposing voltage, if an overshoot beyond the spec
ified position is to be prevented or reversed. Actuation of the transmission motors is monitored by the incremental sensors, which are located on each motor shaft. These detect the rotation angle and rotation direction of the respective transmis
sion motor using the integrated Hall sensors. The transmission motors are only actuated to execute the shift operations. Once a target position is reached, a pin engages in the locking groove of the selector drum to maintain the selected gear. P26.60-2321-00 1 Transmission motor 1 selector drum 2 Transmission motor 2 selector drum M17/3 Transmission motor 1 M17/4 Transmission motor 2 SN_Typ 451_us.book Seite 56 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Transmission control

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 58 · Applies to: 451

Automated manual transmission 57 Introduction of the smart fortwo, Model Series 451 Automated manual transmission control unit (N15/6) Location The automated manual transmission control unit is located in the passenger compartment under the driver seat. General The transmission control converts the driver's shift requests into corresponding control signals to the clutch and the 5
speed automated manual transmission. This is done by relaying the shift signal about the shift request at the electronic selector lever module control unit over a direct line to the auto
mated manual transmission control unit. The automated manual transmission control unit checks the plausibility of the shift request in relation to the vehicle speed, the load (acceler
ator pedal position) and the engine speed. If the plausibility check is passed, the automated manual transmission control unit sends the signal to initiate the selected shift operation to the two actuator motors for the two selector drums and to the clutch motor to open or close the clutch. Task The automated manual transmission control unit controls the following functions depending on the input information: • Engaging first gear at vehicle standstill • Gear change • Compulsory upshift just before maximum engine speed is reached • Compulsory downshift when engine idle speed is approached • Downshift for kickdown • Disengaging the gear after 1 s when a door is opened without the service brake or accelerator pedal being actuated • Crawl function • Clutch operation • Monitoring of clutch load P26.19-2145-00 N15/6 Automated manual transmission control unit The automated manual transmission control unit directly reads the signals from the following compo
nents: • Transmission rpm sensor (L2) • Transmission motor 1 (M17/3) • Transmission motor 2 (M17/4) • Clutch motor (M18) • Electronic selector lever module control unit (N15/5) • Park pawl switch (S16/2) SN_Typ 451_us.book Seite 57 Freitag, 30. November 2007 1:56 13 4---- --t -+ +- N15/6

Transmission control

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 59 · Applies to: 451

58 Automated manual transmission Introduction of the smart fortwo, Model Series 451 The following components are actuated directly by the automated manual transmission control unit: • Transmission motor 1 (M17/3) • Transmission motor 2 (M17/4) • Clutch motor (M18) Communication via CAN takes place with the following components: • Instrument cluster (A1) • ME
SFI [ME] control unit (N3/10) • SAM control unit (N10/10) • Electronic selector lever module control unit (N15/5) • ESP control unit (N47
5) Electronic selector lever module control unit (N15/5) Location The electronic selector lever module control unit is located in the center console. Task The electronic selector lever module control unit records the shift requests of the driver. The shift positions “N”, “R”, “+” and “
” are detected by Hall sensors in the electronic selector lever module control unit and are read and evalu
ated by the electronics in the electronic selector lever module control unit. The signals corre
sponding to the shift lever positions are trans
ferred to the automated manual transmission control unit. The release button on the selector lever must be actuated in order to move the selector lever to the following positions: • From P to R, N or D • From R to P • From N to R or P The transmitter key can only be removed in position 0 if the selector lever is in position P. When the transmitter key is removed, the selector lever is locked in position P. P26.60-2375-00 1 Unlock button N15/5 Electronic selector lever module control unit P Park R Reverse gear N Neutral position D Automatic mode M Manual mode + Upshift
Downshift i Note When reverse gear is requested, the backup light is actuated directly by the electronic selector lever module control unit. SN_Typ 451_us.book Seite 58 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Transmission control

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 60 · Applies to: 451

Automated manual transmission 59 Introduction of the smart fortwo, Model Series 451 Manual mode In manual mode (selector lever in position M), the gears are shifted either using the selector lever or using the paddle shifts on the steering wheel (SAL). The gear which is currently selected is displayed on the multifunction display in the instrument cluster. The gear indicator may change to provide gearshift recommendations (arrow up or down). The gearshift recommendations are based on a driving style which optimizes fuel consumption. Automatic mode In automatic mode (selector lever in position D), the automated manual transmission control unit deter
mines the gear changes. The selected gear range D is displayed on the multifunction display in the instrument cluster. P54.32-5683-00 1 Gear range display (automatic mode) 2 Gear display (manual mode) A1 Instrument cluster A1p13 Multifunction display SN_Typ 451_us.book Seite 59 Freitag, 30. November 2007 1:56 13 4---- --t A1 18000- 1200.. 'IOIL? 3 I • ' 1 c1 A1p13 2 c· -+ +-

Transmission control

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 61 · Applies to: 451

60 Automated manual transmission Introduction of the smart fortwo, Model Series 451 P26.19-2141-00 1 Circuit status 2 Shift request 3 Transmission speed 4 Clutch request 5 Clutch motor status 6 Gear change request 7 Transmission motor status 8 Engine speed 9 Backup light actuation 10 Vehicle speed 11 Shift program selection 12 Accelerator pedal position 13 Brake pedal status 14 Door status 15 Engaged gear 16 Gear indicator actuation 17 Park pawl status A1 Instrument cluster A45 Fanfare horns and airbag clock spring con
tact E3e3 Left backup light E4e3 Right backup light L2 Transmission rpm sensor M17/3 Transmission motor 1 M17/4 Transmission motor 2 M18 Clutch motor N3/10 ME
SFI [ME] control unit (gasoline engine) 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 S16/2 Park pawl switch S112s1 Steering wheel gear shifter PLUS (SAL) S112s2 Steering wheel gear shifter MINUS (SAL) CAN Controller Area Network (data bus/CAN bus) Data flow chart of transmission control SN_Typ 451_us.book Seite 60 Freitag, 30. November 2007 1:56 13 -+ N3/10 M17/3 M17/4 CAN CAN ~ A1 ~ 5112s1 f S112s2 +-

Park pawl

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 62 · Applies to: 451

Automated manual transmission 61 Introduction of the smart fortwo, Model Series 451 Mechanical park pawl In addition to the parking brake, the 5
speed auto
mated manual transmission is equipped with a mechanical park pawl to prevent the vehicle from rolling away. The mechanical park pawl is operated by the electronic selector lever module control unit via a cable. The status of the park pawl is reported to the auto
mated manual transmission control unit via the park pawl switch (S16/2). P26.60-2377-00 1 Transmission 2 Cable 3 Park pawl N15/5 Electronic selector lever module control unit S16/2 Park pawl switch SN_Typ 451_us.book Seite 61 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Clutch

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 63 · Applies to: 451

62 Automated manual transmission Introduction of the smart fortwo, Model Series 451 Single
plate dry clutch A single
plate dry clutch, consisting of clutch plate and pressure plate, is installed on model 451. An internal computer in the automated manual trans
mission control unit evaluates the clutch load. If a threshold value is exceeded, the clutch starts to pulse as an overload warning to the driver. If the overloading continues, e.g. if the car is being held with the clutch on a gradient, the clutch is closed in order to provoke a stall. P25.00-2010-00 Single
plate dry clutch 1 Pressure plate 2 Clutch plate 3 Flywheel with starter ring gear SN_Typ 451_us.book Seite 62 Freitag, 30. November 2007 1:56 13 -4 -r -+ 2 +- 3

Clutch

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 64 · Applies to: 451

Automated manual transmission 63 Introduction of the smart fortwo, Model Series 451 Clutch motor General Model 451 is fitted with a 5
speed automated manual transmission. This means that a single
plate dry clutch is installed instead of the torque converter that is usual with conventional automatic transmissions. The single
plate dry clutch is actuated by the clutch motor. Function When the automated manual transmission control unit issues a request for a gear change, the clutch motor is actuated at the same time. The electric motor inte
grated in the clutch motor operates the clutch via the actuating plunger. The power flow is interrupted and the shift operation can be performed. P25.19-2010-00 4 Electric motor 5 Electric motor connector 6 Actuating plunger M18 Clutch motor SN_Typ 451_us.book Seite 63 Freitag, 30. November 2007 1:56 13 4---- --t -+ M18 +- 6 5

Front axle

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 65 · Applies to: 451

64 Chassis Introduction of the smart fortwo, Model Series 451 Front axle The front axle has a classic McPherson design. The supporting ball joint is press
fitted with the transverse control arm forming a single component unit. If repairs are necessary, the supporting ball joint must be replaced complete with the cross
member since a satisfactory press
fit cannot be guaranteed in the repair shop. The wheel bearing in the steering knuckle is not available separately either because it is pressed into the steering knuckle and can only be ordered as a complete unit with the steering knuckle. Adjustment capabilities On the front axle it is only possible to adjust the toe; the camber can only be corrected by utilizing the "play" at the attachment points of the front axle. P33.00-2086-00 Front axle
smart fortwo model 451 1 Front axle crossmember 2 Stabilizer bar 3 Transverse control arm with press
fitted support
ing ball joint 4 Coil spring 5 Two
tube shock absorber 6 Wheel carrier, cast iron with pressed
in wheel bearing SN_Typ 451_us.book Seite 64 Freitag, 30. November 2007 1:56 13 -4 -r -+ ~4 +- 5 1 2

Rear axle

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 66 · Applies to: 451

Chassis 65 Introduction of the smart fortwo, Model Series 451 Rear axle with suspension The rear axle consists of: • Axle tube • Frame
type integral support • Coil springs • Bar link • Single
tube shock absorbers • Center bearing The frame
type integral support supports the rear wheel drive module. The coil springs are located at the outsides and support the body against rolling move
ments. The single
tube shock absorbers are fixed in place at the top with pin bearings. P35.00-2075-00 Rear axle
smart fortwo model 451 7 Axle tube 8 Frame
type integral support 9 Coil spring 10 Bar link 11 Single
tube shock absorber pin bearing 12 Single
tube shock absorber 13 Center bearing SN_Typ 451_us.book Seite 65 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Rear module

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 67 · Applies to: 451

66 Chassis Introduction of the smart fortwo, Model Series 451 Lowering the rear module On model 451, the rear wheel drive module can be lowered. This shortens removal/installation time for various major assemblies such as the refrigerant compressor, starter, alternator etc., because all the attached parts on the engine and the engine itself can be reached very quickly and with relatively little effort. This shortens repair times and reduces costs while improving customer satisfaction at the same time. P35.00-2085-00 Lowered rear drive module SN_Typ 451_us.book Seite 66 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Tire pressure monitor

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 68 · Applies to: 451

Chassis 67 Introduction of the smart fortwo, Model Series 451 General The tire pressure monitoring system (TPM [RDK]) monitors the air pressure in the individual tires and improves active safety. A previously stored tire pres
sure is used as a comparative value. If a relevant loss of pressure occurs, the tire pressure monitor warning lamp in the instrument cluster warns the driver. The tire pressure measuring range is p = 0 to 78 psi (p = 0 to 5.5 bar). The TPM [RDK] system has the following subfunctions: • Tire pressure sensing • Warning display • Manual restart Function requirements • Circuit 15 ON • Tire pressure monitor (TPM [RDK]) system functional Tire pressure sensing The TPM [RDK] control unit is permanently opera
tional. Each time the CAN wakes up, the control unit performs a re
initialization. While driving, the tire pressure monitoring (TPM [RDK]) system continuously monitors the tire pressure of all rotating wheels (with circuit 15 OFF for a further t = 19 min). When the vehicle is parked for t > 19 min, on
board wheel detection and axle assignment must first be completed via the TPM [RDK] wheel sensors. While driving, the TPM [RDK] wheel sensors transmit data telegrams every 60 seconds. These data telegrams contain the following informa
tion: • Tire pressure • Tire air temperature • Individual serial number • Status information (manufacturer, direction of rotation, operating mode etc.) In addition the TPM [RDK] control unit takes into account the outside temperature and the vehicle speed for the tire pressure determination. These data are provided via CAN by the instrument cluster. Warning indicator A warning is issued when a relevant loss of pressure has been detected in at least one of the tires. The warning is issued in the instrument cluster via the tire pressure monitor warning lamp, but the specific tire where pressure loss has occurred is not specified. Manual restart The tire pressure to be monitored can be reset via the TPM [RDK] switch on the cockpit switch panel. When the TPM [RDK] switch is pressed, the current tire pressure is stored in the memory of the TPM [RDK] control unit and is then used as the reference pres
sure, as long as it is within the permissible limits. The tire pressure monitor warning lamp in the instru
ment cluster flashes to indicate that a manual restart has taken place. i Note A manual restart must be performed each time the tire inflation pressure is changed and when a wheel, wheel sensor or the TPM [RDK] control unit is replaced. If the nut on the valve element of a wheel sensor is loosened, all components of the valve element must be replaced. See the Workshop Information System (WIS) for further instructions and information. SN_Typ 451_us.book Seite 67 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Tire pressure monitor

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 69 · Applies to: 451

68 Chassis Introduction of the smart fortwo, Model Series 451 P40.15-2424-00 Location of TPM [RDK] components A1 Instrument cluster A1e66 Tire pressure monitor warning lamp A69/1 Left front TPM [RDK] wheel sensor A69/2 Right front TPM [RDK] wheel sensor A69/3 Left rear TPM [RDK] wheel sensor A69/4 Right rear TPM [RDK] wheel sensor B14 Outside temperature display temperature sensor N10/10 SAM control unit N88 TPM [RDK] control unit S6/1 Cockpit switch group S6/1s9 TPM [RDK] switch SN_Typ 451_us.book Seite 68 Freitag, 30. November 2007 1:56 13 i: S6/1 A1 N10/10 S6/1s9 ~ N88 -+ B14 +-

Brakes

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 70 · Applies to: 451

Chassis 69 Introduction of the smart fortwo, Model Series 451 Task The task of the brake system is to brake the vehicle or hold it at a standstill. The system includes the service brake, which brakes the vehicle while it is being driven, and the parking brake, which secures the vehicle when it is at a stand
still. Components of the parking brake • Hand brake lever with hand brake cables • Parking brake mechanism integrated into rear drum brake Function of parking brake When the handbrake lever is actuated, a relay lever is actuated at the rear brake shoes of the left and right drum brakes via the handbrake cables. This presses the brake shoes of the drum brakes against the insides of the brake drums to build up the required brake force. Components of the service brake • Disk brakes with brake calipers on front axle • Drum brakes with aluminum wheel brake cylinders on rear axle • Brake fluid reservoir • Brake lines and brake hoses • Brake pedal module • ESP unit, consisting of ESP control unit and ESP hydraulic unit Function of service brake The service brake is a hydraulic 2
circuit brake system with TT (front/rear) split. The force applied to the brake pedal is transferred to the brake booster via a linkage. The brake booster multiplies this forces and uses it to pressurize the master brake cylinder. The brake pressure is built up via the master brake cylinder. The brake force is distributed to the disk brakes and drum brakes by the ESP unit via the integrated antilock brake system (ABS) and the electronic brake force distribution (EBD) system. SN_Typ 451_us.book Seite 69 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Brakes

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 71 · Applies to: 451

70 Chassis Introduction of the smart fortwo, Model Series 451 P40.10-2711-00 Brake system 1 Brake pedal module 2 Brake disk 3 Brake caliper 4 Expansion reservoir 5 ESP unit 6 Hand brake cables 7 Drum brake (consisting of: anchor plate, wheel brake cylinder, brake shoe, springs and brake drum) 8 Hand brake lever B24/15 Yaw rate, lateral and longitudinal accelera
tion sensor L6/1 Left front rpm sensor L6/2 Right front rpm sensor L6/3 Left rear rpm sensor L6/4 Right rear rpm sensor N47
5 ESP control unit N49 Steering angle sensor SN_Typ 451_us.book Seite 70 Freitag, 30. November 2007 1:56 13 -4 -r -+ L6/3 +- N47-5

Brakes

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 72 · Applies to: 451

Chassis 71 Introduction of the smart fortwo, Model Series 451 Brake pedal module The brake pedal module is located on the underfloor and consists of the following assemblies: • Pedals • Carrier • Brake booster • Master brake cylinder Pedals The pedals consist of: • Pedal head • Perforated boot • Pedal assembly seal • Housing • Linkage rod • Brake pedal module cover • Seal for brake pedal module cover • Brake light switch P42.10-2712-00 Brake pedal module 9 Pedal head 10 Housing 11 Carrier 12 Brake booster 13 Master brake cylinder 14 Grommet 15 Brake pedal module cover 16 Linkage 17 Seal 18 Pedal assembly seal 19 Perforated boot 20 Bolt S9/1 Brake light switch SN_Typ 451_us.book Seite 71 Freitag, 30. November 2007 1:56 13 4---- --t -+ 19 12 +- 13 17 59/1 16 15

Brakes

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 73 · Applies to: 451

72 Chassis Introduction of the smart fortwo, Model Series 451 Pedals The seals and the boot on the pedals may not be damaged otherwise moisture can penetrate into the interior compartment. To ensure that the pedals remain leaktight, the brake pedal module cover must be replaced each time the pedals are disassembled. Brake light switch The brake light switch in the pedal assembly is only accessible after the brake pedal module cover has been removed. The brake light switch is actuated via the linkage in the pedal assembly when the brake is actuated. The signal from the brake light switch is read by the ESP control unit. The free travel of the brake light switch must be correctly adjusted to ensure that the brake light switch operates properly. Brake lines All brake lines may only be retightened twice at the most when work is performed on the vehicle. If a threaded connection on a brake line is loosened and then retightened, this must be documented. The respective threaded connection must be marked in color with a suitable safety paint. The following color codings are specified: • First retightening: yellow marking • Second retightening: red marking If the respective threaded connection is loosened again after being retightened for a second time, the detached brake line must be replaced. This also applies if it is not possible to trace how often the threaded connection has previously been loosened. Brake system bleeding Whereas the brake fluid can be replaced by one person, the hydraulic brake system can only be bled by two people working together. When bleeding the primary and secondary circuit, one person must build up the pressure required by the brake fluid changer by repeatedly actuating the brake pedal. The second person is needed to: • Actuate the ESP hydraulic unit via diagnosis at the same time and perform the bleeding procedure when bleeding the primary circuit • Perform the bleeding procedure when bleeding the secondary circuit i Note To ensure that the brake system is not damaged, the filling pressure on the brake fluid changer may be set to max. 2.8 psi (2 bar). i Note See the Workshop Information System (WIS) for the exact procedure for repairing the brake system and for the relevant safety information. Basic adjustment of brake shoes After brake shoes are replaced or removed/installed, basic adjustment of the drum brake must be performed. To do so, the brake shoes are measured and adjusted using the slack adjuster. Drum brake adjustment Manual adjustment of the clearance between brake shoe and brake drum is not permissible. Adjustment may only be performed via the automatic slack adjuster of the brake shoes to prevent grinding or locking of the drum brake. SN_Typ 451_us.book Seite 72 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Brakes

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 74 · Applies to: 451

Chassis 73 Introduction of the smart fortwo, Model Series 451 ESP system The latest ESP system (version 8.1) is installed next to the brake pedal module on the underfloor and features the following functions: • ABS • ASR • HBA • EBD • ESP • EBR • Start
off assist Antilock brake system (ABS) Prevents individual wheels from locking up by regu
lating the brake pressure at the relevant wheel brakes. The vehicle remains steerable, enabling the driver to take evasive action himself to avoid sudden obstacles during emergency braking. Acceleration skid control (ASR) Prevents the drive wheels from spinning by inter
vening in the engine management and brake pressure regulation. ASR provides good traction and improves vehicle stability and steerability when moving off and accelerating. Hydraulic brake assist (HBA) Regulates the pressure buildup in the brake system in relation to the vehicle speed and the actuation speed of the brake pedal. When emergency braking is detected by means of characteristics defined before
hand, the ESP control unit actuates the return flow pump that is integrated in the hydraulic unit. The maximum brake pressure is built up. Electronic brake force distribution (EBD) Regulates the brake pressure at the rear wheels in the partial braking range in order to improve the stability of the vehicle and the braking effect. Electronic stability program (ESP) Minimizes oversteer or understeer by means of specific intervention by the brake system at each wheel on the front and rear axles. There may also be intervention in the engine and transmission control systems if necessary. Engine braking regulation (EBR) Reduces slip of the drive wheels in deceleration mode and thereby improves directional stability and road adhesion. Start
off assist Maintains the brake pressure for approx. 0.7 s after the brake pedal is released to facilitate start
off on uphill slopes. Rpm sensors The rpm sensors are active sensors, i.e. they must be connected to a voltage source in order to operate. They deliver a signal with an rpm
independent, constant amplitude, and utilize the Hall effect to detect the rpm signal. Yaw rate, lateral and longitudinal acceleration sensor The yaw rate, lateral and longitudinal acceleration sensor is a combined sensor of micromechanical design. It registers the yaw rate (yaw angle velocity) of the vehicle about the vertical axis, the longitudinal acceleration and the lateral acceleration. i Note In the event of an emergency stop in which the vehicle is braked to a standstill from a speed in excess of 43 mph (70 km/h), the SAM control unit automatically activates the hazard warning system. Deactivation of the hazard warning func
tion occurs automatically when the vehicle speed is detected to have risen above 6 mph (10 km/h) or manually by actuation of the hazard warning system switch. SN_Typ 451_us.book Seite 73 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Brakes

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 75 · Applies to: 451

74 Chassis Introduction of the smart fortwo, Model Series 451 P42.45-2662-00 Data flow chart of Electronic Stability Program ESP 1 ESP/ABS/ASR status 2 ESP/ABS/ASR display status 3 Wheel speed signal 4 Steering angle 5 Steering rate 6 Lateral and longitudinal acceleration 7 Yaw rate 8 Engine torque control 9 Transmission control intervention 10 Brake pedal status 11 Emergency stop reference speed 12 Driver door closed status 13 Handbrake status 14 Brake fluid status A1 Instrument cluster A1e41 ESP warning lamp B24/15 Yaw rate, lateral and longitudinal accelera
tion sensor L6/1 Left front rpm sensor L6/2 Right front rpm sensor L6/3 Left rear rpm sensor L6/4 Right rear rpm sensor N3/10 ME
SFI [ME] control unit N10/10 SAM control unit N15/6 Automated manual transmission control unit N47
5 ESP control unit N49 Steering angle sensor S9/1 Brake light switch S11 Brake fluid indicator switch S12 Parking brake indicator switch CAN Controller Area Network (data bus/CAN bus) SN_Typ 451_us.book Seite 74 Freitag, 30. November 2007 1:56 13 i: CAN CAN CAN -+ N49 L6/1 L6/2 L6/3 L6/4 A1e41 +-

Steering

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 76 · Applies to: 451

Chassis 75 Introduction of the smart fortwo, Model Series 451 Rack
and
pinion steering The smart fortwo features rack
and
pinion steering as standard. The steering ratio is 22:1. Electric power steering EPS (special equipment) Electric Power Steering (EPS) is available as special equipment. The steering ratio is 21:1. The tasks of the EPS system are as follows: • Power assistance with Servotronic • Adaptation of the steering forces • Active steering centering General Electric Power Steering (EPS) is a direct steering system with integral speed
dependent power assis
tance and active steering centering. This ensures that steering wheel forces remain low when the vehicle is being maneuvered. An electromechanical system offers the following advantages compared to a conventional hydraulic power steering system: • Less weight and smaller installation space • Greater degree of freedom to adjust the steering assistance • Reduced fuel consumption. EPS operates without hydraulic components such as pumps, reservoirs, coolers, lines and hydraulic fluid, and is therefore a dry, environmentally compatible system. P46.10-2935-00 Electric power steering EPS SN_Typ 451_us.book Seite 75 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Steering

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 77 · Applies to: 451

76 Chassis Introduction of the smart fortwo, Model Series 451 Design The main components of the electric power steering (EPS) system are the power steering motor, a DC brush
type electric motor with maximum 35 Ampere power consumption and the power steering control unit. The power steering control unit communicates via the CAN data bus and is located in the vehicle interior on the left of the firewall. The rack
and
pinion mechanical components for the electric power steering (EPS) are accommodated in a steering housing made of diecast aluminum, to which the power steering motor is also flange
mounted. To provide steering assistance, the steering gear pinion shaft transmits the rotational movement of the steering gear input shaft to the teeth of the toothed rack. The power steering motor transmits force for steering assistance to the spur toothing of the hyper
bolic gear via a worm shaft. The hyperbolic gear is fixed to the pinion of the steering gear pinion shaft. The power steering torque sensor is located in the steering gear housing between the steering gear input shaft and hyperbolic gear. P46.10-2933-00 Components of the electric power steering (EPS) 1 Steering gear housing 2 Steering gear pinion shaft 3 Steering gear input shaft 4 Toothed rack 5 Worm shaft 6 Hyperbolic gear B23 Power steering torque sensor M19 Power steering motor N68 Steering assist control unit SN_Typ 451_us.book Seite 76 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Steering

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 78 · Applies to: 451

Chassis 77 Introduction of the smart fortwo, Model Series 451 Function Function requirement Steering assistance is activated after engine start and at a minimum engine speed of 500 rpm. Steering power assistance As the driver turns the steering wheel, a steering torque is produced at the drag link which is regis
tered by the power steering torque sensor and forwarded to the power steering control unit. The steering torque is used as an actuating variable for the electric assistance force. It is derived from the rotation of the torsion bar, which is located between the steering gear input shaft and steering gear pinion shaft on the same axis. The power steering torque sensor is located around the torsion bar. This determines the torque over a range of +/
8.1 lb
ft (11 Nm) and at a resolution of 0.037 lb
ft (0.05 Nm). The power steering control unit uses the steering torque measurement to determine the level of torque that needs to be provided to supplement the steering force. Based on this information and depending on the vehicle speed signal from the ESP control unit and the engine speed signal from the ME
SFI [ME] control unit, the power steering control unit determines the current requirement of the power steering motor as per the programmed characteristic field. The power steering motor transmits the appropriate supplementary steering torque to the face of the hyperbolic gear via the worm shaft. P46.10-2934-00 Steering torque of the electric power steering (EPS) 2 Steering gear pinion shaft 3 Steering gear input shaft 5 Worm shaft 6 Hyperbolic gear 7 Torsion bar B23 Power steering torque sensor M19 Power steering motor N68 Steering assist control unit SN_Typ 451_us.book Seite 77 Freitag, 30. November 2007 1:56 13 4---- --t 3--1: . B23 I N68 -+ +-

Steering

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 79 · Applies to: 451

78 Chassis Introduction of the smart fortwo, Model Series 451 Steering centering This function returns the steering to the center posi
tion once the driver stops applying steering torque. The power steering motor is actuated accordingly by the power steering control unit. "Active center feeling" function When the steering wheel is registered in the center position and there are no steering movements, the power steering motor is energized by the steering assist control unit so that a sufficient torque is produced to hold the steering in the straightahead position. This actuation conveys an improved steering center feel to the driver. The system is continuously calibrated and learns the center position automati
cally. The long
term calibration is performed via the ESP wheel sensor system. Limp
home function The steering assist control unit constantly checks all the input signals for plausibility. In the case of a faulty component the steering, power assistance is shut down and a fault is stored in the steering assist control unit. The steering then continues to function as a conventional rack
and
pinion steering. i Note If the electric steering suffers a function failure, the electric steering indicator lamp in the instru
ment cluster lights up to indicate this. i Note The steering power assistance is at a maximum at low speeds and when the vehicle is stationary and decreases as the vehicle speed increases. Once the vehicle stops and the engine is switched off, the steering power assistance is deactivated in stages after approx. 3 s. To comply with EMC requirements, the energy line from the power steering control unit to the power steering motor is 85 % shielded against external influ
ences. The power steering control unit is a CAN bus subscriber in the overall network. The vehicle speed, the steering angle and other data are read in over CAN. SN_Typ 451_us.book Seite 78 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Steering

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 80 · Applies to: 451

Chassis 79 Introduction of the smart fortwo, Model Series 451 P46.35-2034-00 Data flow chart of electric power steering EPS 1 Vehicle speed 2 Steering torque 3 Warning and fault message output 4 Power steering motor actuation 5 Steering angle, steering rate 6 Engine speed A1 Instrument cluster A1e18 Electric steering indicator lamp B23 Power steering torque sensor M19 Power steering motor N3/10 ME
SFI [ME] control unit N47
5 ESP control unit N49 Steering angle sensor N68 Steering assist control unit CAN Controller Area Network (data bus/CAN bus) SN_Typ 451_us.book Seite 79 Freitag, 30. November 2007 1:56 13 4---- I CAN ~ N3/10 -+ N49 +-

Steering

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 81 · Applies to: 451

80 Chassis Introduction of the smart fortwo, Model Series 451 Steering wheel Two steering wheel variants are available for model series 451. Variants • Leather two
spoke steering wheel of dia. 14.6 in (370 mm) as standard equipment on the pure • Three
spoke sport steering wheel with integrated paddle shift of dia. 13.8 in (350 mm) as standard equipment on the passion Paddle shifts on steering wheel In vehicles that are fitted with a three
spoke sport steering wheel, the paddle shifts on each side of the steering wheel can be used to shift up and down through the gears. It is therefore possible to select a gear on the steering wheel as well as via the gear selector lever. The left
hand paddle shift is used to downshift and the right
hand paddle shift is for upshifts. The gear which is currently engaged is displayed on the multifunction display in the instrument cluster. P46.10-2839-00 Two
spoke steering wheel P46.10-2840-00 Three
spoke sport steering wheel with paddle shifts SN_Typ 451_us.book Seite 80 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Steering

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 82 · Applies to: 451

Chassis 81 Introduction of the smart fortwo, Model Series 451 Steering wheel removal and installation The following components of the steering wheel are replaceable: • Contact unit with steering angle sensor • Airbag module • Paddle shifts (three
spoke sport steering wheel only) The steering wheel must be detached first before replacing or removing/installing any of the above components. Care must be taken to ensure that the front wheels are in the straightahead position, the battery is discon
nected and the handbrake is applied before the steering wheel is removed. The exact procedure for removal/installation of the steering wheel and its components is described in the Workshop Information System (WIS). i Note All control units must be de
energized before the steering wheel is removed. For this reason, at least 15 minutes must elapse after the battery is disconnected before it is removed. i Note Care must be taken to ensure that the turn signal is not set when removing/installing the steering wheel otherwise the trigger tab may be damaged. P46.10-2841-00 SN_Typ 451_us.book Seite 81 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Interior

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 83 · Applies to: 451

82 Body Introduction of the smart fortwo, Model Series 451 Interior design The interior compartment has a classic look while still displaying modern, typical smart features. This well
balanced overall concept helps the smart fortwo create an exclusive overall impression with high perceived quality. This is helped by the lines of the instrument panel, the door linings and the seats shaped to match. The harmonized color scheme of the interior also gives a positive impression in combination with the passenger compartment as a whole. P68.00-5039-00 Shown on the smart coupé pure SN_Typ 451_us.book Seite 82 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Interior

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 84 · Applies to: 451

Body 83 Introduction of the smart fortwo, Model Series 451 Instrument panel For the design of the instrument panel, particular emphasis was placed on the following criteria: • Ergonomics • Clear layout • Passenger safety The instrument panel is designed with straight lines and equipped with airbags and a full length knee bolster to improve passenger protection. Two additional instruments (tachometer and clock) are available as special equipment (SA) and are posi
tioned above the center console. The air vents on the instrument panel have a cylindrical shape. P68.10-3852-00 Shown on the smart coupé passion SN_Typ 451_us.book Seite 83 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Interior

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 85 · Applies to: 451

84 Body Introduction of the smart fortwo, Model Series 451 Instrument cluster In the center of the instrument cluster is the speed
ometer scale with the multifunction display under
neath. On each side is a strip with indicators and warning displays, as well as the control buttons for the multi
function display. The task of the instrument cluster is to provide the driver with information about the various operating states and to provide acoustic or visual warnings in the event of critical operating conditions. It is the display unit for the vehicle speed and for other systems. In addition, the instrument cluster computes the maintenance intervals and shows them in the multifunction display. The instrument cluster is a device on the data bus/CAN bus in the overall network. Most of the signals are transmitted or received over CAN. The following signals are supplied to the instrument cluster over direct lines: • Signal from outside temperature indicator temperature sensor • Signal from "Fanfare horns and airbag clock spring contact“ (only on variant with SAL). The vehicle speed is displayed by an electronic speedometer that is driven by a stepper motor. The ESP control unit reads the information for the speed display from the wheel speed sensors in the form of signals, and forwards it over CAN to the instrument cluster. The instrument cluster processes the incoming signals and uses them to calculate the vehicle speed and distance traveled. Multifunction display The task of the multifunction display is to provide the driver with information about variable changes in the vehicle, the ambient conditions and the road. The variable displays include: • Outside temperature • Main odometer • Trip odometer • Gear indicator (in manual mode) • Automatic transmission indicator (in automatic mode) • Fuel reserve indicator (US gal) • Maintenance interval display with symbol • Fuel level and reserve indicator • Clock P54.32-5677-00 Multifunction display SN_Typ 451_us.book Seite 84 Freitag, 30. November 2007 1:56 13 -+ so□ miles ~ Lf□B.2 0 1200am 3 I -t= 1 -4 -r +-

Interior

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 86 · Applies to: 451

Body 85 Introduction of the smart fortwo, Model Series 451 P54.30-9683-00 Instrument cluster 1 Left button, select multiple display / set clock 2 Right button, instrument illumination / set clock A1 Instrument cluster A1e1 Left turn signal indicator lamp A1e2 Right turn signal indicator lamp A1e3 High beam indicator lamp A1e5 Alternator charge monitoring and warning lamp A1e7 Brake fluid and parking brake warning lamp A1e9 Seat belt warning lamp A1e15 Airbag indicator and warning lamp A1e17 ABS indicator lamp A1e18 Electric steering indicator lamp A1e26 CHECK ENGINE indicator lamp A1e30 Oil pressure warning lamp A1e41 ESP warning lamp A1e54 Coolant temperature warning lamp A1e66 Tire pressure monitor warning lamp A1e67 Low beam indicator lamp A1p8 Electronic speedometer A1p13 Multifunction display SN_Typ 451_us.book Seite 85 Freitag, 30. November 2007 1:56 13 4---- fr A1 A1e67 A1e18 A1e3 A1e26 A1e66 A1e9 A1e17 A1e7 -+ A1e15 +- 1 2 A1e5 A1p13 A1e54 A1e30

Doors/flaps

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 87 · Applies to: 451

86 Body Introduction of the smart fortwo, Model Series 451 Side doors The doors of the new smart fortwo follow the typical smart brand construction principle with a metal carrier part and the plastic CBS door paneling. The doors of the smart coupé and the smart cabrio are identical. The triangular windows located above each door handle are stationary windows held in place by bolts. Crash requirements The door support structure in model 451 is made of steel. In addition, panels and sections of high
strength steel are used at strategically important points. This is the case, for example, with the diagonal struts and the side window slot frames. In combination with the cockpit crossmember, this makes the passenger compartment highly resistant to side impacts in this section of the vehicle. P72.00-2185-00 Door structure 1 Door carrier module 2 Diagonal strut 3 Side window slot frame 4 Cockpit crossmember Emergency opening Normally, the smart fortwo is opened from outside via the standard
equipment central locking system using the transmitter key. If the battery in the transmitter key cannot supply enough power, a lock cylinder installed behind a small cover under the handle of the left door can be used to open the driver door manually in an emergency. P80.20-3225-00 1 Lock cylinder for emergency opening SN_Typ 451_us.book Seite 86 Freitag, 30. November 2007 1:56 13 4 -+ 3 2 1 -4 -r +-

Doors/flaps

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 88 · Applies to: 451

Body 87 Introduction of the smart fortwo, Model Series 451 P72.10-3403-00 Design of driver door with power window and electric outside mirror 1 Door carrier module 2 Window lifter mechanism 3 Diagonal strut 4 Top door hinge assembly 5 Bottom door hinge assembly 6 Inner door lining 7 CBS door paneling 8 Curved handle 9 Side window 10 Triangular window H4/9 Left front speaker M10/3 Left power window motor M14/6 Left door CL [ZV] motor M14/6s1 Left door CL [ZV] microswitch M21/1 Left electrically adjustable and heated out
side mirror S21/1 Left power window switch S21/2 Right power window switch S50 Outside mirror adjustment switch S87/7 Left door rotary tumbler microswitch SN_Typ 451_us.book Seite 87 Freitag, 30. November 2007 1:56 13 4---- fr , -+ +-

Doors/flaps

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 89 · Applies to: 451

88 Body Introduction of the smart fortwo, Model Series 451 Rear
end door P72.20-2599-00 Design of rear
end door shown on the smart fortwo coupé 1 Upper rear
end door 2 Upper rear
end door paneling 3 Rear spoiler 4 Upper rear
end door hinges 5 Gas
operated strut 6 Rear window 7 CBS rear
end door paneling 8 Lower rear
end door 9 Right door lock of lower rear
end door 10 Left door lock of lower rear
end door 11 Door lock of upper rear
end door 12 Door panel lining 13 Lower rear
end door hinges 14 Seal E21 Center high
mounted brake lamp M6/4 Rear
end door wiper motor S88/9 Rear
end door handle switch SN_Typ 451_us.book Seite 88 Freitag, 30. November 2007 1:56 13 -4 -r 3 -+ +-

Doors/flaps

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 90 · Applies to: 451

Body 89 Introduction of the smart fortwo, Model Series 451 Emergency unlocking of rear
end door The rear
end door in the smart fortwo can be unlocked from the inside in an emergency, if the trunk lid central locking motor for operating the rotary tumbler is defective or de
energized. Emergency unlocking in smart fortwo coupé To do this, a small tab at the side of the trunk lid lock paneling must be carefully bent over or broken off to produce a small hole. A shop
made wire must then be inserted through the small hole so that enough downward pressure is exerted on the relay lever in the door lock to unlock the rear
end door at the top. A description of the procedure for manufacturing the emergency release wire in the workshop is given in the Workshop Information System (WIS). Emergency unlocking in smart fortwo cabrio In order to open the two door locks in the cabrio, a hole must be accurately marked on the inside of the rear
end door on each side. Then a hole of 0.2 in (5 mm) diameter is drilled through the paneling on each side of the rear
end door.. A suitable screwdriver is inserted into each hole and the rear
end door is unlocked by moving the screw
driver handles simultaneously in the directions of the arrows. The exact dimensions for the holes and a detailed description of the procedure can be found in the Workshop Information System (WIS). P72.20-2583-00 A Actuation direction 1 Tab/paneling hole on trunk lid lock 2 Emergency release wire P72.20-2582-00 B Actuation direction 3 Hole (0.2 in (5 mm)) 4 Screwdriver SN_Typ 451_us.book Seite 89 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Roof systems

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 91 · Applies to: 451

90 Body Introduction of the smart fortwo, Model Series 451 Variants of roof system Two roof variants are available for the model series 451 coupé. A fully electric Tritop fabric soft top is installed in the cabrio. smart fortwo coupé • Full roof made of glass fiber reinforced polyurethane (PU) • Panoramic sunroof made of polycarbonate (PC) smart fortwo cabrio • Fully electric Tritop fabric soft top P65.00-2119-00 Vehicle with PU roof P77.21-2226-00 Vehicle with panoramic sunroof P77.00-2338-00 Vehicle with fully electric Tritop fabric soft top SN_Typ 451_us.book Seite 90 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Roof systems

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 92 · Applies to: 451

Body 91 Introduction of the smart fortwo, Model Series 451 Hard roofs on smart fortwo coupé Full roof In the standard equipment pure version the smart fortwo coupé is supplied with the polyurethane (PU) full roof. The PU roof is only available in pitted matt black. The PU full roof sits on the body and is bonded to the bodyshell structure. Panoramic sunroof A polycarbonate (PC) panoramic sunroof with step
lessly variable roller sun blind is available for some equipment variants. The roof module is bonded to the tridion safety cell. The latest in plastics technology makes it possible to use breakproof material extensively in the vehicle. The material is covered with a scratch
resistant coating and the light transmission of the tint is approx. 13 %. The material also provides 100 % protection against UV light. The steplessly adjustable inside roller blind can be used to block out the sun. The roller sun blind is made of a polyester fabric and covers the entire trans
parent area of the panoramic sunroof. The roof and roller blind can be replaced separately. The panoramic sunroof is manufactured by a two
component injection molding process in which the second component material serves to blacken the edges. P77.21-2225-00 Panoramic sunroof with roller sun blind SN_Typ 451_us.book Seite 91 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Roof systems

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 93 · Applies to: 451

92 Body Introduction of the smart fortwo, Model Series 451 Tritop fabric soft top The Tritop fabric soft top of the smart fortwo cabrio is the only one in the world that can be opened and closed while driving up to the maximum speed. The name TRITOP comes from the three main components of the soft top: • Folding top open • Rear soft top stowed • Side supports removed The soft top control system is fully electronic and features the following functions: • Opening the folding top • Closing the folding top • Lowering the rear soft top • Raising the rear soft top P77.30-2390-00 Components of Tritop textile soft top 1 Folding top 2 Rear soft top 3 Left and right side supports SN_Typ 451_us.book Seite 92 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Roof systems

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 94 · Applies to: 451

Body 93 Introduction of the smart fortwo, Model Series 451 Soft top operation The folding top and rear soft top are opened and closed using the power soft top switch on the elec
tronic selector lever module control unit. The folding top can also be opened remotely and auto
matically by means of a button on the transmitter key. To operate the soft top via the power soft top switch the vehicle's ignition must be switched on. A short press of the power soft top switch in the "Open" direction causes the folding top to open all the way to its end position. The folding top must always be fully opened before the rear soft top can be opened. If the power soft top switch is then pressed again and held in the "Open" direction, the rear soft top is folded away for as long as the switch is actuated. As soon as the rear soft top has been stowed in its end position, its motors cut out and the switch can be released. To close the soft top, the power soft top switch is pressed and held in the "Close" direction until the rear soft top has reached its upper end position and the motors of the rear soft top cut out; the switch can then be released. If the power soft top switch is pressed and held again, the folding top closes until it reaches its own end position and the motor cuts out; then the switch can be released again. The rear soft top and folding top lock automatically as soon as they reach their end positions. i Note For safety reasons, it is not possible to close the folding top automatically. There would be a risk of injury during the closing process because limbs of vehicle occupants could become trapped between the roof frame and folding top in the area of the windshield. P80.35-2333-00 3 Folding top automatic open button A Transmitter key P77.00-2332-00 S84 Power soft top switch SN_Typ 451_us.book Seite 93 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Roof systems

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 95 · Applies to: 451

94 Body Introduction of the smart fortwo, Model Series 451 Targa roof position In the targa roof position, the folding top is fully opened, the side supports are removed and the rear soft top is closed. The targa roof position is important with regard to the operation of the folding top because the side supports must be inserted before the folding top can be closed. The side supports are detected by a mechanical catch in the roof cassette lock. Soft top control The central controller unit of the soft top is the SAM control unit. The SAM control unit reads in the actuation request from the power soft top switch and actuates the appropriate motors depending on the position and status of the soft top. The soft top is powered by a total of three motors. A central motor in the roof cassette is responsible for opening and closing the folding top. The folding and raising of the rear soft top is carried out by two motors in the left and right main bearings of the soft top. The soft top also incorporates the center high
mounted brake lamp and a glass rear window with an integral rear window heater, which is also activated by the SAM control unit. Function sequence of soft top actuation Function requirements: • Switch circuit 15 ON Pressing the power soft top switch sends a direct signal to open or close to the SAM control unit. The SAM control unit reads in the signal, checks whether the function requirements are satisfied and deter
mines the status of the soft top via the microswitches installed on the soft top. If all the preconditions are met, the SAM control unit actuates the appropriate motor(s) for the desired operation. P77.00-2340-00 Targa roof position SN_Typ 451_us.book Seite 94 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Roof systems

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 96 · Applies to: 451

Body 95 Introduction of the smart fortwo, Model Series 451 P77.39-2210-00 Data flow chart of soft top control 1 Circuit 15 ON 2 Request to open folding top 3 Request to open rear soft top 4 Request to close rear soft top 5 Request to close folding top 6 Status of soft top 7 Status of roof cassette latch 8 Status of rear soft top 9 Vehicle speed A1 Instrument cluster K66/1 Open soft top relay K66/2 Close soft top relay M12/6 Electric soft top motor M12/7 Left soft top drive M12/8 Right soft top drive N10/10 SAM control unit S2/1 Ignition/starter switch S84 Power soft top switch S84/37 Folding top microswitch S84/38 Left roof cassette microswitch S84/39 Right rear soft top microswitch S84/40 Right roof cassette microswitch S84/41 Left rear soft top microswitch A Transmitter key CAN Controller Area Network (data bus/CAN bus) SN_Typ 451_us.book Seite 95 Freitag, 30. November 2007 1:56 13 4---- N10/10 ~ K66/1 -+ K66/2 $84/37 $84/38 $84/39 $84/40 $84/41 M1217 M12/8 fr +-

Central locking

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 97 · Applies to: 451

96 Body Introduction of the smart fortwo, Model Series 451 Central locking (CL [ZV]) The central locking in the smart fortwo includes the locking and unlocking of both doors and the fuel filler flap, and the opening of the rear
end door in the smart coupé or the opening of the soft top on the smart cabrio. A distinction is drawn between manual and automatic functions. Manual functions: • Remote control with the transmitter key • Door opening from the inside • Operation via the interior CL [ZV] locking and unlocking switches in the cockpit switch group • Manual unlocking with the transmitter key at the driver
side door lock Automatic functions: • Speed
dependent locking • Emergency opening after crash detection • Relocking Unlocking or locking via the transmitter key When the Unlock or Lock button on the transmitter key is pressed, it sends a radio signal to the SAM control unit. The SAM control unit checks the access authori
zation of the transmitter key. If the access authoriza
tion is valid, it actuates the following motors directly to unlock or lock the vehicle: • Right door CL [ZV] motor • Left door CL [ZV] motor • Fuel filler flap CL [ZV] motor When the vehicle is globally unlocked, the rear
end door handle switch is enabled; and when the vehicle is locked, it is disabled. If the rear
end door handle switch is actuated when the central locking has been globally unlocked, the SAM control unit directly actuates the trunk lid CL [ZV] motor to unlock the rotary tumbler. Selective unlocking If the Unlock button on the transmitter key is pressed once, only the driver door and fuel filler flap are unlocked. The anti
theft alarm system is deactivated and all turn signal indicators flash once. Global unlocking If the Unlock button on the transmitter key is pressed again, the passenger door is unlocked and the rear
end door handle switch is enabled. The turn signal indicators flash again once. Door opening from the inside The vehicle doors can always be opened from the inside with the door handle regardless of the status of the central locking. In this case, only the respective vehicle door and the fuel filler flap are unlocked. P80.35-2332-00 A Transmitter key 1 Locking button 2 Unlocking button 3 Open folding top button (cabrio) Open rear
end door button (coupé) 4 PANIC button SN_Typ 451_us.book Seite 96 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Central locking

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 98 · Applies to: 451

Body 97 Introduction of the smart fortwo, Model Series 451 PANIC alarm Pressing the PANIC button for at least 1 s triggers an acoustic alarm. The turn signal indicators also flash. The alarm is deactivated when • Circuit 15 is switched ON or • The PANIC button is pressed Unlocking and locking from the inside via the switches in the cockpit switch group When the side doors and the rear
end door are closed, pressing the "Lock or unlock" switch in the cockpit switch group causes a signal to be sent straight to the SAM control unit. This actuates the central locking motors. The vehicle doors and the fuel filler flap are either locked or unlocked accordingly and the rear
end door handle switch is either enabled or disabled. Special function: If the vehicle cannot be locked using the transmitter key due to a flat battery in the key, proceed as follows: • Open driver door • Switch circuit 15 ON • Actuate inside CL [ZV] switch • Within 5 s, switch circuit 15 OFF and remove transmitter key • Close driver door, vehicle is locked. Manual unlocking of the driver door with the trans
mitter key at the door lock When the door lock on the driver door is operated with the transmitter key, the driver door and (if the on
board power supply voltage is sufficient) the fuel filler flap are unlocked. If the antitheft alarm system on the vehicle is armed, an alarm is triggered. Speed
dependent locking The vehicle is automatically locked if circuit 15 is ON and the vehicle speed exceeds 8 mph (14 km/h). Speed
dependent locking can be activated or deacti
vated as required. Relocking This function relocks the vehicle automatically if none of the doors is opened 60 s after unlocking. Emergency opening after crash recognition This functions unlocks the doors after an accident that triggers a crash signal. Remote rear
end door opening (smart fortwo coupé only) When the "Open rear
end door" button on the trans
mitter key is pressed, it sends a radio signal to the SAM control unit. This checks the access authorization of the transmitter key. If the access authorization is valid, the SAM control unit actuates the trunk lid CL [ZV] motor directly. Remote folding top opening (smart fortwo cabrio only) When the "Open folding top" button on the transmitter key is pressed, it sends a radio signal to the SAM control unit. This checks the access authorization of the transmitter key. If the access authorization is valid, the SAM control unit actuates the electric soft top motor directly. i Note The radio signal for unlocking the door is picked up by an antenna integrated in the SAM control unit. There is no external antenna for the central locking. SN_Typ 451_us.book Seite 97 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Central locking

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 99 · Applies to: 451

98 Body Introduction of the smart fortwo, Model Series 451 1 Unlocking/locking request 2 Doors status 3 Rear
end door status 4 Unlocking/locking actuation 5 Rear
end door unlocking request 6 Visual feedback actuation 7 Rear
end door unlocking actuation 8 Unlocking via inside door opener request 9 Inside unlocking/locking request 10 Emergency opening request 11 Rear
end door opening request (coupé) 12 Open soft top actuation (cabrio) 13 Open soft top request (cabrio) 14 Vehicle speed A1 Instrument cluster E1e5 Left turn signal light E2e5 Right turn signal light E3e11 Left brake/turn signal light E4e11 Right brake/turn signal light E22/1 Left additional turn signal lamp E22/2 Right additional turn signal lamp M12/6 Electric soft top motor (cabrio) M14/5 Right door CL [ZV] motor M14/5s1 Right door CL [ZV] microswitch M14/6 Left door CL [ZV] motor M14/6s1 Left door CL [ZV] microswitch M14/7 Rear
end door CL [ZV] motor M14/10 Fuel filler flap CL [ZV] motor N2/7 Restraint systems control unit N10/10 SAM control unit S6/1 Cockpit switch group S6/1s1 Hazard warning flasher switch S6/1s11 Inside unlock CL [ZV] switch S6/1s12 Inside lock CL [ZV] switch S15 Remote trunk opening switch (coupé) S17/8 Trunk lid rotary tumbler microswitch (cabrio) S88/9 Rear
end door handle switch A Transmitter key CAN Controller Area Network (data bus/CAN bus) P80.20-3177-00 SN_Typ 451_us.book Seite 98 Freitag, 30. November 2007 1:56 13 A1 N217 CAN CAN M14/5 M14/5s1 S6/1s1 M14/6 M14/6s1 $6/1 L -©-----©-®- -~ ~ - N10/10 ~ S6/1s12 S6/1s11 $88/9 ~ ~ E4e11 ~~ -+ M12/6 $15 11 +- $17/8 ~ E3e11 E2e5 E1e5 ~

Anti
theft alarm system (ATA [EDW])

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 100 · Applies to: 451

Body 99 Introduction of the smart fortwo, Model Series 451 ATA [EDW] system The anti
theft alarm system (ATA [EDW]) monitors all relevant inputs for their non
actuated state. If a change of status is detected at one of the monitored inputs, an acoustic and visual alarm is issued. The acoustic signals are output by the alarm signal siren with inclination sensor. The visual signals are output via the turn signal indicators. The SAM control unit is the master control unit for the anti
theft alarm system (ATA [EDW]). When armed, the anti
theft alarm system (ATA [EDW]) monitors: • The doors • The rear
end door • The alarm siren with inclination sensor • The position change of the vehicle • Movements in the interior compartment Activation and deactivation The anti
theft alarm system (ATA [EDW]) is activated when the vehicle is locked with the transmitter key. The anti
theft alarm system (ATA [EDW]) is deacti
vated by unlocking the vehicle with the transmitter key or by inserting an authorized transmitter key in the ignition lock and turning circuit 15 ON. Alarm triggering An alarm is triggered when the SAM control unit receives a status change from the following compo
nents: • ATA [EDW] microwave sensor • Inclination sensor in alarm siren • Trunk lid rotary tumbler microswitch • Right door rotary tumbler microswitch • Left door rotary tumbler microswitch Alarm output The alarm is output via the turn signal indicators and the alarm siren with inclination sensor. Interior protection/tow
away protection The ATA [EDW] microwave sensor is activated approx. 30 s after the vehicle is locked. Interior protection can be deactivated using the tow
away protec
tion/interior protection switch. The inclination sensor in the alarm siren with inclina
tion sensor registers a positional change of the vehicle. The inclination sensor, and thus the tow
away protection, can be deactivated using the tow
away protection/interior protection switch. The interior protection or tow
away protection is reactivated automatically the next time the vehicle is locked. SN_Typ 451_us.book Seite 99 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Anti
theft alarm system (ATA [EDW])

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 101 · Applies to: 451

100 Body Introduction of the smart fortwo, Model Series 451 P80.50-2648-00 Data flow chart of anti
theft alarm system (ATA [EDW]) 1 Activate ATA [EDW] with transmitter key 2 Deactivate ATA [EDW] with transmitter key 3 Rear
end door status 4 Doors status 5 Deactivate ATA [EDW] via ignition/starter switch 6 Movement in interior signal 7 Alarm siren actuation 8 Turn signal lights actuation 9 Inclination sensor status change 10 Turn signal indicator actuation 11 Tow
away protection/interior protection shutoff A1 Instrument cluster A1e1 Left turn signal indicator lamp A1e2 Right turn signal indicator lamp B32 ATA [EDW] microwave sensor E1e5 Left turn signal light E2e5 Right turn signal light E3e11 Left brake/turn signal light E4e11 Right brake/turn signal light E22/1 Left additional turn signal lamp E22/2 Right additional turn signal lamp H3/2 Alarm siren with inclination sensor L11 Transponder coil N10/10 SAM control unit S2/1 Ignition/starter switch S6/1 Cockpit switch group S6/1s10 Tow
away protection/interior protection switch S15 Remote trunk opening switch (coupé) S17/8 Trunk lid rotary tumbler microswitch (cabrio) S87/6 Right door rotary tumbler microswitch S87/7 Left door rotary tumbler microswitch A Transmitter key CAN Controller Area Network (data bus/CAN bus) LIN C Interior Local Interconnect Network 2 SN_Typ 451_us.book Seite 100 Freitag, 30. November 2007 1:56 13 -+ CAN A1e1 A1e2 S15 S17/8 N10/10 ---©- S6/1 ~ 1 C L 11 S2/1 ~ E22/2 ~ E4e11 j1_ ii ~~ +- E3e11 E2e5 '~' rnf E22/1 E1e5 ~ ~

Exterior lights

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 102 · Applies to: 451

Body 101 Introduction of the smart fortwo, Model Series 451 Auto on/off headlamps (Autolight function) The basic equipment can be expanded with the conve
nient Autolight function as special equipment. A rain sensor/light sensor is additionally installed for the Autolight function. The rain sensor/light sensor is located on the inside of the windshield near the inside rearview mirror. The rain/light sensor distinguishes between light and dark by measuring the intensity of the light and thereby enables the exterior lights to be switched on and off automatically according to the ambient light conditions. The activated light corre
sponds to the "usual" driving lights with low beam. Special feature The Autolight function is activated by moving the combination switch to the AUTO position. The AUTO position of the combination switch is only available in vehicles with Autolight function installed as special equipment. Signal flow When the Autolight function is activated and darkness is detected, the rain sensor/light sensor sends a corresponding signal via the LIN B to the SAM control unit. This evaluates the signal and actuates the appropriate lamps over direct lines. P54.21-2893-00 B38 Rain sensor/light sensor P54.25-5577-00 1 AUTO position S4 Combination switch Coming
Home function The function is a component of the Autolight function. When the vehicle is locked or unlocked, the driving lights are switched on for 12 s. The function is also activated by the rain sensor/light sensor; the position of the combination switch is immaterial. The Coming
Home function can only be deactivated by coding in the workshop. SN_Typ 451_us.book Seite 101 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Audio system

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 103 · Applies to: 451

102 Body Introduction of the smart fortwo, Model Series 451 Radio and sound systems Two radio variants are available as special equipment and accessories for model series 451. Variant 1: smart radio 9 with radio and CD player P82.60-5802-00 smart radio 10 Variant 2: smart radio 10 with radio, integral 6
disk CD changer, MP3
compatible P82.60-5801-00 smart radio 9 SN_Typ 451_us.book Seite 102 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Audio system

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 104 · Applies to: 451

Body 103 Introduction of the smart fortwo, Model Series 451 Speaker sound variants Basic package A basic package with one broadband speaker in each door is available as special equipment. P82.62-3243-00 Speaker diagram
basic package A2/1 smart radio 9 A2/2 smart radio 10 H4/9 Left front speaker H4/10 Right front speaker Sound system The sound system (special equipment) includes two tweeters/midrange speakers and a subwoofer. Due to the modular design, these components can also be retrofitted individually as accessories. The smart MP3 interface (AUX jack) is installed as standard. smart accessory sound system (two tweeters, two midrange speakers): The tweeters are simply clipped in place under the instrument panel; the wiring harness is already installed. The door panels must be removed in order to install the midrange speakers. Subwoofer: The driver seat is removed and the subwoofer is bolted on together with the driver seat; the wiring harness is already there under the floor carpeting. P82.62-3242-00 Speaker diagram
sound systems 1 smart MP3 interface (AUX jack) A2/1 smart radio 9 A2/2 smart radio 10 H4/9 Left front speaker H4/10 Right front speaker H4/29 Subwoofer H4/33 Left tweeter H4/34 Right tweeter SN_Typ 451_us.book Seite 103 Freitag, 30. November 2007 1:56 13 4---- fr -+ +-

Climate control

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 105 · Applies to: 451

104 Body Introduction of the smart fortwo, Model Series 451 Heating Model series 451 is equipped with a heating system as standard. The temperature and blower speed are each set by means of a slide control. The temperature blend flap in the air distribution box is operated mechani
cally via a Bowden cable. The air distribution is adjusted with a 360° rotating button switch. The air distribution flap is actuated mechanically via a cable shaft. The blower can be adjusted in four power stages. The rpm is regulated by means of an external series resistor: • Stage 0: Blower off • Stage 1: Blower on Weak, low speed • Stage 2: Blower on Strong, higher speed • Stage 3: Blower on Stronger, higher speed • Stage 4: Blower on Maximum strength The rear window heater button in the heater/AC oper
ating unit switches on the heated rear window and the function LED in the button lights up. The heated rear window is switched off either auto
matically via a timer control or by pressing the rear window heater button again. The function LED goes out. If the on
board power supply voltage is too low, the rear window heater is switched off automatically. Temperature
regulated air conditioning The control functions of air distribution, blower output, temperature setting and heated rear window are as described for the heater. Activation of the air conditioning: • Press A/C button. The function LED lights up. Deactivation of the air conditioning: • Press A/C button. The function LED goes out. P83.10-2640-00 Air outlets for heater and temperature
regulated air conditioning SN_Typ 451_us.book Seite 104 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Climate control

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 106 · Applies to: 451

Body 105 Introduction of the smart fortwo, Model Series 451 For safety reasons, if the air distribution lever is moved precisely to "Windshield Defrost", the air conditioning switches itself on automatically with no action by the occupants in order to ensure that the windshield is defrosted and dried as quickly as possible. In this case the function LED does not light up to indi
cate that the air conditioning has been activated automatically. When the air distribution lever is moved away from the Defrost position, this function is canceled. This happens regardless of the programmed temperature or blower stage. In addition, air recirculation mode is deactivated if it is on. The air recirculation flap and the temperature blend flap are actuated via electric actuator motors. The cooling output of the refrigerant compressor is controlled by means of an appropriate CAN signal from the SAM control unit. The interior temperature is measured by an integral interior temperature sensor located on the bottom of the heater/air conditioning operating unit. Air recirculation mode When the air recirculation mode button is pressed, the fresh air flap is closed. This causes the air to circu
late in the interior compartment only. The function LED in the button lights up during air recirculation mode. P83.40-3926-00 Heater/AC operating unit i Note The air conditioning cannot be operated in temperatures below 37 °F (3 °C). i Note The temperature
regulated air conditioning switches off temporarily: • If the engine speed is too low • When starting up • At a coolant temperature greater than 239 °F (115 °C), • At outside temperatures below 37 °F (3 °C). SN_Typ 451_us.book Seite 105 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Customized Bodypanel System (CBS)

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 107 · Applies to: 451

106 Body Introduction of the smart fortwo, Model Series 451 CBS concept The CBS concept is composed of "bodypanels" that are installed as detachable parts around the vehicle and form a large proportion of the vehicle's external skin. Front end module The statics of the CBS in the area of the front end are based on a one
piece, bolt
on front end module with integral pedestrian protection. The front end module is injection molded polypropy
lene plastic stiffened with partial reinforcement panels on the longitudinal frame member. The front end module also holds the engine radiator module, including the AC condenser, the headlamps, the front fog lamp and the CBS bodypanels. Bodypanels Depending on the color variant, the bodypanels are supplied either as colored plastic or with 2
coat metallic paintwork. The bodypanels are overcoated with a clearcoat to protect against UV radiation. The bodypanel concept has proven to be robust and easy to repair in practice. If damaged, they can be replaced with little effort and at low cost. Rear
end door The inside of the rear
end door in the new smart fortwo coupé contains an integral compartment for accommodating the hazard warning triangle, the first aid kit or similar. In the smart fortwo cabrio the stowage space is intended for crash
proof storage of the roof side supports. Surfaces and paintwork General features • Galvanized body • Cathodic immersion painting • Seam sealing • Powder paint • tridion safety cell in two colors: Black as standard equipment or silver as special equipment • Painted CBS (Customized Bodypanel System) components Paint of the Customized Bodypanel System The plastic parts of the Customized Bodypanel System (CBS) are dyed through and/or painted. A two
coat system of base coat and clearcoat is applied. Paintwork repairs are possible only if the paint coat has not been worn down to the polypropylene (PP) base material. A new paintwork structure can then be built up. Otherwise proper adhesion of the paint on the component cannot be guaranteed. SN_Typ 451_us.book Seite 106 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Customized Bodypanel System (CBS)

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 108 · Applies to: 451

Body 107 Introduction of the smart fortwo, Model Series 451 P88.00-2375-00 CBS components with front end module and crash management system (CMS) 1 Front end module 2 Front CMS 3 Left fender 4 Right fender 5 Front spoiler 6 Front center part 7 Maintenance flap 8 Fresh
air intake cover 9 Left door paneling 10 Right door paneling 11 Left side part 12 Fresh
air intake 13 Right side part 14 Fuel filler flap 15 Rear CMS 16 Exhaust system covering 17 Rear center part 18 Rear
end door paneling SN_Typ 451_us.book Seite 107 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Seats

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 109 · Applies to: 451

108 Body Introduction of the smart fortwo, Model Series 451 Seats, general The safety integral seats on both sides of model series 451 can be adjusted in terms of seat length and backrest angle. The backrest of the passenger seat can be folded forwards to allow through
loading of long loads. A TopTether anchor is bolted to the load compartment floor behind the passenger seat as standard. The guide for the TopTether belt is located on the back
rest cover of the passenger seat level with the head restraint. Seat heaters in the seat bolster and backrest cushion are available as special equipment. Seat heaters The seat heater special equipment in model 451 consists of two heating elements which are installed in the seat bolster and backrest cushion of each seat. The seat heaters are activated separately for each side via the switch panel in the center console. Pressing the seat heater switch for the driver or passenger side switches on the seat heater at stage 2. Another press of the switch switches the seat heater to stage 1. If the switch is pressed a third time, the seat heater is switched off. The different stages are indicated in the relevant switch by the lighting of one LED for stage 1 and two LEDs for stage 2. The heated seats control unit incorporates a temper
ature sensor that measures the ambient temperature. The heating elements in the driver and passenger seats follow a temperature profile based on this temperature. The heater output is constantly moni
tored to check the seat temperature. Function Function requirements: • Switch circuit 15 ON When the seat heater switch for the driver or passenger seat is pressed, a request signal is sent directly to the heated seats control unit. In the heated seats control unit the request for activation of the seat heater is processed with the function require
ment. The function requirement is transmitted by the igni
tion/starter switch straight to the SAM control unit, from where it is forwarded to the heated seats control unit. If all the criteria for activation are satisfied, the appropriate seat heater is switched on by the heated seats control unit over a direct line. P91.10-3254-00- Integral seats SN_Typ 451_us.book Seite 108 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Supplemental restraint system

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 110 · Applies to: 451

Body 109 Introduction of the smart fortwo, Model Series 451 Restraint system The restraint system consists of the following compo
nents: • 2
stage full size airbag for driver and passenger • Head/thoraxbag for driver and passenger in outsides of backrests • Seat belt emergency tensioning retractors and belt force limiters for driver and passenger • Passenger seat with Weight Sensing System (WSS) and belt tension sensor In the event of a frontal impact and depending on the deceleration values, the driver airbag, the energy
absorbing steering column and the passenger airbag improve occupant protection by absorbing energy in a targeted manner and thus minimizing the risk of injury. The pyrotechnical emergency tensioning retractors ensure that the occupants are properly restrained in their seats in a frontal impact and that they follow a defined forward displacement with the energy being absorbed by the belt force limiter. The passenger airbag, emergency tensioning retractor and head/thoraxbag are switched off in accordance with the predefined weight class that the seat is assigned to. The airbag OFF indicator lamp is located in at the front above the interior lamp and lights up as soon as the shutoff function is activated. In order to activate the systems in good time in the event of a crash and thus keep the physical conse
quences for the occupants low, sensors are installed to detect the occurrence of a collision at an early stage. The following sensors are installed: • Side trigger sensors in the left and right inner sills near the B
pillars for detecting a side impact • Two frontal acceleration sensor on left and right of front crossmember • Trigger sensor in the restraint systems control unit for detecting a frontal crash, a rear
end impact or a side
on collision The central controller unit of the supplemental restraint system is the restraint systems control unit, which is located in the center of the vehicle on the crossmember under the instrument panel. If the restraint systems control unit detects a fault in the system, this is indicated by the lighting of a warning lamp in the instrument cluster. As well as triggering the restraint equipment, the following interventions are initiated by the restraint systems control unit in the event of a crash: • Shutoff of engine and fuel pump • Unlocking of door locks • Activation of hazard warning lamp function SN_Typ 451_us.book Seite 109 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Supplemental restraint system

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 111 · Applies to: 451

110 Body Introduction of the smart fortwo, Model Series 451 Weight sensing system (WSS) To determine the situation in the interior compart
ment, the system detects whether the passenger seat is occupied. The seat occupied recognition pressure sensor determines the weight on the passenger seat by means of a pressure measure
ment from a seat mat filled with silicone oil. The force applied to the seat belt is measured via the belt tension sensor. These two measured values are used by the Weight Sensing System (WSS) control unit to classify the weight on the seat. The values are transferred to the instrument cluster via CAN
B, which acts as a gateway to transfer the data to the restraint systems control unit via CAN. The following conditions are defined depending on the occupant classification: • Passenger seat not occupied: Passenger airbag unit, passenger head/thoraxbag and passenger emergency tensioning retractor unit are disabled; the airbag OFF indicator lamp is switched ON. • Passenger seat occupied
light weight (e.g. hand luggage): Passenger airbag unit, passenger head/thoraxbag and passenger emergency tensioning retractor unit are disabled; the airbag OFF indicator lamp is switched ON. • Passenger seat occupied
person detected: The required restraint equipment is enabled; the airbag OFF indicator lamp is switched OFF. P91.60-3635-00 1 Seat cushion frame 2 Seat mat filled with silicone oil B48/4 Seat occupied recognition pressure sensor N110 Weight Sensing System (WSS) control unit SN_Typ 451_us.book Seite 110 Freitag, 30. November 2007 1:56 13 -+ +-

Supplemental restraint system

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 112 · Applies to: 451

Body 111 Introduction of the smart fortwo, Model Series 451 P91.60.3634-00 Data flow chart of supplemental restraint system See next page for legend SN_Typ 451_us.book Seite 111 Freitag, 30. November 2007 1:56 13 4---- -+ E16 S68/3 S68/4 R12/13 R12/14 N10/10 ~ N2/7 R12/20 fr 848/1 N110 CAN-B ~ A53 f 4 7 ~ I +- ~ A54 ~ R12/2 848/2 R12/21

Supplemental restraint system

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 113 · Applies to: 451

112 Body Introduction of the smart fortwo, Model Series 451 1 Occupant classification 2 Crash signal 3 Warning and fault message output 4 Squib and sensor monitoring 5 Trigger restraint equipment 6 Passenger airbag cutout display 7 Impact detection 8 Seat occupied status 9 'Belt tension sensor status 10 Seat belt buckle status A1 Instrument cluster A1e9 Seat belt warning lamp A1e15 Airbag indicator and warning lamp A53 Driver head/thoraxbag sensor A54 Passenger head/thoraxbag sensor E16 Automatic child seat recognition airbag OFF indicator lamp B48/1 Driver
side frontal acceleration sensor B48/2 Passenger
side frontal acceleration sensor B48/3 Belt tension sensor B48/4 Seat occupied recognition pressure sensor N2/7 Restraint systems control unit N3/10 ME
SFI [ME] control unit N10/10 SAM control unit N110 Weight Sensing System (WSS) control unit R12/1 Left emergency tensioning retractor squib R12/2 Right emergency tensioning retractor squib R12/4 Passenger airbag ignition squib 1 R12/5 Passenger airbag ignition squib 2 R12/13 Driver airbag ignition squib 1 R13/14 Driver airbag ignition squib 2 R12/20 Driver head/thoraxbag squib R12/21 Passenger head/thoraxbag squib S68/3 Driver seat belt buckle restraint systems switch S68/4 Passenger seat belt buckle restraint sys
tems switch CAN Controller Area Network (data bus/CAN bus) CAN
B Controller Area Network bus class B (interior compartment) SN_Typ 451_us.book Seite 112 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Body

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 114 · Applies to: 451

Body 113 Introduction of the smart fortwo, Model Series 451 Bodyshell structure The bodyshell structure of model series 451 exhibits the following features: • tridion safety cell with high
strength steels and low weight: — smart fortwo coupé: 352 lb (160 kg) — smart fortwo cabrio: 379 lb (172 kg) • Light alloy detachable parts • Front CMS • Rear CMS tridion safety cell The tridion safety cell which forms the bodyshell ensures that the vehicle is robust, absorbs energy by deformation in the event of a crash and provides optimum protection of the survival space to keep the occupants safe. Design
based benefits of tridion safety cell: • Its longitudinal members and crossmembers absorb impact energy at front and rear • The most important major assemblies are safely accommodated in its underfloor area. • Crash boxes attached at the front and rear absorb the impact energy at speeds of up to approx. 10 mph (16 km/h). • It supports the extendable steering column via the cockpit crossmember. The tridion safety cell consists of more than 50 percent high
strength steel sheet. These steels are alloyed to be more rigid and stronger than standard steel sheet. The high
strength sheet metal parts can be worked in the same way as standard sheet metal and provide the following benefits: • Improved torsional stiffness • Optimized crash behavior • Reduced metal sheet thickness • Weight saving Bodyshell material diagram of the steels used (coupé and cabrio) Silver areas The silver areas are soft deep
drawing steels of regular strength. In these areas all the usual welding methods can be used. Red areas The red areas consist of micro
alloyed high
strength steels. Resistance spot welding can easily be carried out in these areas. However, metal active gas (MAG) welding is only permissible on approved areas. See the Workshop Information System (WIS) for further instructions and information. Green area (cabrio only) The green area consists of a particularly high
strength and torsionally stiff martensite phase steel. This steel is only used in the cabrio for the window pillars of the A
pillars because particularly stringent demands are made on the strength of the vehicle at these points. SN_Typ 451_us.book Seite 113 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Body

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 115 · Applies to: 451

114 Body Introduction of the smart fortwo, Model Series 451 P60.20-2063-00 Overview of bodyshell materials
smart fortwo coupé P60.20-2064-00 Overview of bodyshell materials
smart fortwo cabrio SN_Typ 451_us.book Seite 114 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

Body

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 116 · Applies to: 451

Body 115 Introduction of the smart fortwo, Model Series 451 Crash management system (CMS) CMS concept Model series 451 features a bolt
on crash manage
ment system at the front and rear in the smart fortwo coupé and smart fortwo cabrio. To prevent damage, the front CMS is mounted on the longitudinal frame member and the rear CMS on the frame
type integral support. The CMS is a specially shaped steel profile that absorbs impact energy at a defined rate in the low vehicle speed range up to approx. 10 mph (16 km/h). P64.20-4995-00 Rear CMS 3 Rear steel profile P62.30-2944-00 Front CMS 1 Front steel profile SN_Typ 451_us.book Seite 115 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

smart accessories

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 117 · Applies to: 451

116 Accessories Introduction of the smart fortwo, Model Series 451 i A complete overview of all accessory packages can be found: • On the Internet at http://pit.smart.com Accessory designation Brief description WIS no. ASRA no. Interior All
weather floor mats To protect the standard carpeting. — G 68 9210 0 Velour floor mats Optimum fit for the footwell on the driver and passenger side. — G 68 9210 0 Divider plus (including luggage compartment cover) Luggage net with integral luggage compartment cover to allow the full volume of the luggage compartment to be used safely. AZ68.50
P
0005MCC AZ68.50
P
0005MCO G 68 9240 0 Telephone console Plastic platform for MP3 player etc. AZ82.70
P
0010MCU G 82 8872 0 Rubber mats for the stowage compartments (set of 3) For reducing the noise and preventing the slippage of small arti
cles on the dashboard. — — Smoking set Package consisting of ashtray and cigarette lighter for the standard 12 V socket, clips easily in and out of the vertical strut. — G 68 5194 0 CD box (for 6 CDs) Storage slots for up to 6 CDs, clips easily in and out of the vertical strut. — G68 4852 0 Luggage anchoring For versatile anchoring of objects in the trunk. — — Trunk net package Package consisting of one net pocket for the left trunk side panel and one trunk floor net. AZ68.50
P
0003MCC G 68 7476 0 SN_Typ 451_us.book Seite 116 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

smart accessories

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 118 · Applies to: 451

Accessories 117 Introduction of the smart fortwo, Model Series 451 Accessory designation Brief description WIS no. ASRA no. Eyeglass compartment Flip
top plastic spectacle case with magnetic catch. AZ68.10
P
0010MCC G 68 4846 0 Luggage compartment cover (retractable cover with net pocket) Retractable luggage compartment cover box with integral net pocket in the passenger compartment. — — Cargo management system Complete solution for clearly dividing the trunk with three different solu
tions: divider, fastening strap and shopping bag. Exterior smart design sticker Decorative film with one or more digits in black or silver. The self
adhesive decorative film is car wash
proof, lightfast and can be applied horizontally or vertically with or without digits. AZ72.10
P
0003MCC G 72 7178 0 Bodypanel Fresh Up Contains all CBS detachable parts installed on a smart fortwo in stan
dard or metallic colors. AR88.00
P
1200MCC G 88 9991 0 Attaching parts for Body
panel Fresh Up Contains all attaching parts for all CBS detachable parts installed on the vehicle. — — Chrome package Radiator grille, outside mirror caps and rear trim strip plated in high gloss chrome. — — Front fog lamps (chrome style) The ideal supplement to the chrome package. — — SN_Typ 451_us.book Seite 117 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

smart accessories

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 119 · Applies to: 451

118 Accessories Introduction of the smart fortwo, Model Series 451 Accessory designation Brief description WIS no. ASRA no. Exterior Car cover The portable garage for the smart fortwo made of hard
wearing, breathable and water
repellent material. — — Function and electrical components Additional instruments (cockpit clock and tachom
eter) Tachometer and cockpit clock, both with analog display and night illumi
nation. Accent trim rings are avail
able to match the interior color scheme. AZ54.30
P
0001MCC G 54 5073 0 Audio and telematics smart radio 9 Radio and CD player. AZ82.60
P
0003MCC G 82 7660 0 smart radio 10 Radio with integral 6
disk CD changer, MP3
compatible. The design differs from the smart radio 9 by its silver trim. AZ82.60
P
0003MCC G 82 7660 0 smart sound system Consists of two tweeters and two midrange speakers. AZ82.62
P
0002MCC G 82 7970 0 Subwoofer Active subwoofer, optimally tuned to suit the smart interior. It is mounted under the driver seat. AZ82.62
P
0004MCU G 82 7970 0 G 82 7814 0 SN_Typ 451_us.book Seite 118 Freitag, 30. November 2007 1:56 13 -4 -r -+ +-

smart accessories

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 120 · Applies to: 451

Accessories 119 Introduction of the smart fortwo, Model Series 451 Wheels and tires Light alloy wheel Alurad Design 5 Front 155/60 R15 Rear 175/55 R15 AR40.10
P
1030MCU G 40 1450 0 V40 2740 0 Safety First
aid pouch Packed in a waterproof nylon pouch, with velcro fastener for attaching to the carpet. — — Safety Plus package 2
piece foam insert for the stowage compartment in the liftgate with useful accessories such as a first
aid pouch, smart umbrella, flashlight and smart ice scraper. — — Accessory designation Brief description WIS no. ASRA no. SN_Typ 451_us.book Seite 119 Freitag, 30. November 2007 1:56 13 4---- --t -+ +-

Index

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 121 · Applies to: 451

120 Introduction of the smart fortwo, Model Series 451 Numerics 5
speed automated manual transmission . . . . . . . . . . . . . . . . . . . 47 A Acceleration skid control . . . . . . . . . . . 73 Accessories . . . . . . . . . . . . . . . . . . . 116 Active safety . . . . . . . . . . . . . . . . . . . 17 Air conditioning . . . . . . . . . . . . . . . . 104 Alternator . . . . . . . . . . . . . . . . . . . . . 21 Antilock brake system . . . . . . . . . . . . . . 73 ATA . . . . . . . . . . . . . . . . . . . . . . . . . 99 Auto on/off headlamps . . . . . . . . . . . . 101 Autolight function . . . . . . . . . . . . . . . 101 Automated manual transmission control unit . . . . . . . . . . . 57 B Battery . . . . . . . . . . . . . . . . . . . . . . . 20 Belt drive . . . . . . . . . . . . . . . . . . . . . 38 Bleed cooling system . . . . . . . . . . . . . . 40 Body . . . . . . . . . . . . . . . . . . . . . . . . 114 Bodypanels . . . . . . . . . . . . . . . . . . . 106 Bodyshell . . . . . . . . . . . . . . . . . . . . . 113 Borg
Warner synchronization . . . . . . . . 54 Brake assist system . . . . . . . . . . . . . . . 73 Brake pedal module . . . . . . . . . . . . . . . 71 C CBS . . . . . . . . . . . . . . . . . . . . . . . . . 107 Central locking . . . . . . . . . . . . . . . . . . 96 Clutch motor . . . . . . . . . . . . . . . . . . . . 63 Coming
Home function . . . . . . . . . . . . 101 control unit . . . . . . . . . . . . . . . . . . . . 68 Coolant circuit . . . . . . . . . . . . . . . . . . 39 Crash management system . . . . . . . . . . 115 Customized Bodypanel System (CBS) . . . . 106 D Data link connector . . . . . . . . . . . . . . . 26 Diagnostic tester . . . . . . . . . . . . . . . . 26 Dimensions smart fortwo cabrio . . . . . . . . . . . . . . 11 smart fortwo coupé . . . . . . . . . . . . . . 10 Door structure . . . . . . . . . . . . . . . . . . 86 E Electric power steering . . . . . . . . . . . . 75 Electronic brake force distribution . . . . 73 Electronic selector lever module control unit . . . . . . . . . . . . . . . 58 Electronic Stability Program . . . . . . . 73, 74 Emergency unlocking of rear
end door . . . . . . . . . . . . . . . . . . 89 Engine braking regulation . . . . . . . . . . . 73 Engine mount . . . . . . . . . . . . . . . . . . . 41 Evaporative emission control system . . . . 42 Exhaust aftertreatment . . . . . . . . . . . . 45 F Front axle . . . . . . . . . . . . . . . . . . . . . 64 Fuel tank . . . . . . . . . . . . . . . . . . . . . . 42 Full roof . . . . . . . . . . . . . . . . . . . . . . 91 H Heated seats . . . . . . . . . . . . . . . . . . .108 Heating . . . . . . . . . . . . . . . . . . . . . . .104 I Injection control . . . . . . . . . . . . . . . . . 35 Instrument cluster . . . . . . . . . . . 21, 84, 85 Instrument panel . . . . . . . . . . . . . . . . 83 Interior design . . . . . . . . . . . . . . . . . . 82 Interior protection/ tow
away protection . . . . . . . . . . . . . . 99 SN_Typ 451_us.book Seite 120 Freitag, 30. November 2007 1:56 13 --t-

Index

2008 smart fortwo (451) - US Introduction into Service Manual.pdf · p. 122 · Applies to: 451

121 Introduction of the smart fortwo, Model Series 451 L Leak test . . . . . . . . . . . . . . . . . . . . . . 42 M Maintenance concept . . . . . . . . . . . . . . 13 Maintenance interval display . . . . . . . . . 14 Maintenance intervals . . . . . . . . . . . . . 13 Maintenance points Engine compartment . . . . . . . . . . . . . . 16 Front end . . . . . . . . . . . . . . . . . . . . 15 Mechanical park pawl . . . . . . . . . . . . . . 61 Muffler system . . . . . . . . . . . . . . . . . . 45 Multifunction display . . . . . . . . . . . . . . 84 O Occupant restraint systems . . . . . . . . . 18 Oil Service Plus . . . . . . . . . . . . . . . . . 13 Overall network
CAN bus/LIN bus . . . . . 23 P Paddle shifts on steering wheel . . . . . . . 80 Paintwork . . . . . . . . . . . . . . . . . . . . .106 PANIC alarm . . . . . . . . . . . . . . . . . . . . 97 Panoramic sunroof . . . . . . . . . . . . . . . 91 Parking brake . . . . . . . . . . . . . . . . . . 69 Passive safety . . . . . . . . . . . . . . . . . . 18 Power and torque graph . . . . . . . . . . . . 31 R Radio 10 . . . . . . . . . . . . . . . . . . . . . .102 Radio 9 . . . . . . . . . . . . . . . . . . . . . . .102 TPM . . . . . . . . . . . . . . . . . . . . . . . . . 68 Rear axle . . . . . . . . . . . . . . . . . . . . . 65 Rear
end door . . . . . . . . . . . . . . . . . . 88 Recirculated air mode . . . . . . . . . . . . .105 Remote soft top opening . . . . . . . . . . . . 97 Remote trunk opening . . . . . . . . . . . . . 97 Restraint system . . . . . . . . . . . . . . . . .109 S Safety concept . . . . . . . . . . . . . . . . 17, 18 SAM control unit . . . . . . . . . . . . . . . . . .28 SCN (Software Calibration Number) coding . . . . . . . . . . . . . . . . . . . . . . . .27 Seats . . . . . . . . . . . . . . . . . . . . . . . . 108 Service brake . . . . . . . . . . . . . . . . . . .69 Service flap . . . . . . . . . . . . . . . . . . . .15 Shift mechanism . . . . . . . . . . . . . . . . . .49 Side door emergency opening . . . . . . . . .86 Side doors . . . . . . . . . . . . . . . . . . . . .86 Single
plate dry clutch . . . . . . . . . . . . .62 Soft top control . . . . . . . . . . . . . . . 94, 95 Soft top operation . . . . . . . . . . . . . . . .93 Speakers . . . . . . . . . . . . . . . . . . . . . 103 Starter . . . . . . . . . . . . . . . . . . . . . . . .20 Start
off assist . . . . . . . . . . . . . . . . . .73 Stretch belt . . . . . . . . . . . . . . . . . . . . .38 System . . . . . . . . . . . . . . . . . . . . . . . .99 T TAN generator . . . . . . . . . . . . . . . . . . .27 Tire pressure sensing . . . . . . . . . . . . . .67 Torque support . . . . . . . . . . . . . . . . . .41 Transmission motors . . . . . . . . . . . . . . .56 Transmission mount . . . . . . . . . . . . . . .41 Transmission rpm sensor . . . . . . . . . . . .55 tridion safety cell . . . . . . . . . . . . . . . . 113 Tritop fabric soft top . . . . . . . . . . . . . .92 V Valve assembly . . . . . . . . . . . . . . . . . . .33 Vehicle characteristics . . . . . . . . . . . . . 9 Vehicle concept . . . . . . . . . . . . . . . . . . 9 W Weight sensing system (WSS) . . . . . . . . . 110 Wiring harness repair capability . . . . . . .25 Wiring harness repair kit . . . . . . . . . . . .25 SN_Typ 451_us.book Seite 121 Freitag, 30. November 2007 1:56 13 --t-