2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf

254 excerpts.

Location and assignment of Z connector sleeves (line connectors in

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 262 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-3000MCU, PE54.00-P-1100MCU

wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > LEGEND OF FUNCTION DIAGRAM FOR ELECTRICAL SYSTEM OF ELECTRONIC STABILITY PROGRAM (ESP) - PE42.45-P-2050-60MCU > MODEL 451 Code Designation Coordinates A1 Instrument cluster 21L A1e7 Brake fluid and parking brake warning lamp 23J A1e41 ESP warning lamp 23K A1p8 Electronic speedometer 23K B24/15 Yaw rate, lateral and longitudinal acceleration sensor 7D E3e4 Left stop light 13H E4e4 Right stop light 13H E21 Center high-mounted stop lamp 13J L6/1 Left front RPM sensor 12H L6/2 Right front RPM sensor 12H L6/3 Left rear RPM sensor 12J L6/4 right rear RPM sensor 12J N3/10 ME-SFI [ME] control unit 16C N10/10 SAM control unit 3L N15/6 Automated manual transmission control unit 21D N47-5 ESP control unit 11G N49 Steering angle sensor 3D N68 Steering assist control unit 7L S9/1 Stop lamp switch 10H S11 Brake fluid indicator switch 10H S12 Parking brake indicator switch 10J U492 Valid for power steering 6H X11/4 Data link connector 16L WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR ELECTRONIC STABILITY PROGRAM (ESP) - PE42.45-P-2050-99MCU >

Location and assignment of ground points

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 266 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE07.00-P-1100MCU, PE42.00-P-1100MCU, PE46.00-P-1100MCU (+1 more)

GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE07.00-P-1100MCU Further wiring diagrams PE42.00-P-1100MCU Further wiring diagrams PE46.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU SPECIAL TOOLS > 000 589 52 43 00 RESETTING DEVICE - WS42.00-P-0009A > FG 42/Set A MODEL 450, 451, 452, 107, 123, 124, 126, 129, 140, 163, 164, 168, 169.0 /3, 170, 171, 172, 197, 199, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 240, 245, 251, 414, 460, 461, 463.2 /3

Further use FG42/Set A WS42.00-N-0009A 15.10.10 Replacement for 450 589 02 37 00 brake piston pusher tool FG42/Set A WS42.00-P-0062A Use: Resetting device for brake piston.

SPECIAL TOOLS > 140 589 00 19 00 CALIPER GAUGE - WS42.00-P-0028A > FG 42/Set A MODEL all MODIFICATION NOTES 10.12.92 Replacement for: 124 589 05 19 00 124 589 05 19 00 WS42.00-N-3001B Fig 1: Identifying Resetting Device (000 589 52 43 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MAINTENANCE > REPLACE AIR FILTER ELEMENT - AP09.10-P-0980MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 287 · Applies to: 450, 451, 452, 454 · AR: AP09.10-P-0980MCU, AR09.00-Z-9132CB, AR09.41-P-6823MCC

ENGINE 132.910 in MODEL 451.3/4

Remove/install

1 Remove resonance tank

Remove/install resonance chamber

AR09.20- P- 0010MCU 2 Open clamps (3) and remove top part of air filter housing (2) Installation: Insert top part of air filter housing (2) in the rear area (arrow) in the guides on the bottom part of air filter housing (4) and close clamps (3).

3 Take out air cartridge (1) Installation: Clean bottom part of air filter housing (4) with rag.

4 Install in the reverse order

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: AIR INTAKE, SUPERCHARGING - AR09.00-Z-9132CB > ENGINE 132 Remove/install air ducting for charge ENGINE 132.930 in MODEL AR09.41-P-6823MCC Fig 1: Identifying Air Filter Element Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

air cooler

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 288 · Applies to: 450, 451, 452, 454 · AR: AR09.10-P-1150MCB, AR09.10-P-1150MCC, AR09.10-P-1150MCU, AR09.41-P-2001MCC, AR09.41-P-6817MCC (+5 more)

451 3/4 Remove/install air filter housing ENGINE 132.930 in MODEL 451.3/4 AR09.10-P-1150MCB Remove/install air filter housing ENGINE 132.910 in MODEL 451.3/4 AR09.10-P-1150MCC Remove/install air filter housing ENGINE 132.910 in MODEL 451.3/4 AR09.10-P-1150MCU Remove/install boost pressure sensor ENGINE 132.930 in MODEL 451.3/4 AR09.41-P-2001MCC Remove/install charge air cooler ENGINE 132.930 in MODEL 451.3/4 AR09.41-P-6817MCC Remove/install charge air cooler fan ENGINE 132.930 in MODEL 451.3/4 AR09.41-P-6820MCC Remove/install charge air hose downstream of the charge air cooler ENGINE 132.930 in MODEL 451.3/4 AR09.41-P-8625MCC Remove/install charge air manifold ENGINE 132.930 in MODEL 451.3/4 AR09.41-P-1310MCC Remove/install intake manifold ENGINES 132.910 in MODEL 451.3/4 AR09.20-P-1310MCC Remove/install intake manifold ENGINES 132.910 in MODEL 451.3/4 AR09.20-P-1310MCU Remove/install oil feed line for turbocharger ENGINES 132.930 in MODEL 451.3/4 AR09.40-P-6022MCC Remove/install oil return flow line of turbocharger ENGINES 132.930 in MODEL 451.3/4 AR09.40-P-6021MCC Remove/install resonance chamber ENGINES 132.930 in MODEL 451.3/4 AR09.20-P-0010MCB Remove/install resonance chamber ENGINES 132.910 in MODEL 451.3/4 up to 30.8.10 AR09.20-P-0010MCC Remove/install resonance chamber ENGINE 132... AR09.20-P-0010MCU Remove/install turbocharger ENGINES 132.930 in MODEL 451.3/4 AR09.40-P-6020MCC Remove/install wastegate valve ENGINE 132.930 in MODEL 451.3/4 AR09.40-P-1000MCC TESTING & REPAIR > REMOVE/INSTALL AIR FILTER HOUSING - AR09.10-P-1150MCU > ENGINE 132.910 in MODEL 451.3/4

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 289 · Applies to: 450, 451, 452, 454 · AR: AR09.20-P-0010MCU

1 Remove resonance tank

AR09.20- P- 0010MCU 2 Unlock retaining clamps (3) and remove top section of air filter housing (2) from air filter housing bottom section (1) Installation: Ensure correctObserve seating of top section of air filter housing (2) in the mounts on the air filter housing bottom section (1).

3 Remove air filter element from air filter housing bottom section (1)

4 Remove bolts (4) for air filter housing bottom section (1) on transmission and remove together with shims

5 Unclip air filter housing bottom section (1) upwards from holder on transmission

6 Remove air intake pipe (5) on air filter housing bottom section (1)

7 Lead air filter housing bottom section (1) out of engine compartment

8 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL RESONANCE CHAMBER - AR09.20-P-0010MCU

Fig 1: Identifying Air Filter Housing Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove bracket (3) from

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 291 · Applies to: 450, 451, 452, 454 · AR: AR09.20-P-1310MCU

8 Remove bracket (3) from resonator (1) When replacing the resonator (1).

9 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL INTAKE MANIFOLD - AR09.20-P-1310MCU > ENGINES 132.910 in MODEL 451.3/4

Remove/install

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00- Z-0001- 01A 1 Remove interior flap above engine

AR88.40- P-1100- 03MCC 2 Disconnect ground line of battery

AR54.10- P- 0003MCC AR01.00- Fig 1: Identifying Intake Manifold Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BA09.40-P-1004-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 295 · Applies to: 450, 451, 452, 454 · AR: GF09.00-P-3000MCC

01O Bolt, oil suction line bracket to crankcase Nm 11 BA09.40-P-1005- 01O Banjo bolt, oil pressure line to timing case cover Nm 17 BA09.40-P-1006- 01O Bolt, oil return flow line to turbocharger Nm 9 BA09.40-P-1007- 01O Bolt, oil return line bracket to cylinder head Nm 23 BA09.40-P-1008- 01O Bolt, oil return flow line to crankcase Nm 11 BA09.40-P-1009- 01O Banjo bolt, coolant return line to turbocharger Nm 31 BA09.40-P-1010- 01O Bolt, coolant return line holder to Wastegate valve holder Nm 10 BA09.40-P-1011- 01O Banjo bolt, coolant line to turbocharger Nm 31 BA09.40-P-1012- 01O Bolt, coolant line bracket to turbocharger Nm 10 BA09.40-P-1013- 01O Banjo bolt, coolant line to cylinder head Nm 31 BA09.40-P-1014- 01O Bolt of turbocharger bracket to cylinder head Nm 23 BA09.40-P-1015- 01O Bolt for turbocharger retaining bracket on turbocharger Nm 23 BASIC KNOWLEDGE > AIR INTAKE, FUNCTION - GF09.00-P-3000MCC > ENGINE 132.910 in MODEL 451.3/4 Fig 1: Identifying Air Filter Housing, Air Line And Intake Air Resonator Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Function

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 296 · Applies to: 450, 451, 452, 454 · AR: GF09.20-P-3110MCC

The fresh air is suctioned in via the air filter housing and cleaned by the air filter installed in the air filter housing. The cleaned fresh air is then passed back via the air line to the individual intake ports. The intake air resonator mounted on the air line serves as a pulsation damper. This reduces intake noise and minimizes the fluctuations which occur in the air flow during load changes. Component description for the intake air resonator GF09.20-P-3110MCC BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE INTAKE AIR RESONATOR - GF09.20-P-3110MCC > ENGINE 132.9 in MODEL 451.3/4 Shown on engine 132.910 Location The intake air resonator is located on the upper side of the engine on the air line coming from the air filter. Task The intake air resonator serves as a pulsation damper. This reduces intake noise and minimizes the fluctuations which occur in the air flow during load changes. SPECIAL TOOLS > SPECIAL TOOLS: SMART: AIR INTAKE, SUPERCHARGING - WS09.00- Z-9999CZ > MODEL all 001 589 01 16 00 Engine mount wrench set FG 22/07/09/28/61/ Set B WS22.00-P-0008B Fig 1: Identifying Intake Air Resonator Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MAINTENANCE > REPLACE AIR FILTER ELEMENT - AP09.10-P-0980MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 298 · Applies to: 450, 451, 452, 454 · AR: AP09.10-P-0980MCU, AR09.00-Z-9132CB

ENGINE 132.910 in MODEL 451.3 /4

Remove/install

1 Remove resonance tank

Remove/install resonance chamber

AR09.20- P- 0010MCU 2 Open clamps (3) and remove top part of air filter housing (2) Installation: Insert top part of air filter housing (2) in the rear area (arrow) in the guides on the bottom part of air filter housing (4) and close clamps (3).

3 Take out air cartridge (1) Installation: Clean bottom part of air filter housing (4) with rag.

4 Install in the reverse order

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: AIR INTAKE, SUPERCHARGING - AR09.00-Z-9132CB > ENGINE 132

Remove/install air ducting for charge air ENGINE 132.930 in MODEL AR09.41-P- Fig 1: Identifying Air Filter Element Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

cooler

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 299 · Applies to: 450, 451, 452, 454 · AR: AR09.10-P-1150MCU

451 3 /4 6823MCC

Remove/install air filter housing ENGINE 132.930 in MODEL 451.3 /4 AR09.10-P- 1150MCB

Remove/install air filter housing ENGINE 132.910 in MODEL 451.3 /4 AR09.10-P- 1150MCC

Remove/install air filter housing ENGINE 132.910 in MODEL 451.3 /4 AR09.10-P- 1150MCU

Remove/install boost pressure sensor ENGINE 132.930 in MODEL 451.3 /4 AR09.41-P- 2001MCC

Remove/install charge air cooler ENGINE 132.930 in MODEL 451.3 /4 AR09.41-P- 6817MCC

Remove/install charge air cooler fan ENGINE 132.930 in MODEL 451.3 /4 AR09.41-P- 6820MCC

Remove/install charge air hose downstream of the charge air cooler ENGINE 132.930 in MODEL 451.3 /4 AR09.41-P- 8625MCC

Remove/install charge air manifold ENGINE 132.930 in MODEL 451.3 /4 AR09.41-P- 1310MCC

Remove/install intake manifold ENGINES 132.910 in MODEL 451.3 /4 AR09.20-P- 1310MCC

Remove/install intake manifold ENGINES 132.910 in MODEL 451.3 /4 AR09.20-P- 1310MCU

Remove/install oil feed line for turbocharger ENGINES 132.930 in MODEL 451.3 /4 AR09.40-P- 6022MCC

Remove/install oil return flow line of turbocharger ENGINES 132.930 in MODEL 451.3 /4 AR09.40-P- 6021MCC

Remove/install resonance chamber ENGINES 132.930 in MODEL 451.3 /4 AR09.20-P- 0010MCB

Remove/install resonance chamber ENGINES 132.910 in MODEL 451.3 /4 up to 30.8.10 AR09.20-P- 0010MCC

Remove/install resonance chamber ENGINE 132... AR09.20-P- 0010MCU

Remove/install turbocharger ENGINES 132.930 in MODEL 451.3 /4 AR09.40-P- 6020MCC

Remove/install wastegate valve ENGINE 132.930 in MODEL 451.3 /4 AR09.40-P- 1000MCC TESTING & REPAIR > REMOVE/INSTALL AIR FILTER HOUSING - AR09.10-P-1150MCU > ENGINE 132.910 in MODEL 451.3 /4

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 300 · Applies to: 450, 451, 452, 454 · AR: AR09.20-P-0010MCU

1 Remove resonance tank

AR09.20- P- 0010MCU 2 Unlock retaining clamps (3) and remove top section of air filter housing (2) from air filter housing bottom section (1) Installation: Ensure correctObserve seating of top section of air filter housing (2) in the mounts on the air filter housing bottom section (1).

3 Remove air filter element from air filter housing bottom section (1)

4 Remove bolts (4) for air filter housing bottom section (1) on transmission and remove together with shims

5 Unclip air filter housing bottom section (1) upwards from holder on transmission

6 Remove air intake pipe (5) on air filter housing bottom section (1)

7 Lead air filter housing bottom section (1) out of engine compartment

8 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL RESONANCE CHAMBER - AR09.20-P-0010MCU

Fig 1: Identifying Air Filter Housing Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

re onator (1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 302 · Applies to: 450, 451, 452, 454 · AR: AR09.20-P-1310MCU

8 re onator (1) When replacing the re onator (1)

9 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL INTAKE MANIFOLD - AR09.20-P-1310MCU > ENGINES 132.910 in MODEL 451.3 /4

Remove/install

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00- Z-0001- 01A 1 Remove interior flap above engine

AR88.40- P-1100- 03MCC 2 Disconnect ground line of battery

AR54.10- P- 0003MCC 3 Lower rear drive module

AR01.00- P- Fig 1: Identifying Intake Manifold Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TORQUE SPECIFICATIONS > TURBOCHARGER - BA09.40-P-1000-01O >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 306 · Applies to: 450, 451, 452, 454 · AR: GF09.00-P-3000MCC

Engine 132.9 TURBOCHARGER Number Designation Engine 132.930 BA09.40-P-1001- 01O Nut of turbocharger to exhaust manifold Nm 30 BA09.40-P-1002- 01O Bolt, exhaust pipe to turbocharger Nm 50 BA09.40-P-1003- 01O Banjo bolt, oil pressure line to turbocharger Nm 17 BA09.40-P-1004- 01O Bolt, oil suction line bracket to crankcase Nm 11 BA09.40-P-1005- 01O Banjo bolt, oil pressure line to timing case cover Nm 17 BA09.40-P-1006- 01O Bolt, oil return flow line to turbocharger Nm 9 BA09.40-P-1007- 01O Bolt, oil return line bracket to cylinder head Nm 23 BA09.40-P-1008- 01O Bolt, oil return flow line to crankcase Nm 11 BA09.40-P-1009- 01O Banjo bolt, coolant return line to turbocharger Nm 31 BA09.40-P-1010- 01O Bolt, coolant return line holder to Wastegate valve holder Nm 10 BA09.40-P-1011- 01O Banjo bolt, coolant line to turbocharger Nm 31 BA09.40-P-1012- 01O Bolt, coolant line bracket to turbocharger Nm 10 BA09.40-P-1013- 01O Banjo bolt, coolant line to cylinder head Nm 31 BA09.40-P-1014- 01O Bolt of turbocharger bracket to cylinder head Nm 23 BA09.40-P-1015- 01O Bolt for turbocharger retaining bracket on turbocharger Nm 23 BASIC KNOWLEDGE > AIR INTAKE, FUNCTION - GF09.00-P-3000MCC > ENGINE 132.910 in MODEL 451.3 /4

Function

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 307 · Applies to: 450, 451, 452, 454 · AR: GF09.20-P-3110MCC

The fresh air is sectioned in via the air filter housing and cleaned by the air filter installed in the air filter housing. The cleaned fresh air is then passed back via the air line to the individual intake ports. The intake air resonator mounted on the air line serves as a pulsation damper. This reduces intake noise and minimizes the fluctuations which occur in the air flow during load changes. Component description for the intake air resonator GF09.20-P-3110MCC BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE INTAKE AIR RESONATOR - GF09.20-P-3110MCC > ENGINE 132.9 in MODEL 451.3 /4 Shown on engine 132.910 Fig 1: Identifying Air Filter Housing, Air Line And Intake Air Resonator Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

platform.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 315 · Applies to: 450, 451, 452, 454 · AR: AR01.00-P-1200MCU

specified by vehicle manufacturer. 01A 1 Lift vehicle using the vehicle lift until the rear wheels can be turned freely

2 Remove expansion clips (1) and remove cover (2)

3 Remove spark plugs (R4)

Replace spark plugs

AP15.10- P- 1580MCU 4 Lead a suitable hose through the spark plug threaded hole in the respective cylinder and turn engine at the center bolt (3) of the crankshaft belt pulley (4) in the direction of engine rotation until the piston stands at the bottom dead center of the cylinder to be checked

5 Attach inspection light to endoscope and lead inspection light through the spark plug threaded hole in the cylinder to be checked Endoscope (cold light) http://gotis.aftersales.mercedes- benz.com

Checking

6 Check cylinder wall, piston crown and valves In the case of visible cylinder wear the cylinder barrel is roughened and the honing marks are no longer visible.The cylinder head must be removed in cases of doubt.Refer to: ↓

Remove/install cylinder head AR01.30- P- 5800MCU Notes for evaluation of a cylinder barrel

AH01.40- P-0001- 03SM 7 Inspect other cylinders in the same way

8 Install in the reverse order

TESTING & REPAIR > TEST COMPRESSION PRESSURE - AR01.00-P-1200MCU > ENGINE 132.910 in MODEL 451.3/4

TESTING & REPAIR > INSPECT CYLINDERS FOR LEAKS - AR01.00-P-1300MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 318 · Applies to: 450, 451, 452, 454 · AR: AR01.00-P-1300MCU

01G TESTING & REPAIR > INSPECT CYLINDERS FOR LEAKS - AR01.00-P-1300MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 2: Identifying Compression Tester (001 589 76 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Expansion Clip, Crankshaft Belt Pulley, Cover And Center Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: COMPLETE ENGINE,

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 334 · Applies to: 450, 451, 452, 454 · AR: AR01.00-Z-9132CB, AR01.00-P-1300MCC, AR01.00-P-1300MCU, AR01.00-P-0200MCC, AR01.00-P-0200MCU (+4 more)

CRANKCASE VENTILATION, CYLINDER HEAD, CRANKCASE - AR01.00-Z-9132CB > ENGINE 132 Inspect cylinders for leaks ENGINE 132.9 in MODEL 451.3/4 AR01.00-P-1300MCC Inspect cylinders for leaks ENGINE 132.910 in MODEL 451.3/4 AR01.00-P-1300MCU Inspect cylinders with a light probe ENGINE 132.9 in MODEL 451.3/4 AR01.00-P-0200MCC Inspect cylinders with a light probe ENGINE 132.910 in MODEL 451.3/4 AR01.00-P-0200MCU Measure cylinder bores ENGINES 132.9 in MODEL 451.3/4 AR01.40-P-9202MCC Release and position rear drive module ENGINE 132.9, 660.9 in MODEL 451.3/4 AR01.00-P-3050MCC Release and position rear drive module ENGINE 132.910 in MODEL 451.3/4 AR01.00-P-3050MCU Remove/install cover on crankcase ENGINE 132.9 in MODEL 451.3/4 AR01.20-P-0100MCC Fig 3: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Mount (451 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install cover on crankcase

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 335 · Applies to: 450, 451, 452, 454 · AR: AR01.20-P-0100MCU, AR01.20-P-0010MCC, AR01.20-P-0010MCU, AR01.30-P-5800MCC, AR01.30-P-5800MCU (+5 more)

ENGINE 132.910 in MODEL 451.3/4 AR01.20-P-0100MCU Remove/install crankcase ventilation valve (partial load) ENGINE 132.9 in MODEL 451.3/4 AR01.20-P-0010MCC Remove/install crankcase ventilation valve (partial load) ENGINE 132.910 in MODEL 451.3/4 AR01.20-P-0010MCU Remove/install cylinder head ENGINES 132.9 in MODEL 451.3/4 AR01.30-P-5800MCC Remove/install cylinder head ENGINE 132.910 in MODEL 451.3/4 AR01.30-P-5800MCU Remove/install cylinder head cover ENGINES 132.9 in MODEL 451.3/4 AR01.20-P-5014MCC Remove/install cylinder head cover ENGINE 132.910 in MODEL 451.3/4 AR01.20-P-5014MCU Remove/install end cover together with shaft seal ENGINE 132.9 in MODEL 451.3/4 AR01.40-P-8920MCC Remove/install end cover together with shaft seal ENGINE 132.910 in MODEL 451.3/4 AR01.40-P-8920MCU Remove/install engine with transmission ENGINES 132.930 in MODEL 451.3/4 AR01.10-P-2401MCB Remove/install engine with transmission ENGINES 132.910 in MODEL 451.3/4 AR01.10-P-2401MCC Remove/install engine with transmission ENGINES 132.910 in MODEL 451.3/4 AR01.10-P-2401MCU Remove/install oil pan ENGINE 132.9 in MODEL 451.3/4 AR01.45-P-7500MCC Remove/install oil pan ENGINE 132.910 in MODEL 451.3/4 AR01.45-P-7500MCU Remove/install rear-wheel drive module ENGINE 132.9, 660.9 in MODEL 451.3/4 AR01.00-P-3060MCC Remove/install rear-wheel drive module ENGINE 132.910 in MODEL 451.3/4 AR01.00-P-3060MCU Remove/install timing case cover ENGINES 132.9 in MODEL 451.3/4 AR01.40-P-8000MCC Remove/install timing case cover ENGINE 132.910 in MODEL 451.3/4 AR01.40-P-8000MCU Test compression pressure ENGINE 132.9 in MODEL 451.3/4 (except 451.380 /480) AR01.00-P-1200MCC Test compression pressure ENGINE 132.910 in MODEL 451.3/4 AR01.00-P-1200MCU TESTING & REPAIR > TURN ENGINE TO TOP DEAD CENTER POSITION - AR01.10-P- 1000-01MCU >

TESTING & REPAIR > REMOVE/INSTALL CRANKCASE VENTILATION VALVE (PARTIAL

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 343 · Applies to: 450, 451, 452, 454 · AR: AR01.20-P-0010MCU

LOAD) - AR01.20-P-0010MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install

1 Remove intake manifold (2)

AR09.20- P- 1310MCU 2 Remove crankcase ventilation valve (1) from grommet (3) on partial load vent plate (4) Installation: Check hose (5) on crankcase ventilation valve (1); replace if necessary.

3 Remove grommet (3) from partial load vent plate (4) Installation: Check grommet (3) and replace if necessary.

4 Detach clamp (6) and detach crankcase ventilation valve (1) from hose (5) When replacing crankcase ventilation valve (1).

5 Install in the reverse order

Fig 3: Identifying Support (451 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Crankcase Ventilation Valve Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL COVER ON CRANKCASE - AR01.20-P-0100MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 344 · Applies to: 450, 451, 452, 454 · AR: AR01.20-P-0100MCU

ENGINE 132.910 in MODEL 451.3/4 Remove/install

1 Remove intake manifold (2)

AR09.20-P- 1310MCU 2 Remove crankcase ventilation valve (3) from grommet (4) on partial load vent plate (1)

3 Remove bolts (5) *BA01.20-P- 1003-01I 4 Detach partial load venting plate (1) from the crankcase using the knife and take off

Installation: Clean sealing surfaces to partial load venting plate (1) and on crankcase. Apply sealant to cylinder crankcase. 122589002800 Sealant BR00.45-Z- 1053-01A 5 Install in the reverse order

CRANKCASE VENTILATION, CYLINDER HEAD COVER Number Designation Engine 132.9 BA01.20-P-1003- 01I Bolt, partial load venting plate to crankcase Nm 10 Fig 1: Identifying Crankcase Cover Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL CYLINDER HEAD COVER - AR01.20-P-5014MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 346 · Applies to: 450, 451, 452, 454 · AR: AR01.20-P-5014MCU

ENGINE 132.910 in MODEL 451.3/4 Fig 1: Identifying Cylinder Head Cover Bolts Tightening Sequence Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Stage 2

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 350 · Applies to: 450, 451, 452, 454 · AR: AR01.30-P-5800MCU

01K Stage 2 ∠° 90 Stage 3 ∠° 90 Stage 4 ∠° - 1. Tighten cylinder head bolt (1 to 8) in stages in sequence of the tightening procedure. Direction of travel see arrow. TESTING & REPAIR > REMOVE/INSTALL CYLINDER HEAD - AR01.30-P-5800MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 1: Identifying Cylinder Head Bolts Tightening Sequence Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > BOLT PLAN FOR TIMING CASE COVER - AR01.40-P-8000-01MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 358 · Applies to: 450, 451, 452, 454 · AR: AR01.40-P-8000MCU

TESTING & REPAIR > REMOVE/INSTALL TIMING CASE COVER - AR01.40-P-8000MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 6: Identifying Retaining Plates (451 589 02 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Timing Case Cover Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 365 · Applies to: 450, 451, 452, 454 · AR: AR01.40-P-8920MCU

Number Designation Order number BR00.45-Z-1053-01A Sealing compound Q0000282V000000000 TESTING & REPAIR > REMOVE/INSTALL END COVER TOGETHER WITH SHAFT SEAL - AR01.40-P-8920MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 6: Identifying Guide (451 589 03 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 7: Identifying Drift (711 589 13 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

application of

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 367 · Applies to: 450, 451, 452, 454 · AR: AR01.40-P-9202MCC

sealant to end cover with radial shaft seal AH01.40- P-1000- 06MCC 6 Install in the reverse order

CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 132.9 BA01.40-P-1006- 01M Bolt connecting end cover of radial shaft sealing ring to the crankcase Nm 10 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1053-01A Sealant Q0000282V000000000 TESTING & REPAIR > MEASURE CYLINDER BORES - AR01.40-P-9202MCC > ENGINES 132.9 in MODEL 451.3/4 Removing

1 Remove pistons

AR03.10-P- 7021MCC 2 Clean cylinder bores for the crankcase

Fig 1: Measuring Cylinder Bores Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Checking

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 368 · Applies to: 450, 451, 452, 454 · AR: AR01.45-P-7500MCU

3 Measure cylinder bore at the measuring points (1, 2, 3) in a longitudinal direction (A) and transverse direction (B) Replace crankcase if the wear or damage is too high. *BE01.40-P-1001- 01P Install

4 Install pistons

AR03.10-P- 7021MCC TEST SPECIFICATIONS FOR CYLINDER BORE Number Designation Engine 132.910/930 BE01.40-P-1001- 01P Dia. of cylinder bore Standard size mm 72.010 to 72.025 Out-of-roundness (in a new condition) mm 0.01 Wear limit in longitudinal and transverse direction mm 0.15 TESTING & REPAIR > REMOVE/INSTALL OIL PAN - AR01.45-P-7500MCU > ENGINE 132.910 in MODEL 451.3/4 Shown on vehicle with Code (I01) AC Plus

Remove/install

Fig 1: Identifying Oil Pan Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

between individual cylinders

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 376 · Applies to: 450, 451, 452, 454 · AR: BE01.00-Z-9999CZ

CHECK VALUES FOR COMPRESSION PRESSURE Number Designation Engine 135.930 Engine 135.950 Engine 639 Engine 660.940 BE01.00-P- 1001-01G Compression pressure new value bar 14.3 15.5 18 18.5 BE01.00-P- 1002-01G Compression pressure wear limit or limit value bar ≈10 ≈11 ≈10.5 - BE01.00-P- 1003-01G Compression pressure: permissible difference between individual cylinders bar ≤0.98 ≤0.98 ≤2.5 - CHECK VALUES FOR COMPRESSION PRESSURE Number Designation Engine 660.950 Engine 660.951 BE01.00-P-1001- 01G Compression pressure new value bar 28 - BE01.00-P-1002- 01G Compression pressure wear limit or limit value bar 18 18 BE01.00-P-1003- 01G Compression pressure: permissible difference between individual cylinders bar 3 3 TEST & ADJUSTMENT VALUES > CYLINDER LEAKTIGHTNESS - BE01.00-P-1000-02Z > All engines CYLINDER LEAKTIGHTNESS Number Designation All engines BE01.00-P-1001- 02Z Cylinder leaktightness permissible loss total indication % ≤25 BE01.00-P-1002- 02Z Cylinder leaktightness permissible losses at valves and cylinder head gasket % ≤10 BE01.00-P-1003- 02Z Cylinder leaktightness permissible losses at pistons and piston rings % ≤20 TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: COMPLETE ENGINE, CRANKCASE VENTILATION, CYLINDER HEAD, CRANKCASE - BE01.00-Z-9999CZ > MODEL all Check values for crankcase ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 in MODEL 454.0 BE01.40-P-1000-02I

The following functions were realized:

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 378 · Applies to: 450, 451, 452, 454 · AR: GF07.10-P-1016MCC, GF09.00-P-3000MCC, GF13.21-P-1000MCU, GF18.00-P-1100MCU, GF20.00-P-1000MCU (+5 more)

Camshaft adjustment Air intake Belt drive Engine lubrication Engine cooling Camshaft adjustment, function GF07.10-P-1016MCC Air intake, function GF09.00-P-3000MCC Belt drive function GF13.21-P-1000MCU Engine lubrication function GF18.00-P-1100MCU Engine cooling function GF20.00-P-1000MCU BASIC KNOWLEDGE > TABLE OF CONTENTS FOR FUNCTION DESCRIPTION, MECHANICAL ENGINE COMPONENTS - GF01.10-P-0998MCU > ENGINES 132.9 in MODEL 451.3/4 Mechanical engine components, function GF01.10-P-0001MCU Camshaft adjustment, function GF07.10-P-1016MCC Air intake, function GF09.00-P-3000MCC Belt drive function GF13.21-P-1000MCU Engine lubrication function GF18.00-P-1100MCU Engine cooling function GF20.00-P-1000MCU Overview of system components, mechanical engine components GF01.10-P-9998MCU BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS, MECHANICAL ENGINE COMPONENTS - GF01.10-P-9998MCU > ENGINE 132.9 in MODEL 451.3/4 Component description for the camshaft adjuster

GF05.20-P-1110MCC Component description for the intake air resonator

GF09.20-P-3110MCC Component description for stretch belts For code (I01) Air conditioning Plus GF13.21-P-6000MCU Component description for the clamping device Model 451.33/43 GF13.25-P-3202MCC Component description for the oil pump

GF18.10-P-4000MCC

Component description for the coolant

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 379 · Applies to: 450, 451, 452, 454 · AR: GF20.10-P-3162MCC, GF01.40-P-2100MCC, GF01.10-P-0998MCU

thermostat

GF20.10-P-3162MCC Component description for the baffle plate

GF01.40-P-2100MCC Table of contents for function description, mechanical engine components

GF01.10-P-0998MCU BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE BAFFLE PLATE - GF01.40- P-2100MCC > ENGINE 132.9 in MODEL 451.3/4 Location The baffle plate is located below on the crankcase. Task A baffle plate is located between the oil pan and crankcase in order to optimize the power output of the engine. The baffle plate prevents direct immersion of the crankshaft in engine oil remaining in the oil pan. This reduces the resistance at the crankshaft and also prevents foaming of the engine oil. Furthermore, returning engine oil from the engine flows via the baffle plate into the oil pan. This causes calming of the engine oil. The whipped up engine oil for various driving conditions is held back by the baffle plate and therefore does not come into direct contact with the crankshaft. This also prevents air being sucked in by the die oil pump when the vehicle is tilted. SPECIAL TOOLS > 639 589 00 61 00 ENGINE LIFTING DEVICE - WS01.00-N-3106C > FG 01/33/Set C Fig 1: Identifying Baffle Plate And Crankcase Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Checking

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 403 · Applies to: 450, 451, 452, 454 · AR: AR01.00-P-1200MCU

6 Check cylinder wall, piston crown and valves In the case of visible cylinder wear the cylinder barrel is roughened and the honing marks are no longer visible.The cylinder head must be removed in cases of doubt.Refer to: ↓

Remove/install cylinder head AR01.30- P- 5800MCU Notes for evaluation of a cylinder barrel

AH01.40- P-0001- 03SM 7 Inspect other cylinders in the same way

8 Install in the reverse order

TESTING & REPAIR > TEST COMPRESSION PRESSURE - AR01.00-P-1200MCU > ENGINE 132.910 in MODEL 451.3 /4

Remove/install

Risk of accident caused by vehicle starting off by itself when engine is Secure vehicle to prevent it Fig 1: Testing Compression Pressure Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Compare measurements obtained with the

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 405 · Applies to: 450, 451, 452, 454 · AR: AR01.00-P-1300MCU

12 Compare measurements obtained with the specified pressures limit or limit value If the wear limit is not reached, cylinder leakage must be checked on the respective cylinder.See: ↓ *BE01.00- P-1002- 01G Inspect cylinders for leaks AR01.00- P- 1300MCU 13 Install in the reverse order

14 Read out fault memory, erase if necessary

Connect STAR DIAGNOSIS and read out fault memory

AD00.00- P-2000- 04MCC CHECK VALUES FOR COMPRESSION PRESSURE Number Designation Engine 132.910 BE01.00-P-1001-01G Compression pressure new value bar 15 BE01.00-P-1002-01G Compression pressure wear limit or limit value bar ≈11 TESTING & REPAIR > INSPECT CYLINDERS FOR LEAKS - AR01.00-P-1300MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 2: Identifying Compression Tester (001 589 76 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

GENERAL INFORMATION > NOTES ON THREAD REPAIRS - AH00.00-P-0008-01MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 415 · Applies to: 450, 451, 452, 454 · AR: AR01.00-Z-9132CB, AR01.00-P-1300MCC, AR01.00-P-1300MCU, AR01.00-P-0200MCC

Model 451.3/4 Thread repairs at body: Thread repairs of frame-type integral support mountings are to be carried out exclusively with Time Sert M12 x 1.5 threaded inserts (1). Thread repairs using screw thread inserts (e.g. Heli Coil, Kerb Konus or similar) are not approved. TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: COMPLETE ENGINE, CRANKCASE VENTILATION, CYLINDER HEAD, CRANKCASE - AR01.00-Z-9132CB > ENGINE 132 Inspect cylinders for leaks ENGINE 132.9 in MODEL 451.3 /4 AR01.00-P-1300MCC Inspect cylinders for leaks ENGINE 132.910 in MODEL 451.3 /4 AR01.00-P-1300MCU Inspect cylinders with a light ENGINE 132.9 in MODEL 451.3 /4 AR01.00-P-0200MCC Fig 5: Identifying Mount (451 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Threaded Inserts On Frame-Type Integral Support Mounting Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

probe

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 416 · Applies to: 450, 451, 452, 454 · AR: AR01.00-P-0200MCU, AR01.40-P-9202MCC, AR01.00-P-3050MCC, AR01.00-P-3050MCU, AR01.20-P-0100MCC (+5 more)

Inspect cylinders with a light probe ENGINE 132.910 in MODEL 451.3 /4 AR01.00-P-0200MCU Measure cylinder bores ENGINES 132.9 in MODEL 451.3 /4 AR01.40-P-9202MCC Release and position rear drive module ENGINE 132.9, 660.9 in MODEL 451.3 /4 AR01.00-P-3050MCC Release and position rear drive module ENGINE 132.910 in MODEL 451.3 /4 AR01.00-P-3050MCU Remove/install cover on crankcase ENGINE 132.9 in MODEL 451.3 /4 AR01.20-P-0100MCC Remove/install cover on crankcase ENGINE 132.910 in MODEL 451.3 /4 AR01.20-P-0100MCU Remove/install crankcase ventilation valve (partial load) ENGINE 132.9 in MODEL 451.3 /4 AR01.20-P-0010MCC Remove/install crankcase ventilation valve (partial load) ENGINE 132.910 in MODEL 451.3 /4 AR01.20-P-0010MCU Remove/install cylinder head ENGINES 132.9 in MODEL 451.3 /4 AR01.30-P-5800MCC Remove/install cylinder head ENGINE 132.910 in MODEL 451.3 /4 AR01.30-P-5800MCU Remove/install cylinder head cover ENGINES 132.9 in MODEL 451.3 /4 AR01.20-P-5014MCC Remove/install cylinder head cover ENGINE 132.910 in MODEL 451.3 /4 AR01.20-P-5014MCU Remove/install end cover together with shaft seal ENGINE 132.9 in MODEL 451.3 /4 AR01.40-P-8920MCC Remove/install end cover together with shaft seal ENGINE 132.910 in MODEL 451.3 /4 AR01.40-P-8920MCU Remove/install engine with transmission ENGINES 132.930 in MODEL 451.3 /4 AR01.10-P-2401MCB Remove/install engine with transmission ENGINES 132.910 in MODEL 451.3 /4 AR01.10-P-2401MCC Remove/install engine with transmission ENGINES 132.910 in MODEL 451.3 /4 AR01.10-P-2401MCU Remove/install oil pan ENGINE 132.9 in MODEL 451.3 /4 AR01.45-P-7500MCC Remove/install oil pan ENGINE 132.910 in MODEL 451.3 /4 AR01.45-P-7500MCU Remove/install rear-wheel drive module ENGINE 132.9, 660.9 in MODEL 451.3 /4 AR01.00-P-3060MCC Remove/install rear-wheel drive ENGINE 132.910 in MODEL 451.3 AR01.00-P-3060MCU

module

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 417 · Applies to: 450, 451, 452, 454 · AR: AR01.40-P-8000MCC, AR01.40-P-8000MCU, AR01.00-P-1200MCC, AR01.00-P-1200MCU

/4 Remove/install timing case cover ENGINES 132.9 in MODEL 451.3 /4 AR01.40-P-8000MCC Remove/install timing case cover ENGINE 132.910 in MODEL 451.3 /4 AR01.40-P-8000MCU Test compression pressure ENGINE 132.9 in MODEL 451.3 /4 (except 451.380 /480) AR01.00-P-1200MCC Test compression pressure ENGINE 132.910 in MODEL 451.3 /4 AR01.00-P-1200MCU TESTING & REPAIR > TURN ENGINE TO TOP DEAD CENTER POSITION - AR01.10-P- 1000-01MCU > 1. Remove expansion clips (1) and remove cover (2) 2. Transfer marking (arrow A) on crankshaft belt pulley (3) to the front side using a suitable colored pencil. If necessary turn engine at the center bolt (4) of the crankshaft belt pulley (3) in the direction of engine rotation. 3. Rotate engine at crankshaft in direction of engine rotation until marking (arrow A) on crankshaft belt pulley (3) coincides with the TDC marking (arrow B) on the timing case cover (5). Fig 1: Turning Engine To Top Dead Center Position Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Number

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 424 · Applies to: 450, 451, 452, 454 · AR: AR01.20-P-0010MCU

Designation Engine 132.9 BA15.30-P-1002-01E Cable to starter circuit 30 Nm 10 ALTERNATOR Number Designation Engine 132.9 BA15.40-P-1002-01G Cable on alternator terminal B+ Nm 10 ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 BA22.10-P-1007-01M Bolt, right engine mount to timing case cover Nm 80 BA22.10-P-1010-01M Bolt, torque support to frame-type integral support Nm 115 COMPLETE MANUAL TRANSMISSION Number Designation Transmission 717.48 BA26.00-P-1002-01D Bolt, transmission mount to transmission Nm 80 REFRIGERANT COMPRESSOR Number Designation Engine 132.9 BA83.55-P-1001-01V Bolt, refrigerant compressor to cylinder crankcase Nm 20 BA83.55-P-1002-01V Bolt, AC compressor to oil pan Nm 20 TESTING & REPAIR > REMOVE/INSTALL CRANKCASE VENTILATION VALVE (PARTIAL LOAD) - AR01.20-P-0010MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 3: Identifying Support (451 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 425 · Applies to: 450, 451, 452, 454 · AR: AR01.20-P-0100MCU

1 Remove intake manifold (2)

AR09.20- P- 1310MCU 2 Remove crankcase ventilation valve (1) from grommet (3) on partial load vent plate (4) Installation: Check hose (5) on crankcase ventilation valve (1); replace if necessary.

3 Remove grommet (3) from partial load vent plate (4) Installation: Check grommet (3) and replace if necessary.

4 Detach clamp (6) and detach crankcase ventilation valve (1) from hose (5) When replacing crankcase ventilation valve (1).

5 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL COVER ON CRANKCASE - AR01.20-P-0100MCU

ENGINE 132.910 in MODEL 451.3 /4 Fig 1: Identifying Crankcase Ventilation Valve (Partial Load) Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Crankcase Cover Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

CRANKCASE VENTILATION, CYLINDER HEAD COVER

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 427 · Applies to: 450, 451, 452, 454 · AR: AR01.20-P-5014MCU

Number Designation Engine 132.9 BA01.20-P-1002-01I Bolt, cylinder head cover to cylinder head Nm 10 1. Screw in bolts (1 to 10) for cylinder head cover in a number of stages according to the represented sequence all the way and tighten using the prescribed torque. Loosen bolts for the cylinder head cover in reverse order of the tightening procedure. TESTING & REPAIR > REMOVE/INSTALL CYLINDER HEAD COVER - AR01.20-P-5014MCU

ENGINE 132.910 in MODEL 451.3 /4 Fig 1: Identifying Cylinder Head Cover Bolt Tightening Sequence Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BA01.30-P-1001-01K

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 431 · Applies to: 450, 451, 452, 454 · AR: AR01.30-P-5800MCU

Bolt, cylinder head to crankcase Stage 2 ∠° 90 Stage 3 ∠° 90 Stage 4 ∠° - 1. Tighten cylinder head bolt (1 to 8) in stages in sequence of the tightening procedure. Direction of travel see arrow. TESTING & REPAIR > REMOVE/INSTALL CYLINDER HEAD - AR01.30-P-5800MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 1: Identifying Cylinder Head Bolt Tightening Sequence Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

adapter to crankshaft,

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 434 · Applies to: 450, 451, 452, 454 · AR: AP05.30-P-0560MCU

remove retaining lock on starter ring gear and turn engine in direction of engine rotation through about two revolutions until the markings on the crankshaft sprocket and on the cylinder crankcase stand opposite each other. Then check whether the marking (arrow B) on the camshaft sprocket (14) and the marking (arrow C) on the camshaft adjuster (15) stand opposite each other; remove timing chain (13) if necessary and mount again anew. Attach/disassemble retaining lock for engine AR03.30-P-1600- 06MCE Fig 4 If the cylinder head (1) was replaced the valve clearance must be checked and adjusted if necessary.Refer to: ↓ Fig 5 Set valve clearance AP05.30-P-0560MCU 6 Unscrew bolts (9) and remove slide rail (10) BA05.10-P-1002- 01P BA05.10-P-1003- 01P 7 Unscrew bolt (11) and remove tensioning rail (12) *BA05.10-P-1001- 01P 8 Take off timing chain (13) Installation: Before mounting the timing chain (13) check whether the marking (arrow B) on the camshaft sprocket (14) and the marking (arrow C) on the camshaft adjuster (15) are standing opposite each other. If this is not the case, the intake camshaft and the exhaust camshaft must be turned appropriately.

TESTING & REPAIR > BOLT PLAN FOR TIMING CASE COVER - AR01.40-P-8000-01MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 439 · Applies to: 450, 451, 452, 454 · AR: AR01.40-P-8000MCU

TESTING & REPAIR > REMOVE/INSTALL TIMING CASE COVER - AR01.40-P-8000MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 6: Identifying Retaining Plates (451 589 02 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Timing Case Cover Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REPAIR MATERIALS

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 446 · Applies to: 450, 451, 452, 454 · AR: AR01.40-P-8920MCU

Number Designation Order number BR00.45-Z-1053-01A Sealing compound Q0000282V000000000 TESTING & REPAIR > REMOVE/INSTALL END COVER TOGETHER WITH SHAFT SEAL - AR01.40-P-8920MCU > Fig 5: Identifying Retaining Plates (451 589 02 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Guide (451 589 03 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 7: Identifying Drift (711 589 13 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Notes on

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 448 · Applies to: 450, 451, 452, 454 · AR: AR01.40-P-9202MCC

application of sealant to end cover with radial shaft seal Sealant AH01.40- P-1000- 06MCC 6 Install in the reverse order

CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 132.9 BA01.40-P-1006-01M Bolt connecting end cover of radial shaft sealing ring to the crankcase Nm 10 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1053-01A Sealant Q0000282V000000000 TESTING & REPAIR > MEASURE CYLINDER BORES - AR01.40-P-9202MCC > ENGINES 132.9 in MODEL 451.3 /4 Removing

1 Remove pistons

AR03.10- P- Fig 1: Identifying Cylinder Bore Measuring Points Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

7021MCC

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 449 · Applies to: 450, 451, 452, 454 · AR: AR01.45-P-7500MCU

2 Clean cylinder bores for the crankcase

Checking

3 Measure cylinder bore at the measuring points (1, 2, 3) in a longitudinal direction (A) and transverse direction (B) Replace crankcase if the wear or damage is too high. *BE01.40- P-1001- 01P Install

4 Install pistons

AR03.10- P- 7021MCC TEST SPECIFICATIONS FOR CYLINDER BORE Number Designation Engine 132.910/930 BE01.40-P-1001- 01P Dia. of cylinder bore Standard size mm 72.010 to 72.025 Out-of-roundness (in a new condition) mm 0.01 Wear limit in longitudinal and transverse direction mm 0.15 TESTING & REPAIR > REMOVE/INSTALL OIL PAN - AR01.45-P-7500MCU > ENGINE 132.910 in MODEL 451.3 /4 Shown on vehicle with Code (I01) AC Plus Fig 1: Identifying Oil Pan Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BE01.00-P-1003-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 458 · Applies to: 450, 451, 452, 454 · AR: BE01.00-Z-9999CZ

02Z Cylinder leaktightness permissible losses at pistons and piston rings % ≤20 TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: COMPLETE ENGINE, CRANKCASE VENTILATION, CYLINDER HEAD, CRANKCASE - BE01.00-Z-9999CZ > MODEL all Check values for crankcase ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 in MODEL 454.0 BE01.40-P-1000-02I Check values for cylinder bore ENGINE 122, 134, 135, 160, 639... BE01.40-P-1000-01L Compression pressure ENGINE 160.910 /920 /921 /922 BE01.00-P-1000-01H Compression pressure ENGINE 122, 132.910 /930, 134, 135.930 /950, 639, 660.940 /950 /951 BE01.00-P-1000- 01G Cylinder head/cylinder head bolts ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 in MODEL 454.0 BE01.30-P-1000-04F Cylinder leaktightness ENGINE all BE01.00-P-1000- 02Z Inspection data for cylinder head ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 in MODEL 454.0 BE01.30-P-1000-02F Test specifications for cylinder bore ENGINE 132.9 in MODEL 451.3 /4 BE01.40-P-1000- 01P TEST & ADJUSTMENT VALUES > TEST SPECIFICATIONS FOR CYLINDER BORE - BE01.40-P-1000-01P > Engine 132 TEST SPECIFICATIONS FOR CYLINDER BORE Number Designation Engine 132.910/930 BE01.40-P-1001- 01P Ø of cylinder bore Standard size mm 72.010 to 72.025 Out-of-roundness (in a new condition) mm 0.01 Wear limit in longitudinal and transverse direction mm 0.15 BASIC KNOWLEDGE > MECHANICAL ENGINE COMPONENTS, FUNCTION - GF01.10-P- 0001MCU > ENGINES 132.9 in MODEL 451.3 /4 The three-cylinder engine was newly developed from scratch. It is raked to the rear by 45° and installed transversely in front of the rear axle. The engine is characterized by a weight-conscious full aluminum construction from the oil pan to the cylinder head cover. The crankcases are equipped with gray cast iron

bushes for the cylinder barrel.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 459 · Applies to: 450, 451, 452, 454 · AR: GF07.10-P-1016MCC, GF09.00-P-3000MCC, GF13.21-P-1000MCU, GF18.00-P-1100MCU, GF20.00-P-1000MCU (+3 more)

Four valves per cylinder control the gas exchange in the cylinder heads. These are controlled by intake and exhaust camshafts which are driven via a maintenance free timing chain by the crankshaft. Cup tappets serve as transmission elements for cam contours in the valve movement. It was possible to dispense with a balance shaft for the three-cylinder typical vibrations (free mass moment) because of the low moved masses. Significant reduction in the tendency to knock was also achieved through optimization of combustion chambers. The following functions were realized: Camshaft adjustment Air intake Belt drive Engine lubrication Engine cooling Camshaft adjustment, function GF07.10-P-1016MCC Air intake, function GF09.00-P-3000MCC Belt drive function GF13.21-P-1000MCU Engine lubrication function GF18.00-P-1100MCU Engine cooling function GF20.00-P-1000MCU BASIC KNOWLEDGE > TABLE OF CONTENTS FOR FUNCTION DESCRIPTION, MECHANICAL ENGINE COMPONENTS - GF01.10-P-0998MCU > ENGINES 132.9 in MODEL 451.3 /4 Mechanical engine components, function GF01.10-P-0001MCU Camshaft adjustment, function GF07.10-P-1016MCC Air intake, function GF09.00-P-3000MCC Belt drive function GF13.21-P-1000MCU Engine lubrication function GF18.00-P-1100MCU Engine cooling function GF20.00-P-1000MCU Overview of system components, mechanical engine components GF01.10-P-9998MCU BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS, MECHANICAL ENGINE COMPONENTS - GF01.10-P-9998MCU > ENGINE 132.9 in MODEL 451.3 /4

Component description for the camshaft

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 460 · Applies to: 450, 451, 452, 454 · AR: GF05.20-P-1110MCC, GF09.20-P-3110MCC, GF13.21-P-6000MCU, GF13.25-P-3202MCC, GF18.10-P-4000MCC (+1 more)

adjuster

GF05.20-P-1110MCC Component description for the intake air resonator

GF09.20-P-3110MCC Component description for stretch belts For code (I01) Air conditioning Plus GF13.21-P-6000MCU Component description for the clamping device Model 451.33/43 GF13.25-P-3202MCC Component description for the oil pump

GF18.10-P-4000MCC Component description for the coolant thermostat

GF20.10-P-3162MCC Component description for the baffle plate

GF01.40-P- 2100MCC Table of contents for function description, mechanical engine components

GF01.10-P- 0998MCU BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE BAFFLE PLATE - GF01.40- P-2100MCC > ENGINE 132.9 in MODEL 451.3 /4 Location The baffle plate is located below on the crankcase. Task A baffle plate is located between the oil pan and crankcase in order to optimize the power output of the engine. The baffle plate prevents direct immersion of the crankshaft in engine oil remaining in the oil pan. Fig 1: Identifying Baffle Plate And Crankcase Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

GENERAL INFORMATION > ASSIGNMENT OF PISTONS TO CYLINDER BORE - AH03.10-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 476 · Applies to: 450, 451, 452, 454 · AR: AR03.00-Z-9132CB, AR03.30-P-8002MCC, AR03.30-P-8002MCU, AR03.30-P-1700MCC, AR03.30-P-1700MCU (+1 more)

P-0001-02MCC > Model 451.3/4 with engine 132.9 The markings (arrows) on the pistons (1) must point towards the timing case. TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: CRANK ASSEMBLY - AR03.00-Z-9132CB > ENGINE 132 Remove, install a flywheel ENGINE 132.9 in MODEL 451.3/4 AR03.30-P-8002MCC Remove, install a flywheel ENGINE 132.910 in MODEL 451.3/4 AR03.30-P-8002MCU Remove/install belt pulley ENGINE 132.9 in MODEL 451.3/4 AR03.30-P-1700MCC Remove/install belt pulley ENGINE 132.910 in MODEL 451.3/4 AR03.30-P-1700MCU Remove/install crankshaft ENGINES 132.9 in MODEL 451.3/4 AR03.20-P-4351MCC Fig 1: Locating Markings On Pistons Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install piston

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 477 · Applies to: 450, 451, 452, 454 · AR: AR03.10-P-7021MCC, AR03.10-P-7311MCC, AR03.20-P-3000MCC, AR03.20-P-3000MCU

ENGINES 132.9 in MODEL 451.3/4 AR03.10-P-7021MCC Remove/install piston rings ENGINES 132.9 in MODEL 451.3/4 AR03.10-P-7311MCC Replace front crankshaft radial sealing ring ENGINE 132.9 in MODEL 451.3/4 AR03.20-P-3000MCC Replace front crankshaft radial sealing ring ENGINE 132.910 in MODEL 451.3/4 AR03.20-P-3000MCU TESTING & REPAIR > ASSIGN CONNECTING ROD BEARING SHELLS - AR03.10-P-6112- 01MCC > 1. Assign connecting rod bearing shells for crankshaft (1) and the connecting rod (4). Selection of the connecting rod bearing shells takes place over the three numbers (3) on the cheek of the crankshaft (1) and the numbers (arrow) on the associated connecting rod (4). The first four numbers (2) are foreseen for the crankshaft bearing shells. The connecting rod bearing shells should be assigned to the connecting rods (4) according to the sequence of the numbers (3). The first bearing point is located opposite the output side of the engine. Assignment takes place over a number placed on the side on the connecting rod bearing shells and can be taken from the following list. Number on the Number on the marking (arrow) Connecting rod bearing shell (5) Fig 1: Identifying Numbers On Cheek Of Crankshaft And Associated Connecting Rod Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL PISTON - AR03.10-P-7021MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 481 · Applies to: 450, 451, 452, 454 · AR: AR03.10-P-7021MCC

ENGINES 132.9 in MODEL 451.3/4 Fig 3: Inserting Piston, Piston Pin And Connecting Rod Together With Thrust Piece And Guide Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 482 · Applies to: 450, 451, 452, 454 · AR: AR01.10-P-2401MCC, AR01.10-P-2401MCB, AR01.10-P-2401MCU, AR03.30-P-8002MCC, AR03.30-P-8002MCU (+1 more)

1 Remove engine with transmission Only if the engine is removed and should be fixed onto an engine repair stand.

• not for USAEngine 132.910 AR01.10-P-2401MCC
• not for USAEngine 132.930 AR01.10-P-2401MCB

• for USA only AR01.10-P-2401MCU 2 Remove flywheel Only if the engine is removed and should be fixed onto an engine repair stand.

• not for USA AR03.30-P-8002MCC

• for USA only AR03.30-P-8002MCU 3 Fix engine onto an engine repair stand Only if the engine is removed and should be fixed onto an engine repair stand.Engine repair standgotis://A_01_15. Universal mountgotis://A_01_15.

4 Remove cylinder head * not for USA AR01.30-P-5800MCC Fig 1: Identifying Piston Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

* for USA only

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 483 · Applies to: 450, 451, 452, 454 · AR: AR03.10-P-7311MCC

AR01 30 P 5800MCU 5 Check markings on the piston (7), clean piston crown if necessary and make markings with a colored pencil In case of used pistons (7), the markings may no longer be visible due to carbonization.For this reason, remove carbon deposits from pistons (7).If the markings on the pistons (7) are no longer visible, the pistons (7) must be marked again.

6.1 Lower vehicle with vehicle lift If engine installed.

6.2 Turn engine at engine repair stand until the connecting rod bearing cap (3) is accessible For a removed engine.

7 Mark connecting rod (2) and connecting rod bearing cap (3) relative to each other The connecting rods (2) and connecting rod bearing caps (3) are cracked and must not be mixed up with each other.

8 Remove bolts (1)

9 Remove connecting rod bearing cap (3) and connecting rod bearing shells (5) from the crankshaft (6) If worn connecting rod bearing shells (5) are reused these must remain assigned to the respective connecting rod (2) or connecting rod bearing cap (3).

10 Remove piston (7) with connecting rod (2) and connecting rod bearing shell (4) from cylinder bore (9) If worn connecting rod bearing shells (4) are reused these must remain assigned to the respective connecting rod (2) or connecting rod bearing cap (3).

11 Remove plain compression ring (10), taper-faced ring (11) and three-piece oil ring (12) on piston (7)

AR03.10-P-7311MCC 12 Remove piston (7) from connecting rod (2)

AR03.10-P-7021- 07MCC Assembly tool *132589003500 Install

13 Attach piston (7) to connecting rod (2)

AR03.10-P-7021- 08MCC Assembly tool *132589003500 14 Clean and lubricate

cylinder bore (9),

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 484 · Applies to: 450, 451, 452, 454 · AR: AR03.10-P-7311MCC

connecting rod bearing journals, connecting rod bearing shells (4, 5) and pistons (7) 15 Install plain compression ring (10), taper-faced ring (11) and three-piece oil ring (12) on piston (7)

AR03.10-P-7311MCC 16 Position plain compression ring (10), taper-faced ring (11) and three-piece oil ring (12) on piston (7)

AR03.10-P-7311- 03MCC 17 Place tensioning strap (8) on the piston (7) and stretch Do not turn plain compression ring (10), taper- faced ring (11) and three-piece oil ring (12) anymore.

Tensioning strap *450589001400 18 Assign connecting rod bearing shells (4, 5) When using new connecting rod bearing shells (4, 5). AR03.10-P-6112- 01MCC 19 Insert connecting rod bearing shells (4, 5) into connecting rod (2) and into connecting rod bearing cap (3).

20.1 Turn engine at engine repair stand through 90° For a removed engine.

20.2 Raise vehicle with vehicle lift If engine installed.

21 Assign piston (7) to cylinder bore (9)

Assignment of pistons to cylinder bore

AH03.10-P-0001- 02MCC 22 Insert connecting rod (2) with piston (7) and connecting rod bearing shell (4) in the respective cylinder bore (9) If necessary turn the crankshaft (6) so that the connecting rod (2) is not touching the connecting rod journal before inserting the piston (7).Ensure that the connecting rod bearing shell (4) does not fall out.

Tensioning strap *450589001400 23 Place connecting rod bearing cap (3) with connecting rod bearing shell (5) in place Observe marking of connecting rod (2) relative to connecting rod bearing cap (3).

Lubricate bolts (1) and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 485 · Applies to: 450, 451, 452, 454 · AR: AR01.30-P-5800MCC, AR01.30-P-5800MCU, AR03.30-P-8002MCC, AR03.30-P-8002MCU, AR01.10-P-2401MCC (+2 more)

24 Lubricate bolts (1) and screw in Replace bolts (1).

*BA03.10-P-1001-01K 25.2 Turn engine at engine repair stand through 90° For a removed engine.

25.1 Raise vehicle with vehicle lift If engine installed.

26 Rotate crankshaft (6) fully and inspect clearance

27 Install cylinder head * not for USA AR01.30-P-5800MCC * for USA only AR01.30-P-5800MCU 28 Remove engine from engine repair stand For a removed engine.

29 Install flywheel For a removed engine.

• not for USA AR03.30-P-8002MCC

• for USA only AR03.30-P-8002MCU 30 Install engine with transmission For a removed engine.

• not for USAEngine 132.910 AR01.10-P-2401MCC

• not for USAEngine 132.930 AR01.10-P-2401MCB
• for USA only AR01.10-P-2401MCU CONNECTING ROD Number Designation Engine 132.9 BA03.10-P-1001- 01K Bolt, connecting rod bearing cap to connecting rod Stage 1 Nm 15 Stage 2 ∠° 90 Fig 2: Identifying Assembly Tool (132 589 00 35 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE, INSTALL A FLYWHEEL - AR03.30-P-8002MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 489 · Applies to: 450, 451, 452, 454 · AR: AR03.30-P-8002MCU

ENGINE 132.910 in MODEL 451.3/4 Remove/install

1 Remove clutch

AR25.10-P- 0050MCU Fig 2: Identifying Retaining Lock In Toothing Of Flywheel And Mounting Screws For Starter Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Flywheel With Mounting Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Number

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 492 · Applies to: 450, 451, 452, 454 · AR: BE03.00-Z-9999CZ

Designation Engine 122.9 Engines 134.910/911, 135.930/950 BA03.20-P-1001- 01G Bolt for crankshaft bearing cap Stage 1 Nm 34 35 Stage 2 ∠° 30 62 BA03.20-P-1002- 01G Bolt, incremental wheel to crankshaft

Nm

- CRANKSHAFT BEARING CAP Number Designation Engine 132.9 BA03.20-P-1001- 01G Bolt for crankshaft bearing cap Stage 1 Nm 30 Stage 2 ∠° 60 BA03.20-P-1002- 01G Bolt, incremental wheel to crankshaft

Nm 10 TORQUE SPECIFICATIONS > FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR - BA03.30-P-1000-01P > Engine 132.9 FLYWHEEL, DRIVEN PLATE, VIBRATION DAMPER, STARTER RING GEAR Number Designation Engine 132.9 BA03.30-P-1001- 01P Belt pulley / vibration damper to crankshaft Stage 1 Nm 150 2nd stage loosen Nm ≥150 Stage 3 Nm 50 Stage 4 ∠° 60 BA03.30-P-1002- 01P Bolt, flywheel to crankshaft Stage 1 Nm 20 Stage 2 ∠° 90 TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: CRANK ASSEMBLY - BE03.00-Z-9999CZ > MODEL all Check values for piston rings ENGINE 122.9, 132.910 /930, 134.910 /911, 135.930 /950 BE03.10-P-1000- 05H Inspection data of conrod bolts ENGINE 639.939 BE03.10-P-1000-03H Inspection data of crankshaft bearing clearance ENGINE 122.9, 134.9, 135.9 in MODEL 454.0 BE03.20-P-1000-04G

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: CRANK ASSEMBLY -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 501 · Applies to: 450, 451, 452, 454 · AR: AR03.00-Z-9132CB, AR03.30-P-8002MCC, AR03.30-P-8002MCU, AR03.30-P-1700MCC, AR03.30-P-1700MCU (+5 more)

AR03.00-Z-9132CB > ENGINE 132 Remove, install a flywheel ENGINE 132.9 in MODEL 451.3 /4 AR03.30-P-8002MCC Remove, install a flywheel ENGINE 132.910 in MODEL 451.3 /4 AR03.30-P-8002MCU Remove/install belt pulley ENGINE 132.9 in MODEL 451.3 /4 AR03.30-P-1700MCC Remove/install belt pulley ENGINE 132.910 in MODEL 451.3 /4 AR03.30-P-1700MCU Remove/install crankshaft ENGINES 132.9 in MODEL 451.3 /4 AR03.20-P-4351MCC Remove/install piston ENGINES 132.9 in MODEL 451.3 /4 AR03.10-P-7021MCC Remove/install piston rings ENGINES 132.9 in MODEL 451.3 /4 AR03.10-P-7311MCC Replace front crankshaft radial sealing ring ENGINE 132.9 in MODEL 451.3 /4 AR03.20-P-3000MCC Replace front crankshaft radial sealing ring ENGINE 132.910 in MODEL 451.3 /4 AR03.20-P-3000MCU Fig 1: Identifying Crankshaft Bearing Cap Numbers Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL PISTON - AR03.10-P-7021MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 506 · Applies to: 450, 451, 452, 454 · AR: AR03.10-P-7021MCC

ENGINES 132.9 in MODEL 451.3 /4 Fig 3: Inserting Piston, Piston Pin And Connecting Rod Together With Thrust Piece And Guide Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

2. Position the taper-faced ring with the piston ring end gap at "B".

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 514 · Applies to: 450, 451, 452, 454 · AR: AR03.10-P-7311MCC

1. Position the upper section of the three-piece oil ring with the piston ring end gap at "C".
2. Position the spring for the three-piece oil ring with the piston ring end gap at "A or B".
3. Position the lower section of the three-piece oil ring with the piston ring end gap at "D". TESTING & REPAIR > REMOVE/INSTALL PISTON RINGS - AR03.10-P-7311MCC > ENGINES 132.9 in MODEL 451.3 /4 Fig 1: Identifying Positions Of Piston Ring End Gaps Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Piston, Rings & Pliers Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 515 · Applies to: 450, 451, 452, 454 · AR: AR03.10-P-7021MCC

1 Remove piston (1)

AR03.10-P-7021MCC 2 Remove plain compression ring (2 and taper-faced ring (3) from piston (1) using the pliers (5) Pliers Fig 4 3 Remove three-piece oil ring (4) by hand from piston (1)

4 Clean piston (1) and check for damage Replace piston (1) if necessary.

5 Measure side clearance of the plain compression ring (2) and the taper-faced ring (3) Replace plain compression ring (2), taper-faced ring (3) and oil scraper ring (4) together with the piston (1) if necessary. AR03.10-P-7311- 01MCC BE03.10-P-1001-05H 6 Measure end gap of the plain compression ring (2) of the taper-faced ring (3) and the upper and lower rings of the oil scraper ring (4) Also replace the plain compression ring (2), taper-faced ring (3) and oil scraper ring (4) set by set if necessary. AR03.10-P-7311- 02MCC Groove 1, 2 BE03.10-P-1002-05H Groove 3 *BE03.10-P-1004-05H 7 Remove piston (1) from connecting rod Only if the plain compression ring (2), taper-faced ring (3) and oil scraper ring (4) must be replaced together with the AR03.10-P-7021- 07MCC Fig 2: Identifying Plain Compression Ring And Taper-Faced Ring Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

pi ton (1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 516 · Applies to: 450, 451, 452, 454 · AR: AR03.10-P-7021MCC

the pi ton (1) and connecting rod are delivered separately. Assembly tool Figure Install

8 Assemble piston (1) together with the connecting rod Only if the plain compression ring (2), taper-faced ring (3) and oil scraper ring (4) were replaced together with the piston (1). the piston (1) and connecting rod are delivered separately. AR03.10-P-7021- 08MCC Assembly tool Figure 9 Attach three-piece oil ring (4) by hand to the piston (1)

10 Attach plain compression ring (2 and taper-faced ring (3) to piston (1) using the pliers (5) Observe installation positionThe marking (arrow) on the plain compression ring (2) and the marking (arrow) on the taper-faced ring (3) must point towards the piston crown.First attach taper- faced ring (3) then plain compression ring (2).

Pliers Fig 4 11 Install piston (1)

AR03.10-P-7021MCC CHECK VALUES FOR PISTON RINGS Number Designation Engine 132.910/930 BE03.10-P- 1001-05H Piston ring vertical clearance Groove 1 mm 0.03 to 0.07 Groove 2 mm 0.02 to 0.06 max. mm 0.1 BE03.10-P- 1002-05H Piston ring end gap Groove 1 mm 0.15 to 0.30 Groove 2 mm 0.15 to 0.30 max. mm 0.08 BE03.10-P- 1004-05H End gap for upper and lower ring of the oil scraper ring Groove 3 mm 0.10 to 0.40

TESTING & REPAIR > REPLACE FRONT CRANKSHAFT RADIAL SEALING RING -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 517 · Applies to: 450, 451, 452, 454 · AR: AR03.20-P-3000MCU

ma mm 1 0 TESTING & REPAIR > REPLACE FRONT CRANKSHAFT RADIAL SEALING RING - AR03.20-P-3000MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 3: Identifying Assembly Tool (132 589 00 35 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Pliers (450 589 14 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 518 · Applies to: 450, 451, 452, 454 · AR: AR03.30-P-1700MCU, AR32.20-P-0230MCU

1 Remove belt pulley for crankshaft

AR03.30-P-1700MCU 2 Lever crankshaft radial sealant ring (1) out of timing case cover (2) using a suitable tool Ensure that timing case cover (2) is not damage otherwise it must be replaced.

3 Remove right rear spring

AR32.20-P-0230MCU Install

4 Clean sealing surface on timing case cover (2) The sealing surface on the timing case cover (2) must be absolutely dust and grease-free otherwise leaks can occur.

5 Screw guide into crankshaft threaded hole Fig 2 6 Insert crankshaft radial sealing ring (1) via the guide in the timing case cover (2) and then press in flush with the timing case cover (2) The crankshaft radial sealing ring (1) must be installed dry.

Fig 3 7 Install right rear spring

AR32.20-P-0230MCU 8 Install crankshaft belt pulley

AR03.30-P-1700MCU Risk of accident caused by vehicle starting off by itself when engine is running. Risk Secure vehicle to prevent it from moving by itself.Wear closed and AS00.00-Z-0005-01A Fig 1: Identifying Crankshaft Radial Seal And Timing Case Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL CRANKSHAFT - AR03.20-P-4351MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 521 · Applies to: 450, 451, 452, 454 · AR: AR03.20-P-4351MCC

ENGINES 132.9 in MODEL 451.3 /4 Fig 1: Identifying Crankshaft Bearing Cap Bolt Length Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Crankshaft Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 522 · Applies to: 450, 451, 452, 454 · AR: AR03.10-P-7021MCC, AR01.40-P-8920MCC

The bearing shell (6) differ from each other and must not get mixed up.If the removed bearing shells (6) must be reused then these must remain assigned to the respective crankshaft bearing cap (2) or the respective bearing point in the cylinder crankcase (5).

1 Remove piston with connecting rod (4)

AR03.10-P-7021MCC 2 Remove end cover (3) with radial shaft sealing ring

AR01.40-P-8920MCC 3 Loosen bolts for the crankshaft bearing cap (2) in reverse order of the tightening procedure

AR03.20-P-4351- 02MCC 4 Remove crankshaft bearing cap (2) with bearing shells (6) Note installation position of crankshaft bearing cap (2).

5 Take crankshaft (1) out of crankcase (5)

6 Take bearing shells (6) out of crankcase (5)

7 Take thrust plates (7) out of crankcase (5)

Fig 2: Identifying Cylinder Crankcase, Bearing Shell And Thrust Plate Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 523 · Applies to: 450, 451, 452, 454 · AR: AR01.40-P-8920MCC, AR03.10-P-7021MCC

8 Assign bearing shells (6) to the bearing points in the cylinder crankcase (5) and the crankshaft bearing caps (2)

AR03.20-P-4360- 01MCC 9 Insert bearing shells (6) in the respective bearing points in the cylinder crankcase (5) and lubricate with engine oil

10 Insert bearing shells (6) in the respective crankshaft bearing cap (2) and lubricate with engine oil The crankshaft bearing caps (2) are numbered.

Interference fit of crankshaft bearing cap

AH03.20-P-4351- 02MCC 11 Lubricate thrust plate (7) with engine oil and insert in the crankcase (5) The grooves (arrows) for the thrust plates (7) are attached single-sidedly and must be visible after insertion.

12 Lubricate crankshaft (1) crankshaft bearing journal with engine oil and insert crankshaft (1) in the crankcase (5)

13 Place crankshaft bearing cap (2) on the crankshaft (1) crankshaft bearing journal The crankshaft bearing caps (2) are numbered.

Interference fit of crankshaft bearing cap

AH03.20-P-4351- 02MCC 14 Check bolt for the crankshaft bearing cap (2) for maximum length

AR03.20-P-4351- 03MCC *BE03.20-P-1001-01G 15 Screw in bolts for crankshaft bearing cap (2) and tighten according to the tightening procedure

AR03.20-P-4351- 02MCC *BA03.20-P-1001-01G 16 Rotate crankshaft (1) fully and inspect clearance

17 Install end cover (3) with radial shaft seal

AR01.40-P-8920MCC 18 Install piston with

AR03.10-P-7021MCC

TESTING & REPAIR > REMOVE/INSTALL BELT PULLEY - AR03.30-P-1700MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 530 · Applies to: 450, 451, 452, 454 · AR: AR03.30-P-1700MCU

ENGINE 132.910 in MODEL 451.3 /4 Remove/install

1 Remove poly-V belt

AR13.22- P- 1202MCU Fig 2: View Of Retaining Lock In Toothing Of Flywheel And Mounting Screws For Starter Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Crankshaft Belt Pulley With Screw And Washer Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE, INSTALL A FLYWHEEL - AR03.30-P-8002MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 532 · Applies to: 450, 451, 452, 454 · AR: AR03.30-P-8002MCU

ENGINE 132.910 in MODEL 451.3 /4 Remove/install

1 Remove clutch

AR25.10- P- 0050MCU 2 Remove bolts (2) Install new self-locking bolts (2). Installation: To exclude any possibility of offset angle errors, a bending rod torquing angle wrench must not be used for tightening.If no torquing angle wrench is available, the bolts (2) can be torqued further by the specified angle in a single operation using a wrench and Tommy bar.

*BA03.30- Fig 2: Identifying Retaining Lock (451 589 01 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Flywheel & Mounting Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Observe the legal provisions and local waste water regulations. The following brochures are available about

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 544 · Applies to: 450, 451, 452, 454 · AR: AP20.00-P-2010MCU

disposing of waste products in auto repair trade for the location Federal Republic of Germany: "Environmental protection manual for motor vehicle repair operations" Publisher: Verband der Automobilindustrie e.V. (VDA) 60325 Frankfurt am Main, Westendstraβe 61 to be ordered under: Tel no.: 069/97507-0 or at www.vda.de or "The new waste laws" Publisher: Zentralverband Deutsches Kraftfahrzeuggewerbe e. V. (ZDK) 53129 Bonn, Franz - Lohe - Straβe 21 to be ordered under: Tel no.:0261/8059-584, Fax no. 0261/8059-585 or at www.kfz-meistershop.de MAINTENANCE > ENGINE COOLING SYSTEM - CHECK FLUID LEVEL, ADJUST TO CORRECT LEVEL. INSPECT ANTICORROSION/ANTIFREEZE PROTECTION, ADJUST TO CORRECT CONCENTRATION - AP20.00-P-2010MCU > ENGINE 132.910 in MODEL 451.3/4 Removal

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00-Z-0001- 01A Fig 1: Identifying Cap, Expansion Reservoir And Maintenance Flap Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MAINTENANCE > REPLACE COOLANT - AP20.00-P-2080MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 546 · Applies to: 450, 451, 452, 454 · AR: AP20.00-P-2080MCU

ENGINE 132.910 in MODEL 451.3/4

Drain

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear AS20.00-Z-0001- 01A Fig 2: Identifying Antifreeze Spindle (450 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Cap, Expansion Reservoir, Coolant Hose, Hose Clamp, Radiator And Coolant Drain Plug Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Run engine until warm

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 549 · Applies to: 450, 451, 452, 454 · AR: AR20.00-P-1010MCU

17 Run engine until warm Until the coolant fan motor cuts in. 18 Check coolant level in the expansion reservoir (2) and correct if necessary

AP20.00-P- 2010MCU 19 Inspecting cooling system for leaks

Inspecting cooling system for leaks AR20.00-P- 1010MCU 20 Raise vehicle with vehicle lift

21 Install underfloor paneling

22 Lower vehicle with lifting platform

23 Install engine compartment cover

Remove/install interior compartment flap above engine AR88.40-P-1100- 03MCC 24 Install maintenance flap

TESTING & REPAIR > INSPECT COOLING SYSTEM FOR LEAKS - AR20.00-P-1010MCU > ENGINE 132.910 in MODEL 451.3/4 Checking

Risk of injury to skin and eyes caused by Do not open cooling system unless coolant temperature is below 90°C. AS20.00-Z-0001- 01A Fig 1: Identifying Cap, Expansion Reservoir And Maintenance Flap Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Disconnect pressure

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 551 · Applies to: 450, 451, 452, 454 · AR: AR20.00-P-1142MCU

10 Disconnect pressure pump on expansion reservoir (2) and check coolant level in expansion reservoir (2); correct if necessary After removing the leakage in the cooling system. The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.

*450589072100 Coolant specifications Sheet 310.1 BB00.40-P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325- 00A 11 Attach pressure pump to expansion reservoir (2) and apply a pressure to the cooling system again of a maximum of 1.6 bar After removing the leakage in the cooling system. Observe pressure gauge for pressure pump.

*450589072100 12 Raise vehicle with vehicle lift

13 Install underfloor paneling After removing the leakage in the cooling system.

14 Lower vehicle with lifting platform

15 Install interior flap above engine After removing the leakage in the cooling system. AR88.40-P-1100- 03MCC 16 Detach pressure pump on expansion reservoir (2) *450589072100 17 Seal expansion reservoir (2) with cap (1)

18 Install maintenance flap (3)

TESTING & REPAIR > DRAIN/FILL IN COOLANT - AR20.00-P-1142MCU > Fig 2: Identifying Pressure Pump (450 589 07 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Coolant pecification

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 554 · Applies to: 450, 451, 452, 454 · AR: AR20.00-Z-9132CB, AR20.00-P-1142MCC, AR20.00-P-1142MCU, AR20.00-P-1010MCC

Sheet 310 1 BB00 40 P 0310 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325- 00A 14 Seal expansion reservoir (2) with cap (1)

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00-Z-0005- 01A 15 Run engine until warm until the radiator fan motor switches on. 16 Check coolant level in expansion reservoir (2), correct if necessary. The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.

Coolant specifications Sheet 310.1 BB00.40-P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325- 00A 17 Inspecting cooling system for leaks

AR20.00-P- 1010MCU 18 Raise vehicle with vehicle lift

19 Install underfloor paneling Rechargeable drill / screwdriver gotis://G_58.0_01.1

20 Lower vehicle with vehicle lift

21 Install interior flap above engine

AR88.40-P-1100- 03MCC 22 Install maintenance flap

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: ENGINE COOLING SYSTEM - AR20.00-Z-9132CB > ENGINE 132 Drain/fill in coolant ENGINES 132.9 in MODEL 451.3/4 AR20.00-P-1142MCC Drain/fill in coolant ENGINES 132.910 in MODEL 451.3/4 AR20.00-P-1142MCU Inspect cooling system for leaks ENGINE 132.9, 660.9 in MODEL 451.3/4 AR20.00-P-1010MCC

Inspect cooling system for

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 555 · Applies to: 450, 451, 452, 454 · AR: AR20.00-P-1010MCU, AR20.20-P-1000MCC, AR20.20-P-7441MCC, AR20.20-P-7441MCU, AR20.20-P-1050MCC (+5 more)

leaks ENGINE 132.910 in MODEL 451.3/4 AR20.00-P-1010MCU Remove, install coolant feed line for turbocharger ENGINES 132.930 in MODEL 451.3/4 AR20.20-P-1000MCC Remove, install coolant line ENGINE 132.9 in MODEL 451.3/4 AR20.20-P-7441MCC Remove, install coolant line ENGINE 132.910 in MODEL 451.3/4 AR20.20-P-7441MCU Remove, install coolant return line for turbocharger ENGINES 132.930 in MODEL 451.3/4 AR20.20-P-1050MCC Remove/install belt pulley for the coolant pump ENGINES 132.9 in MODEL 451.3/4 AR20.10-P-1275MCC Remove/install belt pulley for the coolant pump ENGINES 132.910 in MODEL 451.3/4 AR20.10-P-1275MCU Remove/install coolant pipe ENGINE 132.9 in MODEL 451.3/4 AR20.20-P-7450MCC Remove/install coolant pipe ENGINE 132.910 in MODEL 451.3/4 AR20.20-P-7450MCU Remove/install coolant pump ENGINES 132.9 in MODEL 451.3/4 AR20.10-P-1271MCC Remove/install coolant pump ENGINE 132.910 in MODEL 451.3/4 AR20.10-P-1271MCU Remove/install coolant thermostat ENGINES 132.9 in MODEL 451.3/4 AR20.10-P-2460MCC Remove/install coolant thermostat ENGINE 132.910 in MODEL 451.3/4 AR20.10-P-2460MCU Remove/install electric fan ENGINE 132.9 in MODEL 451.3/4 AR20.40-P-5000MCC Remove/install electric fan ENGINE 132.910 in MODEL 451.3/4 AR20.40-P-5000MCU Remove/install expansion reservoir ENGINES 132.9 in MODEL 451.3/4 ENGINES 780.009 in MODEL 451.391/491 AR20.30-P-4950MCC Remove/install expansion reservoir ENGINES 132.910 in MODEL 451.3/4 ENGINES 780.009 in MODEL 451.391/491 AR20.30-P-4950MCU Remove/install radiator ENGINE 132.9 in MODEL 451.3/4 AR20.20-P-3865MCC Remove/install radiator ENGINE 132.910 in MODEL 451.3/4 AR20.20-P-3865MCU Remove/install shutoff valve ENGINES 132.9 in MODEL 451.3/4 as of 31.8.10 AR20.00-P-0300MCC TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: ENGINE COOLING SYSTEM - AR20.00-Z-9451CA > MODEL 451 Drain, fill drive electric motor coolant MODEL 451.391/491 with ENGINE 780.009 AR20.00-P- 1143MEV

Drain/fill in coolant

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 556 · Applies to: 450, 451, 452, 454 · AR: AR20.10-P-1271MCU

MODEL 451 391/491 with ENGINE 780 009 High-voltage battery coolant circuit AR20 00 P 1142MEV TESTING & REPAIR > REMOVE/INSTALL COOLANT PUMP - AR20.10-P-1271MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install

1 Drain coolant

AR20.00- P- 1142MCU 2 Remove belt pulley (2) for coolant pump (1)

AR20.10- P- 1275MCU 3 Remove poly-V belt tensioning device (3)

AR13.25- P- 3200MCU 4 Remove poly-V belt for supercharger On vehicles with code (I01) Air conditioning Plus AR13.21- P- 1202MCU 5 Remove bolt (4) on timing case cover (5) and lay ground line (6) for engine mass to one side

6 Remove bolts (7, 8) Catch coolant in a suitable vessel.

*BA20.10- Fig 1: Identifying Coolant Pump Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

P-1007-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 557 · Applies to: 450, 451, 452, 454 · AR: AR20.10-P-1275MCU, AR13.22-P-1202MCU

01J 7 Remove coolant pump (1) from timing case cover (5) Installation: Replace profiled rubber seal of coolant pump (1).

8 Install in the reverse order

COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 BA20.10-P-1007- 01J Bolt, coolant pump to timing case cover M6 Nm 10 M8 Nm 23 TESTING & REPAIR > REMOVE/INSTALL BELT PULLEY FOR THE COOLANT PUMP - AR20.10-P-1275MCU > ENGINES 132.910 in MODEL 451.3/4

Remove/install

1 Remove poly-V belt (2)

AR13.22-P-1202MCU 2 Counterhold belt pulley (1) and remove bolts (3) 451589004000 BA20.10-P-1001-01J 3 Remove belt pulley (1) from the coolant pump

4 Install in the reverse order

COOLANT PUMP, COOLANT THERMOSTAT Fig 1: Identifying Belt Pulley, Poly-V-Belt And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Number

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 558 · Applies to: 450, 451, 452, 454 · AR: AR20.10-P-2460MCU

Designation Engine 132.9 BA20.10-P-1001- 01J Belt pulley on coolant pump Nm 10 TESTING & REPAIR > REMOVE/INSTALL COOLANT THERMOSTAT - AR20.10-P-2460MCU

ENGINE 132.910 in MODEL 451.3/4 Fig 2: Identifying Counterholder (451 589 00 40 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Coolant Thermostat Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

ALTERNATOR

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 560 · Applies to: 450, 451, 452, 454 · AR: AR20.20-P-3865MCU

Number Designation Engine 132.9 BA15.40-P-1002- 01G Cable to alternator terminal B+ Nm 10 BA15.40-P-1008- 01G Bolt, alternator to timing case cover Nm 23 COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 BA20.10-P-1008- 01J Bolt, thermostat housing to crankcase Nm 10 BA20.10-P-1011- 01J Bolt connecting coolant line to cylinder head Nm 24 BA20.10-P-1012- 01J Bolt, coolant line to crankcase Nm 24 TESTING & REPAIR > REMOVE/INSTALL RADIATOR - AR20.20-P-3865MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install

1 Remove front module

AR62.30- P- 1575MCU 2 Remove condenser On vehicles with code (I01) Air conditioning AR83.30- P- Fig 1: Locating Radiator Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

6540MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 561 · Applies to: 450, 451, 452, 454 · AR: AR20.20-P-7441MCU

Plu 6540MCU 3 Drain coolant at radiator (1)

AR20.00- P- 1142MCU 4 Detach hose clamp (4) on expansion reservoir (3) Replace hose clamp (4).

5 Loosen expansion reservoir (3) from bracket (arrow A) on radiator support, detach from radiator (1) coolant hose (2) and lay to one side with attached coolant hoses Secure expansion reservoir (3) against falling down using a suitable cable tie.

6 Carefully lead radiator (1) on the left side on the brackets (arrows B) and take off

7 Install in the reverse order

TESTING & REPAIR > REMOVE, INSTALL COOLANT LINE - AR20.20-P-7441MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install

1 Drain coolant

AR20.00-P- 1142MCU 2 Remove intake manifold (2)

AR09.20-P- 1310MCU 3 Loosen clamp (3) and detach coolant hose (4) from coolant line (1) Installation: Replace clamp (4).

4 Loosen clamp (5) and detach coolant hose (6) from coolant line (1) Installation: Replace clamp (6).

5 Remove bolts (7) and coolant line (1) BA20.10-P- 1011-01J BA20.10-P- 1012-01J Fig 1: Identifying Coolant Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install in the reverse order

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 562 · Applies to: 450, 451, 452, 454 · AR: AR20.20-P-7450MCU

6 Install in the reverse order

COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 BA20.10-P-1011- 01J Bolt connecting coolant line to cylinder head Nm 24 BA20.10-P-1012- 01J Bolt, coolant line to crankcase Nm 24 TESTING & REPAIR > REMOVE/INSTALL COOLANT PIPE - AR20.20-P-7450MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install

1 Drain coolant

AR20.00-P- 1142MCU 2 Remove intake manifold (2)

AR09.20-P- 1310MCU 3 Mark installation position of the coolant hose (3) to coolant pipe (1) (arrow)

4 Release clamp (4) and detach coolant hose (5) from coolant pipe (1) Installation: Replace clamp (4).

5 Remove bolt (6) for coolant pipe (1) on cylinder crankcase *BA20.10-P- 1009-01J Fig 1: Identifying Coolant Pipe Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove bolt (7) for coolant pipe (1) on oil

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 563 · Applies to: 450, 451, 452, 454 · AR: AR20.30-P-4950MCU

6 Remove bolt (7) for coolant pipe (1) on oil pan *BA20.10-P- 1010-01J 7 Pull coolant pipe (1) out of timing case cover (8) Installation: Replace seal ring on coolant pipe (1).

8 Release clamp (9) and detach coolant hose (3) from coolant pipe (1) Installation: Replace clamp (9).

9 Remove coolant pipe (1)

10 Install in the reverse order

COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 BA20.10-P-1009- 01J Bolt, coolant pipe at crankcase Nm 10 BA20.10-P-1010- 01J Bolt, coolant pipe to oil pan Nm 10 TESTING & REPAIR > REMOVE/INSTALL EXPANSION RESERVOIR - AR20.30-P-4950MCU

ENGINES 132.910 in MODEL 451.3/4 ENGINES 780.009 in MODEL 451.391/491 Shown on vehicle with engine 132 Vehicles with engine 780 Fig 1: Identifying Expansion Reservoir Components (With Engine 132) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Detach coolant ho e (4) on

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 565 · Applies to: 450, 451, 452, 454 · AR: AR20.40-P-5000MCU

6 Detach coolant ho e (4) on expansion reservoir (1) and lay to one side in such a way that so no coolant can run out For engine 132.9 Collect coolant which flows out in a suitable vessel.

7 Detach coolant hoses (5, 6) on expansion reservoir (1) Collect coolant which flows out in a suitable vessel.

8 Detach expansion reservoir (1) from holder (7), detach from coolant hose (8) and take off Collect coolant which flows out in a suitable vessel.

9 Loosen click clamp (10) and detach blind plug (11) For engine 780.009 Only when replacing the expansion reservoir (1). Installation: Replace snap clamp (10).

10 Install in the reverse order

11 Pour in coolant For engine 132.9 AR20.00- P- 1142MCU For engine 780.009 Coolant circuit high- voltage battery AR20.00- P- 1142MEV TESTING & REPAIR > REMOVE/INSTALL ELECTRIC FAN - AR20.40-P-5000MCU > ENGINE 132.910 in MODEL 451.3/4

Remove/install

Fig 1: Identifying Electric Fan Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove radiator (2)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 566 · Applies to: 450, 451, 452, 454 · AR: AR20.20-P-3865MCU

1 Remove radiator (2)

AR20.20-P-3865MCU 2 Disconnect electrical connector (3) at coolant fan motor (M4/2)

3 Unclip retaining clip (4, 5) for electrical line (6) to fan shroud (1) and lay electrical line (6) to one side

4 Remove mounts (7) from fan shroud (1) *451589013100 5 Take off fan shroud (1)

6 Install in the reverse order

SAFETY PRECAUTIONS > RISK OF INJURY TO SKIN AND EYES SUFFERING SCALDING FROM CONTACT WITH HOT COOLANT SPRAY. RISK OF POISONING FROM SWALLOWING COOLANT. - AS20.00-Z-0001-01A > Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles. Wear protective gloves, protective clothing and eye protection. Possible hazards Risk of injury When the engine is warm, the cooling system is pressurized. If the cooling system is opened suddenly, there is a risk of scalding from hot coolant which splashes out. Danger of poisoning If coolant is swallowed, this can result in manifestations of poisoning such as headaches, dizziness, stomach pain, respiratory paralysis, unconsciousness, vomiting and cramps. Safety precautions/instructions Allow cooling system to cool down to a coolant temperature of less than 90°C. Open cap of cooling system slowly; turn a conventional coolant cap as far as the first detent and turn a screwed coolant cap approx. 1/2 turn and release the pressure. Fig 2: Identifying Mount (451 589 01 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

1005-01J

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 569 · Applies to: 450, 451, 452, 454 · AR: BE20.00-Z-9999CZ

housing to cylinder head Continued torque Nm 9.5 9.5 9.5 BA20.10-P- 1006-01J Bolt, water supply connection fitting to major assembly carrier Initial torque Nm 14 14 14 Continued torque Nm 9.5 9.5 9.5 BA20.10-P- 1007-01J Bolt, coolant pump to timing case cover M6 Nm - - - M8 Nm - - - BA20.10-P- 1008-01J Bolt, thermostat housing to crankcase Nm - - - BA20.10-P- 1009-01J Bolt, coolant pipe at crankcase Nm - - - BA20.10-P- 1010-01J Bolt, coolant pipe to oil pan Nm - - - BA20.10-P- 1011-01J Bolt connecting coolant line to cylinder head Nm - - - BA20.10-P- 1012-01J Bolt, coolant line to crankcase Nm - - - TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: ENGINE COOLING SYSTEM - BE20.00-Z-9999CZ > MODEL all Test values for cooling system cap ENGINE all BE20.30-P-1000-01A TEST & ADJUSTMENT VALUES > TEST VALUES FOR COOLING SYSTEM CAP - BE20.30- P-1000-01A > All engines CAP OF RADIATOR OR EXPANSION RESERVOIR Number Designation Cap 2-stage cap 1-stage cap on model 163 BE20.30-P- 1001-01A Cap code number 140 140/200 - BE20.30-P- 1002-01A Pressure relief valve opens New bar overpressure 1.4 (+0.1) - 1.4 (+0.1) Used bar overpressure 1.4 (-0.1) - 1.4 (+0.1) BE20.30-P- 1003-01A Vacuum valve opens (reference value) bar vacuum 0.1 0.1 0.5 BE20.30-P- Pressure Stage bar - 1.4 (1) -

Used

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 571 · Applies to: 450, 451, 452, 454 · AR: BF20.00-Z-9999CZ, GF20.00-P-1000MCU

bar overpressure - - - BE20.30-P- 1003-01A Vacuum valve opens (reference value) bar vacuum 0.1 0.1 0.1 BE20.30-P- 1004-01A Pressure relief valve opens Stage 1 bar overpressure - - - Coolant temp. - - - Stage 2 bar overpressure - - - Coolant temp. - - - BE20.30-P- 1005-01A Test pressure for pressure-testing cooling system bar overpressure 1.6 1.6 1.6 CAPACITIES & SPECIFICATIONS > MIXTURE RATIO FOR COOLANT - BF20.00-P-1000- 04A > Engine all MIXTURE RATIO FOR COOLANT Number Designation Engine all BF20.00-P- 1001-04A Mixture ratio for coolant Antifreeze/water Up to -37°C 50/50 Up to -45°C 55/45 Specifications for Operating Fluids Sheet BB00.40-P-0310- 01A Sheet BB00.40-P-0325- 00A CAPACITIES & SPECIFICATIONS > CAPACITIES: SMART: ENGINE COOLING SYSTEM - BF20.00-Z-9999CZ > MODEL all Cooling system ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 in MODEL 454.0 BF20.00-P-1000-02T Cooling system ENGINE 160.910 /921 /920 /922 /923, 660.940, 780.009 BF20.00-P-1000-02R Mixture ratio for coolant ENGINE all BF20.00-P-1000- 04A BASIC KNOWLEDGE > ENGINE COOLING FUNCTION - GF20.00-P-1000MCU >

e changer and further to the e pan ion re ervoir The coolant flow via the coolant return line from the

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 573 · Applies to: 450, 451, 452, 454 · AR: GF20.10-P-3162MCC

expansion reservoir back to the coolant pump. If the coolant was partially or fully drained off the coolant circuit must be bled. Filling and bleeding of the coolant circuit may only be undertaken on a cold engine. Component description for the coolant thermostat GF20.10-P-3162MCC BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE COOLANT THERMOSTAT - GF20.10-P-3162MCC > ENGINE 132.9 in MODEL 451.3/4 Shown on engine 132.930 Location The thermostat is located in the direction of travel on the right on the engine block. Task The thermostat separates the large from the small coolant circuit for a cold engine. This ensures that the engine reaches its operating temperature quicker. As the coolant temperature increases the thermostat opens and coolant also flows through the large coolant circuit. Fig 1: Locating Thermostat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Design

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 574 · Applies to: 450, 451, 452, 454 · AR: GF20.20-P-1000MCU

The thermostat mainly consists of an expansion element, a return spring and two valve plates. A special wax is used as an expanding material. Function On a cold engine the thermostat is closed and the coolant flows through the small coolant circuit. As the coolant temperature increases the expanding material melts and presses against the rubber insert. The metal pin is pushed out of the rubber insert. The fact that this rests against the upper housing means that the whole metal can with both valve plates is pressed downwards. At full stroke the lower plate closes the small circuit. At the same time the upper plate frees up the large coolant circuit with the maximum cross-section. During cooling of the coolant the expanding material solidifies again and the spring presses the pin back. The large coolant circuit is finally closed. The whole process represents a continuous regulating process for which the coolant temperature can be held constant with a precision of T ± 5°C. BASIC KNOWLEDGE > FAN MOTOR, COMPONENT DESCRIPTION - GF20.20-P-1000MCU

ENGINES 132.9 in MODEL 451.3/4 Fig 2: Thermostat Operation Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

disposing of waste products in auto repair trade for the location Federal Republic of Germany:

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 582 · Applies to: 450, 451, 452, 454 · AR: AP20.00-P-2010MCU

"Environmental protection manual for motor vehicle repair operations" Publisher: Verband der Automobilindustrie e.V. (VDA) 60325 Frankfurt am Main, Westendstraβe 61 to be ordered under: Tel no.: 069/97507-0 or at www.vda.de or "The new waste laws" Publisher: Zentralverband Deutsches Kraftfahrzeuggewerbe e. V. (ZDK) 53129 Bonn, Franz-Lohe-Straβe 21 to be ordered under: Tel no.: 0261/8059-584, Fax no. 0261/8059-585 or at www.kfz-meistershop.de MAINTENANCE > ENGINE COOLING SYSTEM - CHECK FLUID LEVEL, ADJUST TO CORRECT LEVEL. INSPECT ANTICORROSION/ANTIFREEZE PROTECTION, ADJUST TO CORRECT CONCENTRATION - AP20.00-P-2010MCU > ENGINE 132.910 in MODEL 451.3 /4 Removal

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.Wear protective gloves, protective clothing and safety glasses. AS20.00- Z-0001- 01A 1 Remove maintenance flap (3)

Turn cooling system cap (1) Fig 1: Identifying Cap, Expansion Reservoir And Maintenance Flap Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Seal e pan ion re ervoir (2)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 584 · Applies to: 450, 451, 452, 454 · AR: AP20.00-P-2080MCU

5 Seal e pan ion re ervoir (2) with cap (1)

6 Install maintenance flap (3)

MAINTENANCE > REPLACE COOLANT - AP20.00-P-2080MCU > ENGINE 132.910 in MODEL 451.3/4

Drain

Risk of injury to skin and eyes Do not open cooling system unless Fig 2: Identifying Antifreeze Spindle (450 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Cap, Expansion Reservoir, Coolant Hose, Hose Clamp, Radiator And Coolant Drain Plug Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Attach pressure pump to

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 589 · Applies to: 450, 451, 452, 454 · AR: AR20.00-P-1142MCU

11 Attach pressure pump to expansion reservoir (2) and apply a pressure to the cooling system again of a maximum of 1.6 bar After removing the leakage in the cooling system. Observe pressure gauge for pressure pump.

Fig 2 12 Raise vehicle with vehicle lift

13 Install underfloor paneling After removing the leakage in the cooling system.

14 Lower vehicle with lifting platform

15 Install interior flap above engine After removing the leakage in the cooling system. AR88.40- P-1100- 03MCC 16 Detach pressure pump on expansion reservoir (2) Fig 2 17 Seal expansion reservoir (2) with cap (1)

18 Install maintenance flap (3)

TESTING & REPAIR INDEX > DRAIN/FILL IN COOLANT - AR20.00-P-1142MCU > ENGINES 132.910 in MODEL 451.3 /4 Fig 2: Identifying Pressure Pump (450 589 07 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Risk of accident cau ed by

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 592 · Applies to: 450, 451, 452, 454 · AR: AR20.00-Z-9132CB, AR20.00-P-1142MCC, AR20.00-P-1142MCU, AR20.00-P-1010MCC, AR20.00-P-1010MCU (+2 more)

vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine a it i running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 15 Run engine until warm until the radiator fan motor switches on. 16 Check coolant level in expansion reservoir (2), correct if necessary. The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking.

Coolant specifications Sheet 310.1 BB00.40- P-0310- 01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40- P-0325- 00A 17 Inspecting cooling system for leaks

AR20.00- P- 1010MCU 18 Raise vehicle with vehicle lift

19 Install underfloor paneling Rechargeable drill / screwdriver

20 Lower vehicle with vehicle lift

21 Install interior flap above engine

AR88.40- P-1100- 03MCC 22 Install maintenance flap

TESTING & REPAIR INDEX > TESTING AND REPAIR WORK: SMART: ENGINE COOLING SYSTEM - AR20.00-Z-9132CB > ENGINE 132 Drain/fill in coolant ENGINES 132.9 in MODEL 451.3 /4 AR20.00-P-1142MCC Drain/fill in coolant ENGINES 132.910 in MODEL 451.3 /4 AR20.00-P-1142MCU Inspect cooling system for leaks ENGINE 132.9, 660.9 in MODEL 451.3 /4 AR20.00-P-1010MCC Inspect cooling system for leaks ENGINE 132.910 in MODEL 451.3 /4 AR20.00-P-1010MCU Remove, install coolant feed line for turbocharger ENGINES 132.930 in MODEL 451.3 /4 AR20.20-P-1000MCC Remove, install coolant line ENGINE 132.9 in MODEL AR20.20-P-7441MCC

Remove, install coolant line

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 593 · Applies to: 450, 451, 452, 454 · AR: AR20.20-P-7441MCU, AR20.20-P-1050MCC, AR20.10-P-1275MCC, AR20.10-P-1275MCU, AR20.20-P-7450MCC (+5 more)

451 3 /4 Remove, install coolant line ENGINE 132.910 in MODEL 451.3 /4 AR20.20-P-7441MCU Remove, install coolant return line for turbocharger ENGINES 132.930 in MODEL 451.3 /4 AR20.20-P-1050MCC Remove/install belt pulley for the coolant pump ENGINES 132.9 in MODEL 451.3 /4 AR20.10-P-1275MCC Remove/install belt pulley for the coolant pump ENGINES 132.910 in MODEL 451.3 /4 AR20.10-P-1275MCU Remove/install coolant pipe ENGINE 132.9 in MODEL 451.3 /4 AR20.20-P-7450MCC Remove/install coolant pipe ENGINE 132.910 in MODEL 451.3 /4 AR20.20-P-7450MCU Remove/install coolant pump ENGINES 132.9 in MODEL 451.3 /4 AR20.10-P-1271MCC Remove/install coolant pump ENGINE 132.910 in MODEL 451.3 /4 AR20.10-P-1271MCU Remove/install coolant thermostat ENGINES 132.9 in MODEL 451.3 /4 AR20.10-P-2460MCC Remove/install coolant thermostat ENGINE 132.910 in MODEL 451.3 /4 AR20.10-P-2460MCU Remove/install electric fan ENGINE 132.9 in MODEL 451.3 /4 AR20.40-P-5000MCC Remove/install electric fan ENGINE 132.910 in MODEL 451.3 /4 AR20.40-P-5000MCU Remove/install expansion reservoir ENGINES 132.9 in MODEL 451.3 /4 ENGINES 780.009 in MODEL 451.391 /491 AR20.30-P-4950MCC Remove/install expansion reservoir ENGINES 132.910 in MODEL 451.3 /4 ENGINES 780.009 in MODEL 451.391 /491 AR20.30-P-4950MCU Remove/install radiator ENGINE 132.9 in MODEL 451.3 /4 AR20.20-P-3865MCC Remove/install radiator ENGINE 132.910 in MODEL 451.3 /4 AR20.20-P-3865MCU Remove/install shutoff valve ENGINES 132.9 in MODEL 451.3 /4 as of 31.8.10 AR20.00-P-0300MCC TESTING & REPAIR INDEX > TESTING AND REPAIR WORK: SMART: ENGINE COOLING SYSTEM - AR20.00-Z-9451CA > MODEL 451

Drain, fill drive electric motor coolant

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 594 · Applies to: 450, 451, 452, 454 · AR: AR20.10-P-1271MCU

MODEL 451 391 /491 with ENGINE 780 009 Drain/fill in coolant MODEL 451.391 /491 with ENGINE 780.009 High-voltage battery coolant circuit TESTING & REPAIR INDEX > REMOVE/INSTALL COOLANT PUMP - AR20.10-P-1271MCU

ENGINE 132.910 in MODEL 451.3 /4 Remove/install

1 Drain coolant

AR20.00- P- 1142MCU 2 Remove belt pulley (2) for coolant pump (1)

AR20.10- P- 1275MCU 3 Remove poly-V belt tensioning device (3)

AR13.25- P- 3200MCU 4 Remove poly-V belt for supercharger On vehicles with code (I01) Air conditioning Plus AR13.21- P- 1202MCU 5 Remove bolt (4) on timing case cover (5) and lay ground line (6) for engine mass to one side

Catch coolant in a suitable Fig 1: Identifying Coolant Pump Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove bolts (7, 8)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 595 · Applies to: 450, 451, 452, 454 · AR: AR20.10-P-1275MCU, AR13.22-P-1202MCU

6 Remove bolts (7, 8) vessel.

*BA20.10- P-1007- 01J 7 Remove coolant pump (1) from timing case cover (5) Installation: Replace profiled rubber seal of coolant pump (1).

8 Install in the reverse order

COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 BA20.10-P-1007-01J Bolt, coolant pump to timing case cover M6 Nm 10 M8 Nm 23 TESTING & REPAIR INDEX > REMOVE/INSTALL BELT PULLEY FOR THE COOLANT PUMP - AR20.10-P-1275MCU > ENGINES 132.910 in MODEL 451.3 /4

Remove/install

1 Remove poly-V belt (2)

AR13.22-P-1202MCU 2 Counterhold belt pulley (1) and remove bolts (3) Fig 2 *BA20.10-P-1001-01J 3 Remove belt pulley (1) from the coolant pump

4 Install in the reverse order

Fig 1: Identifying Belt Pulley, Poly-V-Belt And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

ALTERNATOR

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 598 · Applies to: 450, 451, 452, 454 · AR: AR20.20-P-3865MCU

Number Designation Engine 132.9 BA15.40-P-1002-01G Cable to alternator terminal B+ Nm 10 BA15.40-P-1008-01G Bolt, alternator to timing case cover Nm 23 COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 BA20.10-P-1008-01J Bolt, thermostat housing to crankcase Nm 10 BA20.10-P-1011-01J Bolt connecting coolant line to cylinder head Nm 24 BA20.10-P-1012-01J Bolt, coolant line to crankcase Nm 24 TESTING & REPAIR INDEX > REMOVE/INSTALL RADIATOR - AR20.20-P-3865MCU > ENGINE 132.910 in MODEL 451.3 /4 Remove/install

1 Remove front module

AR62.30- P- 1575MCU 2 Remove condenser On vehicles with code (I01) Air conditioning Plus AR83.30- P- 6540MCU 3 Drain coolant at radiator (1)

AR20.00- P- 1142MCU Fig 1: Locating Expansion Reservoir And Radiator Brackets Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Detach ho e clamp (4) on e pan ion re ervoir (3)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 599 · Applies to: 450, 451, 452, 454 · AR: AR20.20-P-7441MCU

4 Detach ho e clamp (4) on e pan ion re ervoir (3) Replace ho e clamp (4).

5 Loosen expansion reservoir (3) from bracket (arrow A) on radiator support, detach from radiator (1) coolant hose (2) and lay to one side with attached coolant hoses Secure expansion reservoir (3) against falling down using a suitable cable tie.

6 Carefully lead radiator (1) on the left side on the brackets (arrows B) and take off

7 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE, INSTALL COOLANT LINE - AR20.20-P-7441MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install

1 Drain coolant

AR20.00-P- 1142MCU 2 Remove intake manifold (2)

AR09.20-P- 1310MCU 3 Loosen clamp (3) and detach coolant hose (4) from coolant line (1) Installation: Replace clamp (4).

4 Loosen clamp (5) and detach coolant hose (6) from coolant line (1) Installation: Replace clamp (6).

5 Remove bolts (7) and coolant line (1) BA20.10-P- 1011-01J BA20.10-P- 1012-01J 6 Install in the reverse order

COOLANT PUMP, COOLANT THERMOSTAT Number Designation Engine 132.9 Fig 1: Identifying Coolant Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BA20.10-P-1011-01J

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 600 · Applies to: 450, 451, 452, 454 · AR: AR20.20-P-7450MCU

Bolt connecting coolant line to cylinder head Nm 24 BA20.10-P-1012-01J Bolt, coolant line to crankcase Nm 24 TESTING & REPAIR INDEX > REMOVE/INSTALL COOLANT PIPE - AR20.20-P-7450MCU > ENGINE 132.910 in MODEL 451.3 /4 Remove/install

1 Drain coolant

AR20.00-P- 1142MCU 2 Remove intake manifold (2)

AR09.20-P- 1310MCU 3 Mark installation position of the coolant hose (3) to coolant pipe (1) (arrow)

4 Release clamp (4) and detach coolant hose (5) from coolant pipe (1) Installation: Replace clamp (4).

5 Remove bolt (6) for coolant pipe (1) on cylinder crankcase BA20.10-P- 1009-01J 6 Remove bolt (7) for coolant pipe (1) on oil pan BA20.10-P- 1010-01J 7 Pull coolant pipe (1) out of timing case cover (8) Installation: Replace seal ring on coolant pipe (1).

8 Release clamp (9) and detach coolant hose (3) from coolant pipe (1) Installation: Replace clamp (9).

Fig 1: Identifying Coolant Pipe Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Detach coolant ho e (4) on

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 603 · Applies to: 450, 451, 452, 454 · AR: AR20.40-P-5000MCU

6 Detach coolant ho e (4) on expansion reservoir (1) and lay to one side in such a way that so no coolant can run out For engine 132.9 Collect coolant which flows out in a suitable vessel.

7 Detach coolant hoses (5, 6) on expansion reservoir (1) Collect coolant which flows out in a suitable vessel.

8 Detach expansion reservoir (1) from holder (7), detach from coolant hose (8) and take off Collect coolant which flows out in a suitable vessel.

9 Loosen click clamp (10) and detach blind plug (11) For engine 780.009 Only when replacing the expansion reservoir (1). Installation: Replace snap clamp (10).

10 Install in the reverse order

11 Pour in coolant For engine 132.9 AR20.00- P- 1142MCU For engine 780.009 Coolant circuit high- voltage battery AR20.00- P- 1142MEV TESTING & REPAIR INDEX > REMOVE/INSTALL ELECTRIC FAN - AR20.40-P-5000MCU > ENGINE 132.910 in MODEL 451.3 /4 Remove/install

Fig 1: Identifying Electric Fan Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BA20.10-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 607 · Applies to: 450, 451, 452, 454 · AR: BE20.00-Z-9999CZ

P-1002- 01J Bolt, coolant pump to major assembly carrier Nm 9.5 9.5 9.5 BA20.10- P-1003- 01J Bolt, major assembly carrier to crankcase Nm 20 20 20 BA20.10- P-1004- 01J Banjo bolt, coolant connection to major assembly carrier Nm 19 19 19 BA20.10- P-1005- 01J Bolt, thermostat housing to cylinder head Initial torque Nm 12 12 12 Continued torque Nm 9.5 9.5 9.5 BA20.10- P-1006- 01J Bolt, water supply connection fitting to major assembly carrier Initial torque Nm 14 14 14 Continued torque Nm 9.5 9.5 9.5 BA20.10- P-1007- 01J Bolt, coolant pump to timing case cover M6 Nm - - - M8 Nm - - - BA20.10- P-1008- 01J Bolt, thermostat housing to crankcase Nm - - - BA20.10- P-1009- 01J Bolt, coolant pipe at crankcase Nm - - - BA20.10- P-1010- 01J Bolt, coolant pipe to oil pan Nm - - - BA20.10- P-1011- 01J Bolt connecting coolant line to cylinder head Nm - - - BA20.10- P-1012- 01J Bolt, coolant line to crankcase Nm - - - TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: ENGINE COOLING SYSTEM - BE20.00-Z-9999CZ > MODEL all Test values for cooling system cap ENGINE all BE20.30-P-1000-01A TEST & ADJUSTMENT VALUES > TEST VALUES FOR COOLING SYSTEM CAP - BE20.30- P-1000-01A >

BF20.00-P-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 610 · Applies to: 450, 451, 452, 454 · AR: BF20.00-Z-9999CZ, GF20.00-P-1000MCU

1001-04A Mixture ratio for coolant Antifreeze/water Up to -37°C 50/50 Up to -45°C 55/45 Specifications for Operating Fluids Sheet BB00.40-P- 0310-01A Sheet BB00.40-P- 0325-00A CAPACITIES & SPECIFICATIONS > CAPACITIES: SMART: ENGINE COOLING SYSTEM - BF20.00-Z-9999CZ > MODEL all Cooling system ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 in MODEL 454.0 BF20.00-P-1000-02T Cooling system ENGINE 160.910 /921 /920 /922 /923, 660.940, 780.009 BF20.00-P-1000-02R Mixture ratio for coolant ENGINE all BF20.00-P-1000-04A BASIC KNOWLEDGE > ENGINE COOLING FUNCTION - GF20.00-P-1000MCU > ENGINE 132.9 in MODEL 451.3 /4 Fig 1: Engine Cooling Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

General

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 611 · Applies to: 450, 451, 452, 454 · AR: GF20.10-P-3162MCC

Components of the engine suffer high thermal loading from the combustion taking place in the engine. Apart from actually leading away excess heat a cooling system must also fulfill the following tasks: Rapid reaching of the engine operating temperature Holding the engine operating temperature as constant as possible under all driving conditions Protecting engine lubricants from overheating Protecting fresh air from excessive warming in order to allow high efficiency of the engine Lowering the temperature in the combustion chamber in order to avoid uncontrolled self ignition Function The engine cooling is subdivided into a small and a large coolant circuit. For a cold engine the coolant flows via the small coolant circuit from the coolant pump through the engine to the thermostat and back to the coolant pump. If the engine has reached its operating temperature, the thermostat opens the large coolant circuit. This subdivides immediately after the thermostat into the cooling circuit and the heating circuit. In the cooling circuit, the coolant flows via the coolant feed pipe for the cooling circuit to the radiator and from there via the coolant return line back to the coolant pump. In the heating circuit the coolant flows via the coolant feed pipe for the heating circuit to the heater heat exchanger and further to the expansion reservoir. The coolant flows via the coolant return line from the expansion reservoir back to the coolant pump. If the coolant was partially or fully drained off the coolant circuit must be bled. Filling and bleeding of the coolant circuit may only be undertaken on a cold engine. Component description for the coolant thermostat

GF20.10-P-3162MCC BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE COOLANT THERMOSTAT - GF20.10-P-3162MCC > ENGINE 132.9 in MODEL 451.3 /4 Shown on engine 132.930

Design

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 613 · Applies to: 450, 451, 452, 454 · AR: GF20.20-P-1000MCU

The thermostat mainly consists of an expansion element, a return spring and two valve plates. A special wax is used as an expanding material. Function On a cold engine the thermostat is closed and the coolant flows through the small coolant circuit. As the coolant temperature increases the expanding material melts and presses against the rubber insert. The metal pin is pushed out of the rubber insert. The fact that this rests against the upper housing means that the whole metal can with both valve plates is pressed downwards. At full stroke the lower plate closes the small circuit. At the same time the upper plate frees up the large coolant circuit with the maximum cross-section. During cooling of the coolant the expanding material solidifies again and the spring presses the pin back. The large coolant circuit is finally closed. The whole process represents a continuous regulating process for which the coolant temperature can be held constant with a precision of T ± 5°C. BASIC KNOWLEDGE > FAN MOTOR, COMPONENT DESCRIPTION - GF20.20-P-1000MCU

ENGINES 132.9 in MODEL 451.3 /4 Location The coolant fan motor is located at the rear of the radiator. Task The coolant fan motor actuated by the SAM control unit (N10/10) generates a suctioned air flow behind the cooler. In this way the temperature of the coolant passing through the radiator is lowered. SPECIAL TOOLS > 450 589 06 37 00 PLIERS - WS20.00-P-0040B > FG 20/Set B MODEL 450, 451, 452, 451 Fig 1: Identifying Coolant Fan Motor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MAINTENANCE > ENGINE OIL AND FILTER CHANGE - AP18.00-P-0101MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 619 · Applies to: 450, 451, 452, 454 · AR: AP18.00-P-0101MCU

ENGINES 132.910 in MODEL 451.3/4 Removing

Change the engine oil only when the engine is at operating temperature

1 Remove engine compartment cover

Remove/install interior compartment flap above engine

AR88.40-P-1100- 03MCC 2 Unscrew oil filler neck cap (3)

Risk of death caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A 3 Raise vehicle with vehicle lift

4 Remove oil drain screw (2) Collect engine oil in a

Fig 1: Identifying Oil Filter, Oil Drain Screw And Oil Filler Neck Cap Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

OIL PAN

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 621 · Applies to: 450, 451, 452, 454 · AR: AR18.00-Z-9132CB

Number Designation Engine 132.9 BA01.45-P-1003-01J Oil drain screw to oil pan Nm 65 OIL FILTER Number Designation Engine 132.9 BA18.20-P-1002-01N Oil filter to timing case cover Nm 14 FILLING CAPACITIES OF ENGINE LUBRICATION SYSTEM Number Designation Engine 132.9 BF18.00-P- 1001-01N Engine oil Filling capacity (oil and filter change) Liters 3,7 Specifications for Operating Fluids Sheet - Sheet - Sheet - Sheet - Sheet - Sheet BB00.40-P-0229- 05A Sheet - TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: ENGINE LUBRICATION, ENGINE OIL COOLING - AR18.00-Z-9132CB > ENGINE 132 Check oil pressure ENGINES 132.9, 660.9 in MODEL 451.3/4 AR18.00-P- 1250MCC Check oil pressure ENGINES 132.910 in MODEL 451.3/4 AR18.00-P- Fig 2: Identifying Wrench Socket (454 589 06 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Sheet

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 625 · Applies to: 450, 451, 452, 454 · AR: BE18.00-Z-9999CZ

- BB00.40-P-0223-02A BE18.00-P-1002- 06P Starting distance of 20,000 km for a service when using oils according to MBBV - - 229.3 - 229.31 - 229.5 - 229.51 - Sheet BB00.40-P-0223-02A - ENGINE OIL CHANGE Number Designation Engine 660 in model 451 Engine 660 DPF in model 451 BE18.00-P-1001- 06P Starting distance of 15,000 km for a service when using oils according to MBBV - - 229.3 - 229.31 229.31 229.5 - 229.51 229.51 Sheet BB00.40-P-0223-02A BB00.40-P-0223-02A BE18.00-P-1002- 06P Starting distance of 20,000 km for a service when using oils according to MBBV - - - - - - - - - - Sheet - - TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: ENGINE LUBRICATION, ENGINE OIL COOLING - BE18.00-Z-9999CZ > MODEL all Engine oil change MODEL 450 BE18.00-P-1000-06Z Engine oil change MODEL 451 BE18.00-P-1000-06P Engine oil change MODEL 454 BE18.00-P-1000-06AB Engine oil change MODEL 452 BE18.00-P-1000-06AA Oil pressure ENGINE 639, 660 BE18.00-P-1000-01F Oil pressure ENGINE 122, 132, 134, 135, 160 BE18.00-P-1000-01E CAPACITIES & SPECIFICATIONS > FILLING CAPACITIES, ENGINE LUBRICATION

Sheet

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 627 · Applies to: 450, 451, 452, 454 · AR: BF18.00-Z-9999CZ, GF18.00-P-1100MCU

- BB00.40-P- 0228-03A - Sheet - BB00.40-P- 0228-05A - Sheet - BB00.40-P- 0229-01A - Sheet - BB00.40-P- 0229-03A - Sheet BB00.40-P- 0229-05A BB00.40-P- 0229-05A BB00.40-P- 0229-05A Sheet - BB00.40-P- 0229-31A BB00.40-P- 0229-31A FILLING CAPACITIES OF ENGINE LUBRICATION SYSTEM Number Designation Engine 660.950 with code 474 Engine 660.951 BF18.00-P- 1001-01N Engine oil Filling capacity (oil and filter change) Liters 3.4 3.4 Specifications for Operating Fluids Sheet - - Sheet - - Sheet - - Sheet - - Sheet - - Sheet BB00.40-P- 0229-05A BB00.40-P- 0229-05A Sheet BB00.40-P- 0229-31A BB00.40-P- 0229-31A CAPACITIES & SPECIFICATIONS > CAPACITIES: SMART: ENGINE LUBRICATION, ENGINE OIL COOLING - BF18.00-Z-9999CZ > MODEL all Filling capacities, engine lubrication system ENGINE 132.9, 160.910 /920 /921 /922 /923, 660.940 /950 /951 BF18.00-P-1000- 01N Filling capacities, engine lubrication system ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 BF18.00-P-1000-01P BASIC KNOWLEDGE > ENGINE LUBRICATION FUNCTION - GF18.00-P-1100MCU > ENGINE 132.9 in MODEL 451.3/4

General

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 628 · Applies to: 450, 451, 452, 454 · AR: GF01.40-P-2100MCC, GF18.10-P-4000MCC

Engine oil is led through the for engine lubrication to minimize wear and to prevent overheating of the engine. Function The oil pump driven by the crankshaft delivers the engine oil out of the oil pan to the oil filter. The engine oil then passes from there via the supply ducts in the engine block to the individual lubrication points. The most important lubrication points on the engine are areas on the crankshaft and camshafts. The engine oil wets the lubrication points and drips back into the oil pan. Camshaft adjustment of the intake camshafts is also achieved using pressure generated by the oil pump. To do this the adjustable camshaft timing solenoid is actuated by the ME-SFI [ME] control unit (N3/10) and passes the oil pressure according to requirements via the oil lines "advanced" or "retarded" to the camshaft adjuster. As the motor speed increases the RPM of the oil pump increases which leads to an increase in the oil pressure. This is limited by the pressure limiting valve so that excess delivered engine oil flows back into the oil pan. A baffle plate is mounted between the oil pan and crankcase to optimize the power output of the engine which prevents immersion of the crankshaft in the engine oil remaining in the oil pan. This reduces the resistance at the crankshaft and also prevents foaming of the engine oil. Component description for the baffle plate GF01.40-P-2100MCC Component description for the oil pump GF18.10-P-4000MCC BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE OIL PUMP - GF18.10-P- Fig 1: Engine Lubrication Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE OIL PRESSURE SWITCH -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 630 · Applies to: 450, 451, 452, 454 · AR: GF18.40-P-4000MCC

GF18.40-P-4000MCC > ENGINE 132.9 in MODEL 451.3/4 Fig 2: Oil Pump Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Engine Oil Pressure Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MAINTENANCE > ENGINE OIL AND FILTER CHANGE - AP18.00-P-0101MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 634 · Applies to: 450, 451, 452, 454 · AR: AP18.00-P-0101MCU

ENGINES 132.910 in MODEL 451.3 /4 Removing

Change the engine oil only when the engine is at operating temperature

1 Remove engine compartment cover

Remove/install interior compartment flap above engine

AR88.40- P-1100- 03MCC 2 Unscrew oil filler neck cap (3)

Risk of death caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00- Z-0010- 01A 3 Raise vehicle with vehicle lift

4 Remove oil drain screw (2) and remove seal ring on the oil drain screw (2) Collect engine oil in a suitable container.

5 Remove filter screen on the oil drain screw (2) and clean

Fig 1: Identifying Oil Filter, Oil Drain Screw And Oil Filler Neck Cap Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Number

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 636 · Applies to: 450, 451, 452, 454 · AR: AR18.00-P-0025MCC

Designation Engine 132.9 BA18.20-P-1002-01N Oil filter to timing case cover Nm 14 FILLING CAPACITIES OF ENGINE LUBRICATION SYSTEM Number Designation Engine 132.9 BF18.00-P-1001- 01N Engine oil Filling capacity (oil and filter change) Liters 3,7 Specifications for Operating Fluids Sheet - Sheet - Sheet - Sheet - Sheet - Sheet BB00.40-P-0229- 05A Sheet - TESTING & REPAIR > MEASURE OIL CONSUMPTION - AR18.00-P-0025MCC > ENGINE 160, 660 in MODEL 450 ENGINE 132, 660 in MODEL 451 ENGINE 160 in MODEL 452 ENGINE 122, 134, 135, 639 in MODEL 454 Checking

1 Check engine for oil loss, rectify oil loss if required

2 Check part-load vent lines for signs of leaks, rectify leak if

Fig 2: Identifying Wrench Socket (454 589 06 09 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

required

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 637 · Applies to: 450, 451, 452, 454 · AR: AR18.00-P-1250MCU

3 Check air lines for signs of leaks, rectify leak if necessary

4 Park vehicle horizontally For example on wheel alignment system. 5 Start engine

6 Switch off engine after reaching coolant temperature of 80°C and wait for 5 minutes

7 Clean oil dipstick and insert into oil dipstick guide tube

8 Pull oil dipstick after approx. 1 min. out of oil dipstick guide tube The engine oil level must not exceed the max. mark on the oil dipstick. 9 Use a suitable scriber to mark the oil dipstick This serves to record the current engine oil level with the engine at operating temperature. 10 After a driven distance of roughly 1000 km, check the engine oil level again Steps 1 to 9.To correctly measure the oil consumption, a driven distance of roughly 1000 km should lie between the individual measurements. 11 Top up engine oil in steps of 100 ml to the mark made on the oil dipstick The measurement and refilling of the engine oil should be done in the presence of the customer. 12 Calculate oil consumption Calculate actual oil consumption:V x 1000/SV = Differential quantity in literss = measured distance covered in kmThe oil consumption limit for smart engines over 1000 km is 0.8 liters. TESTING & REPAIR > CHECK OIL PRESSURE - AR18.00-P-1250MCU > ENGINES 132.910 in MODEL 451.3 /4

Turn off engine

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 639 · Applies to: 450, 451, 452, 454 · AR: AR18.00-Z-9132CB

9 Turn off engine

10 Raise vehicle with vehicle lift

11 Detach on oil pressure testing device from adapter and remove adapter from threaded hole for oil pressure switch (S41/1)

Install

12 Install oil pressure switch (S41/1)

AR18.40- P- 4132MCU 13 Lower vehicle with vehicle lift

14 Install interior flap above engine

AR88.40- P-1100- 03MCC CHECK VALUES FOR OIL PRESSURE Number Designation Engine 132 BE18.00-P-1002- 01E Oil pressure engine at operating temperature and idling bar 0.6 to 1.6 BE18.00-P-1003- 01E Oil pressure at engine operating temperature and 3500 rpm bar 2.5 to 4.3 TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: ENGINE LUBRICATION, ENGINE OIL COOLING - AR18.00-Z-9132CB > ENGINE 132

Check oil pressure ENGINES 132.9, 660.9 in MODEL 451.3 /4 AR18.00-P- 1250MCC

Check oil pressure ENGINES 132.910 in MODEL 451.3 /4 AR18.00-P- 1250MCU ENGINE 122, 132, 134, 135, 160, 639, AR18.00-P- Fig 2: Identifying Oil Pressure Tester (450 589 13 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Measure oil consumption

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 640 · Applies to: 450, 451, 452, 454 · AR: AR18.40-P-4132MCU

660... 0025MCC

Remove/install oil pressure switch ENGINE 132.9 in MODEL 451.3 /4 AR18.40-P- 4132MCC

Remove/install oil pressure switch ENGINE 132.910 in MODEL 451.3 /4 AR18.40-P- 4132MCU TESTING & REPAIR > REMOVE/INSTALL OIL PRESSURE SWITCH - AR18.40-P-4132MCU

ENGINE 132.910 in MODEL 451.3 /4

Remove/install

Risk of death caused by vehicle slipping or toppling off the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00- Z-0010- 01A 1 Raise vehicle with vehicle lift

2 Remove expansion clips (1) and remove cover (2)

3 Disconnect electrical connector (3) at oil pressure switch (S41/1)

Installation: Screw oil Fig 1: Identifying Oil Pressure Switch Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BE18.00-P-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 645 · Applies to: 450, 451, 452, 454 · AR: BE18.00-Z-9999CZ

1002-06P Starting distance of 20,000 km for a service when using oils according to MBBV - - - - - - - - Sheet - - TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: ENGINE LUBRICATION, ENGINE OIL COOLING - BE18.00-Z-9999CZ > MODEL all Engine oil change MODEL 450 BE18.00-P-1000-06Z Engine oil change MODEL 451 BE18.00-P-1000-06P Engine oil change MODEL 454 BE18.00-P-1000-06AB Engine oil change MODEL 452 BE18.00-P-1000-06AA Oil pressure ENGINE 639, 660 BE18.00-P-1000-01F Oil pressure ENGINE 122, 132, 134, 135, 160 BE18.00-P-1000-01E CAPACITIES & SPECIFICATIONS > FILLING CAPACITIES, ENGINE LUBRICATION SYSTEM - BF18.00-P-1000-01N > ENGINES 132, 160, 660 FILLING CAPACITIES OF ENGINE LUBRICATION SYSTEM Number Designation Engine 132.9 Engine 160.910 BF18.00-P- 1001-01N Engine oil Filling capacity (oil and filter change) Liters 3.7 2.5 Specifications for Operating Fluids Sheet - - Sheet - - Sheet - - Sheet - - Sheet - - Sheet BB00.40- left-05A BB00.40-P- 0229-05A Sheet - - FILLING CAPACITIES OF ENGINE LUBRICATION SYSTEM Number Designation Engine 160.920 Engine 160.921 Engine 160.922

BF18.00-P-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 647 · Applies to: 450, 451, 452, 454 · AR: BF18.00-Z-9999CZ, GF18.00-P-1100MCU

1001-01N Engine oil Filling capacity (oil and filter change) Liters 3.4 3.4 Specifications for Operating Fluids Sheet - - Sheet - - Sheet - - Sheet - - Sheet - - Sheet BB00.40-P-0229- 05A BB00.40-P- 0229-05A Sheet BB00.40-P-0229- 31A BB00.40-P- 0229-31A CAPACITIES & SPECIFICATIONS > CAPACITIES: SMART: ENGINE LUBRICATION, ENGINE OIL COOLING - BF18.00-Z-9999CZ > MODEL all Filling capacities, engine lubrication system ENGINE 132.9, 160.910 /920 /921 /922 /923, 660.940 /950 /951 BF18.00-P-1000-01N Filling capacities, engine lubrication system ENGINE 122.950, 134.910 /911, 135.930 /950, 639.939 BF18.00-P-1000-01P BASIC KNOWLEDGE > ENGINE LUBRICATION FUNCTION - GF18.00-P-1100MCU > ENGINE 132.9 in MODEL 451.3 /4

General

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 648 · Applies to: 450, 451, 452, 454 · AR: GF01.40-P-2100MCC, GF18.10-P-4000MCC

Engine oil is led through the for engine lubrication to minimize wear and to prevent overheating of the engine. Function The oil pump driven by the crankshaft delivers the engine oil out of the oil pan to the oil filter. The engine oil then passes from there via the supply ducts in the engine block to the individual lubrication points. The most important lubrication points on the engine are areas on the crankshaft and camshafts. The engine oil wets the lubrication points and drips back into the oil pan. Camshaft adjustment of the intake camshafts is also achieved using pressure generated by the oil pump. To do this the adjustable camshaft timing solenoid is actuated by the ME-SFI [ME] control unit (N3/10) and passes the oil pressure according to requirements via the oil lines "advanced" or "retarded" to the camshaft adjuster. As the motor speed increases the rpm of the oil pump increases which leads to an increase in the oil pressure. This is limited by the pressure limiting valve so that excess delivered engine oil flows back into the oil pan. A baffle plate is mounted between the oil pan and crankcase to optimize the power output of the engine which prevents immersion of the crankshaft in the engine oil remaining in the oil pan. This reduces the resistance at the crankshaft and also prevents foaming of the engine oil. Component description for the baffle plate GF01.40-P-2100MCC Component description for the oil pump GF18.10-P-4000MCC BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE OIL PUMP - GF18.10-P- Fig 1: Engine Lubrication Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE OIL PRESSURE SWITCH -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 650 · Applies to: 450, 451, 452, 454 · AR: GF18.40-P-4000MCC

GF18.40-P-4000MCC > ENGINE 132.9 in MODEL 451.3 /4 Fig 2: Oil Pump Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Engine Oil Pressure Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: ENGINE SUSPENSION -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 654 · Applies to: 450, 451, 452, 454 · AR: AR22.00-Z-9132CB, AR22.10-P-1300MCC, AR22.10-P-1001MCC, AR22.10-P-1102MCC

AR22.00-Z-9132CB > ENGINE 132 Remove/install frame-type integral support ENGINES 132.9, 660.9, 780.009 in MODEL 451.3/4 AR22.10-P-1300MCC Remove/install frame-type integral support ENGINES 132.910, 780.009 in MODEL 451.3/4 AR22.10-P- 1300MCU Remove/install carrier for engine mount ENGINE 132.9, 660.9 in MODEL 451.3/4 AR22.10-P-1001MCC Remove/install carrier for engine mount ENGINE 132.910 in MODEL 451.3/4 AR22.10-P- 1001MCU Remove/install front engine mount ENGINE 132.9 in MODEL 451.3/4 ENGINE 780.009 in MODEL 451.391/491 AR22.10-P- 4330MCC Remove/install right engine mount ENGINE 132.9 in MODEL 451.3/4 AR22.10-P-1102MCC Remove/install right engine mount ENGINES 132.910 in MODEL 451.3/4 AR22.10-P- 1102MCU TESTING & REPAIR > REMOVE/INSTALL CARRIER FOR ENGINE MOUNT - AR22.10-P- 1001MCU > ENGINE 132.910 in MODEL 451.3/4

Number

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 656 · Applies to: 450, 451, 452, 454 · AR: AR22.10-P-1102MCU

De ignation Engine 132 9 BA22.10-P-1011- 01M Bolt, torque support to front engine mount carrier Nm 115 BA22.10-P-1012- 01M Bolt, carrier for front engine mount to transmission Nm 23 BA22.10-P-1013- 01M Bolt, carrier for front engine mount to crankcase Nm 56 TESTING & REPAIR > REMOVE/INSTALL RIGHT ENGINE MOUNT - AR22.10-P-1102MCU > ENGINES 132.910 in MODEL 451.3/4 Remove/install

1 Remove interior flap above engine

AR88.40- P-1100- 03MCC 2 Disconnect electrical connector (2) at tank vent valve (Y58/1)

3 Remove tank vent valve (Y58/1) from holder (3) on engine mount (1) and turn until so the lock on the vent line (4) is accessible

4 Disconnect vent line (4) on tank vent valve (Y58/1) and lay tank vent valve (Y58/1) to the side

Use a suitable protective underlay Fig 1: Identifying Right Engine Mount Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REAR AXLE CARRIER

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 660 · Applies to: 450, 451, 452, 454 · AR: AR22.10-P-4330MCC

Number Designation Model 451.3/4 BA35.10-P-1001- 01F Bolt, frame-type integral support to body Nm 125 CMS REAR END Number Designation Model 451.3/4 BA64.20-P-1001- 01B Bolt, CMS rear end to drive module Nm 22 TESTING & REPAIR > REMOVE/INSTALL FRONT ENGINE MOUNT - AR22.10-P-4330MCC

ENGINE 132.9 in MODEL 451.3/4 ENGINE 780.009 in MODEL 451.391/491 Shown on vehicle with engine 132.9

Remove/install

Risk of death when touching components on vehicles with a high-voltage system Do not touch components and open lines of the high-voltage system. Persons with electronic implants (e.g. cardiac pacemakers) must never work on high-voltage systems. AS54.00-Z- 0001-02MEV Note on high-voltage battery Model 451.391/491 AH54.10-P- 0006-01MEV Note on high-voltage system Model 451.391/491 AH54.00-P- 0011-01MEV Risk of death caused by vehicle slipping or toppling off the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z- 0010-01A Fig 1: Identifying Torque Support, Screws And Nut Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > TESTING AND REPAIR WORK: SMART: ENGINE

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 668 · Applies to: 450, 451, 452, 454 · AR: AR22.00-Z-9132CB, AR22.10-P-1300MCC, AR22.10-P-1300MCU, AR22.10-P-1001MCC, AR22.10-P-1001MCU (+3 more)

SUSPENSION - AR22.00-Z-9132CB > ENGINE 132 Remove/install frame-type integral support ENGINES 132.9, 660.9, 780.009 in MODEL 451.3 /4 AR22.10-P-1300MCC Remove/ install frame-type integral support ENGINES 132.910, 780.009 in MODEL 451.3 /4 AR22.10-P-1300MCU Remove/install carrier for engine mount ENGINE 132.9, 660.9 in MODEL 451.3 /4 AR22.10-P-1001MCC Remove/install carrier for engine mount ENGINE 132.910 in MODEL 451.3 /4 AR22.10-P-1001MCU Remove/install front engine mount ENGINE 132.9 in MODEL 451.3 /4 ENGINE 780.009 in MODEL 451.391 /491 AR22.10-P-4330MCC Remove/install right engine mount ENGINE 132.9 in MODEL 451.3 /4 AR22.10-P-1102MCC Remove/install right engine mount ENGINES 132.910 in MODEL 451.3 /4 AR22.10-P-1102MCU TESTING & REPAIR INDEX > REMOVE/INSTALL CARRIER FOR ENGINE MOUNT - AR22.10-P-1001MCU > ENGINE 132.910 in MODEL 451.3 /4

Remove bolts (5)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 671 · Applies to: 450, 451, 452, 454 · AR: AR22.10-P-1300MCU

6 Remove bolts (5) P-1006- 01M 7 Undo bolts (6) and remove bracket (3) *BA22.10- P-1007- 01M 8 Remove engine mount (1) upwards

9 Install in the reverse order

ENGINE MOUNTS, ENGINE SUPPORTS Number Designation Engine 132.9 BA22.10-P-1006- 01M Bolt, right engine mount to frame-type integral support Nm 56 BA22.10-P-1007- 01M Bolt, right engine mount to timing case cover Nm 80 TESTING & REPAIR INDEX > REMOVE/ INSTALL FRAME-TYPE INTEGRAL SUPPORT - AR22.10-P-1300MCU > ENGINES 132.910, 780.009 in MODEL 451.3 /4

Remove/install

Risk of death when touching components on vehicles with high- voltage system Do not touch components and open lines of high-voltage system. Persons with electronic implants (e.g. cardiac pacemakers) must never work on high- AS54.00-Z-0001- 02MEV Fig 1: Identifying Frame-Type Integral Support Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MAINTENANCE > SET VALVE CLEARANCE - AP05.30-P-0560MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 682 · Applies to: 450, 451, 452, 454 · AR: AP05.30-P-0560MCU, AR01.20-P-5014MCU, AR40.10-P-1100MCU

ENGINE 132.910 in MODEL 451.3/4 Removing

1 Remove cylinder head cover

Remove, install cylinder head cover

AR01.10-P-1000- 01MCU 2 Detach right rear wheel

Remove/install wheels

AR01.20-P-5014MCU Checking

3 Turn engine into the TDC position

Turn engine into the TDC position

AR40.10-P-1100MCU 4 Lower vehicle with lifting platform

5 Check whether the valves of the 1st cylinder are relieved of load, if necessary continue turning engine one revolution in direction of engine rotation at the central bolt of the

Fig 1: Identifying Intake And Exhaust Camshafts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

crank haft pulley

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 683 · Applies to: 450, 451, 452, 454 · AR: AR05.00-P-2310MCU

6 Check valve clearance of the intake valves of the 1st and 2nd cylinder as well as the exhaust valves of the 1st and 3rd cylinder It must be possible to insert the feeler gauge making smooth contact all round between the cam of the intake camshaft (1) or exhaust camshaft (2) and the valve tappet, if necessary determine and note the deviation.

Inlet valve *BE05.30-P-1001- 06C

Outlet valve *BE05.30-P-1002- 06C 7 Continue turning engine at the center bolt of the crankshaft belt pulley by 180° in the direction of engine rotation

8 Check valve clearance of exhaust valve of 2nd cylinder as well as the intake valve of the 3rd cylinder It must be possible to insert the feeler gauge making smooth contact all round between the cam of the intake camshaft (1) or exhaust camshaft (2) and the valve tappet, if necessary determine and note the deviation.

Inlet valve *BE05.30-P-1001- 06C

Outlet valve *BE05.30-P-1002- 06C

Adjust

9 Remove valve tappet of the corresponding inlet or exhaust valve

Remove/install valve tappets

AR05.00-P-2310MCU 10 Select valve tappet of appropriate thickness and install The sum of the thickness of the valve tappet removed and the tolerance deviation of the valve clearance gives the thickness of the valve tappet to be installed. The dimension for the thickness of the valve tappet i located on its underside.

Remove valve

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 685 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-6010MCC, AR05.20-P-6010MCU, AR05.20-P-6025MCC, AR05.10-P-8127MCC, AR05.10-P-8127MCU (+5 more)

2 Remove valve tappet (1) from basic bore in cylinder head Do not use magnets. Magnetization of the valve tappet (1) can lead to gathering of the smallest metal chips which can lead to damage to the valve tappet (1) and intake camshaft (2) or exhaust camshaft (3) Installation: When recycling the valve tappet (1), it must be reinstalled at the same location. The valve tappets (1) are designed in various thicknesses to compensate for the valve clearance. The dimension for the thickness of the valve tappet (1) is located on its underside.

Checking

3 Check basic bores in cylinder head In case of damage to the basic bore in the cylinder head, the cylinder head must be replaced, see: ↓

Remove/install cylinder head AR01.30- P- 5800MCU 4 Install in the reverse order

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: ENGINE TIMING - AR05.00- Z-9132CB > ENGINE 132 Check basic position of camshafts ENGINES 132.9 in MODEL 451.3/4 AR05.20-P-6010MCC Check basic position of camshafts ENGINES 132.910 in MODEL 451.3/4 AR05.20-P-6010MCU Correct basic position of camshafts ENGINES 132.9 in MODEL 451.3/4 AR05.20-P-6025MCC Remove, install tensioning rail ENGINE 132.9 in MODEL 451.3/4 AR05.10-P-8127MCC Remove, install tensioning rail ENGINE 132.910 in MODEL 451.3/4 AR05.10-P-8127MCU Remove/install camshaft sprocket ENGINE 132.9 in MODEL 451.3/4 AR05.20-P-6040MCC Remove/install camshaft sprocket ENGINE 132.910 in MODEL 451.3/4 AR05.20-P-6040MCU Remove/install camshafts ENGINE 132.9 in MODEL 451.3/4 AR05.20-P-6992MCC Remove/install camshafts ENGINE 132.910 in MODEL 451.3/4 AR05.20-P-6992MCU Remove/install camshafts ENGINE 132.9 in MODEL 451.3/4 AR05.20-P-7201MCC Remove/install camshafts ENGINE 132.910 in MODEL 451.3/4 AR05.20-P-7201MCU Remove/install chain tensioner ENGINE 132.9 in MODEL 451.3/4 AR05.10-P-7800MCC Remove/install chain tensioner ENGINE 132.910 in MODEL 451.3/4 AR05.10-P-7800MCU

Remove/install slide rail of timing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 686 · Applies to: 450, 451, 452, 454 · AR: AR05.10-P-8128MCC, AR05.10-P-8128MCU, AR05.20-P-7295MCC, AR05.20-P-7295MCU, AR05.00-P-2310MCC (+5 more)

chain ENGINE 132.9 in MODEL 451.3/4 AR05.10-P-8128MCC Remove/install slide rail of timing chain ENGINE 132.910 in MODEL 451.3/4 AR05.10-P-8128MCU Remove/install solenoid camshaft ENGINE 132.9 in MODEL 451.3/4 AR05.20-P-7295MCC Remove/install solenoid camshaft ENGINE 132.910 in MODEL 451.3/4 AR05.20-P-7295MCU Remove/install valve tappets ENGINE 132.9 in MODEL 451.3/4 AR05.00-P-2310MCC Remove/install valve tappets ENGINE 132.910 in MODEL 451.3/4 AR05.00-P-2310MCU Remove/install valves ENGINES 132.9 in MODEL 451.3/4 AR05.30-P-3511MCC Replace timing chain ENGINE 132.9 in MODEL 451.3/4 AR05.10-P-7601MCC Replace timing chain ENGINE 132.910 in MODEL 451.3/4 AR05.10-P-7601MCU Replace valve stem seals. ENGINES 132.9 in MODEL 451.3/4 AR05.30-P-3510MCC Replace valve stem seals with cylinder head installed ENGINES 132.9 in MODEL 451.3/4 AR05.30-P-3512MCC Set basic position of camshafts ENGINES 132.9 in MODEL 451.3/4 AR05.20-P-6020MCC Set basic position of camshafts ENGINES 132.910 in MODEL 451.3/4 AR05.20-P-6020MCU TESTING & REPAIR > REPLACE TIMING CHAIN - AR05.10-P-7601MCU > ENGINE 132.910 in MODEL 451.3/4

TESTING & REPAIR > REMOVE/INSTALL CHAIN TENSIONER - AR05.10-P-7800MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 689 · Applies to: 450, 451, 452, 454 · AR: AR05.10-P-7800MCU

ENGINE 132.910 in MODEL 451.3/4 Remove/install

1 Remove timing case cover (2)

AR01.40- P- 8000MCU 2 Push back ratchet (3) using a suitable screwdriver, press together chain tensioner (1) and secure using a pin with a diameter of 1.5 mm via the bore (arrow)

3 Remove bolts (4) and chain tensioner (1) *BA05.10- P-1004- 01P 4 Install in the reverse order

TIMING CHAIN DRIVE Number Designation Engine 132.9 Fig 3: Identifying Adapter (451 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Chain Tensioner Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BA05.10-P-1004-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 690 · Applies to: 450, 451, 452, 454 · AR: AR05.10-P-8127MCU

01P Bolt, cam chain tensioner to crankcase Nm 9 TESTING & REPAIR > REMOVE, INSTALL TENSIONING RAIL - AR05.10-P-8127MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install

1 Remove timing case cover

AR01.40- P- 8000MCU 2 Mark position of timing chain (2) relative to intake and exhaust camshaft and crankshaft. Mark position of intake and exhaust camshaft relative to cylinder head Installation: Check markings and correct settings if necessary.

3 Push back ratchet (5) using a suitable screwdriver, press together chain tensioner (3) and secure using a pin with a diameter of 1.5 mm via the bore (arrow)

4 Unscrew bolt (4) *BA05.10- P-1001- 01P 5 Pull out tensioning rail (1) between timing chain (2) and chain tensioner (3)

6 Install in the reverse order

Fig 1: Identifying Tensioning Rail Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

*BA05 10

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 692 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-6010MCU

P-1004- 01P 5 Remove bolts (7) *BA05.10- P-1002- 01P

*BA05.10- P-1003- 01P 6 Relieve timing chain (2) through careful turning at the camshaft and remove slide rail (1) from bearing pin (8)

7 Install in the reverse order

TIMING CHAIN DRIVE Number Designation Engine 132.9 BA05.10-P-1002- 01P Bolt, timing chain slide rail to cylinder head Nm 10 BA05.10-P-1003- 01P Bolt, timing chain slide rail to crankcase Nm 10 BA05.10-P-1004- 01P Bolt, cam chain tensioner to crankcase Nm 9 TESTING & REPAIR > CHECK BASIC POSITION OF CAMSHAFTS - AR05.20-P-6010MCU > ENGINES 132.910 in MODEL 451.3/4 Fig 1: Identifying Expansion Clip And Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

clips (1) and remove

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 694 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-6020MCU

3 clips (1) and remove cover (2)

Checking

4 Turn crankshaft on center bolt (4) of crankshaft belt pulley (3) in direction of engine rotation until marking (arrow A) is visible The crankshaft must not be turned back, otherwise timing chain can skip and this can result in engine damage.

5 Transfer marking (arrow A) on crankshaft belt pulley (3) onto the front side of the crankshaft belt pulley (3) (arrow B) using a suitable colored pencil

6 Rotate crankshaft in direction of engine rotation until marking (arrow B) corresponds with marking "10" (arrow C) on timing case cover (5) The marking "10" (arrow C) represents 10° BTDC.

7 Lower vehicle with vehicle lift

8 Check adjustment of camshaft Check whether marking (arrow E) on camshaft adjuster (6) and marking (arrow D) on camshaft sprocket (7) stand opposite each other at the height of the upper edge of the timing case cover (5)If the marking (arrow E) on the camshaft adjuster (6) and marking (arrow D) on the camshaft sprocket (7) are not visible, turn crankshaft one more turn.If marking (arrow D) and marking (arrow E) are not flush: ↓

Set basic position of camshafts AR05.20- P- 6020MCU 9 Install in the reverse order

TESTING & REPAIR > SET BASIC POSITION OF CAMSHAFTS - AR05.20-P-6020MCU > ENGINES 132.910 in MODEL 451.3/4 Checking

Check basic position of camshafts

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 695 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-6010MCU, AR05.20-P-6025MCC

1 Check basic position of camshafts AR05.20-P-6010MCU

Adjust

2 Correct basic position of intake camshaft and exhaust camshaft AR05.20-P-6025MCC 3 Install in the reverse order

TESTING & REPAIR > CORRECT BASIC POSITION OF CAMSHAFTS - AR05.20-P- 6025MCC > ENGINES 132.9 in MODEL 451.3/4 Fig 1: Identifying Crankshaft Belt Pulley And Timing Case Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Bring intake camshaft (10)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 697 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-6010MCC, AR05.20-P-6010MCU

1 Bring intake camshaft (10) and exhaust camshaft (2) into their basic position The marking (arrow A or arrow B) on the crankshaft (11) belt pulley must be correspond during the whole correction process with marking "10" (arrow C) on the timing case cover (5).The marking "10" (arrow C) represents 10° BTDC.

• not for USA AR05.20-P-6010MCC

• for USA only AR05.20-P-6010MCU 2 Counterhold exhaust camshaft (2) at hexagon (arrow D) and loosen bolt (3) on camshaft sprocket (1) *001589011601

*001589011609 3 Remove screw plug (4) on timing case cover (5)

4 Press timing chain (6) downwards using a suitable tool in the area between the camshaft sprocket (1) and the camshaft adjuster (7), push back ratchet (8) on chain tensioner (9) using a suitable screwdriver and lock chain tensioner (9) An aid for pressing down the timing chain (6) is required.In order to lock the chain tensioner (9), place a pin with a diameter of 1.5 mm into the bore (arrow E) in the chain tensioner (9).

5 Remove bolt (3); detach camshaft sprocket (1) from exhaust camshaft (2) and remove from timing chain (6)

Adjust

6 Lift timing chain (6) and turn intake camshaft (10) on hexagon in the direction of the arrow until marking (arrow F) on the camshaft adjuster (7) is standing at the height of the timing case cover contact surface (5) Do not turn intake camshaft (10) against the direction of the arrow; this can cause folding up of the timing chain (6) which will cause damage.

7 Lay timing chain (6) on camshaft adjuster (7) ring gear

Turn exhaust camshaft (2)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 698 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-6010MCC

8 Turn exhaust camshaft (2) at hexagon (arrow D) until the drive plate (12) is vertical to the timing case cover (5) contact surface

9 Align camshaft sprocket (1) according to markings (arrow G) and insert in the timing chain (6). The marking (arrow G) must stand at the height of the timing case cover (5) contact surface and opposite the marking (arrow F) on the camshaft adjuster (7).

10 Screw bolt (3) into exhaust camshaft (2) for centering Just put bolt (3) into place; do not tighten.

11 Press camshaft sprocket (1) with the cutout (arrow H) onto the exhaust camshaft (2) drive plate (12) Turn exhaust camshaft (2) at hexagon if necessary.

Install

12 Counterhold exhaust camshaft (2) at hexagon (arrow D) and tighten bolt (3) on camshaft sprocket (1) *001589011601

*001589011609

*BA05.20-P-1005-01M 13 Push timing chain (6) downwards using a suitable tool in the area between the camshaft sprocket (1) and the camshaft adjuster (7); pull out the pin from the bore (arrow E) on chain tensioner (9) An aid for pressing down the timing chain (6) is required.

14 Remove screw plug (4) on timing case cover (5) Use new sealing ring.

*BA01.40-P-1008-01M 15 Turn engine in direction of engine rotation through two revolutions

16 Again check basic position of intake camshaft (10) and exhaust camshaft (2) Repeat steps 2 to 16 times if necessary.

• not for USA AR05.20-P-6010MCC

* for USA only

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 699 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-6010MCU, AR40.10-P-1100MCC, AR40.10-P-1100MCU, AR01.20-P-5014MCC, AR01.20-P-5014MCU

AR05.20-P-6010MCU 17 Install cover for the belt pulley (11)

18 Attach right rear wheel * not for USA AR40.10-P-1100MCC

• for USA only AR40.10-P-1100MCU 19 Install cylinder head cover

• not for USA AR01.20-P-5014MCC

• for USA only AR01.20-P-5014MCU CRANKCASE, TIMING CASE COVER, END COVER Number Designation Engine 132.9 BA01.40-P-1008- 01M Screw plug at timing case cover Nm 50 CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1005- 01M Bolt connecting camshaft sprocket to exhaust camshaft Nm 90 Fig 4: Identifying Plug-In Adapter (001 589 01 16 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Box Wrench Bit (001 589 01 16 09) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL CAMSHAFT SPROCKET - AR05.20-P-6040MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 700 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-6040MCU

ENGINE 132.910 in MODEL 451.3/4

Remove/install

1 Remove spark plugs

Replace spark plugs

AP15.10-P- 1580MCU 2 Remove cylinder head cover

AR01.20-P- 5014MCU 3 Counterhold exhaust camshaft (2) at hexagon (arrow A) and loosen bolt (3) on camshaft sprocket (1) *001589011601

*001589011609

*BA05.20-P- 1005-01M 4 Detach right rear wheel

AR40.10-P- 1100MCU 5 Check basic position of intake camshaft and exhaust camshaft (2) Installation: Turn engine in direction of engine rotation through two revolutions and check basic position of intake camshaft and exhaust camshaft (2). AR05.20-P- 6010MCU Remove screw plug (4) on timing *BA01.40-P- Fig 1: Identifying Camshaft Sprocket Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

8. Loosen bolts (12 to 17) for bearing cap (18) in a number of stages according to the represented

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 704 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-6992MCU

sequence until the back pressure is dissipated. Installation: Screw in bolts (12 ti 17) in the reverse order in a number of stages all the way and tighten using the prescribed torque. 9. Remove bolts (12 to 17) and take off bearing cap (18). Installation: Clean contact surfaces of bearing cap (18) and wet with engine oil. Pay attention to installation position. The arrows on the bearing caps (18) must be aligned straight to the control side. The bearing caps (18) are numbered in ascending order starting from the control side. 10. Install in the reverse order. TESTING & REPAIR > REMOVE/INSTALL CAMSHAFTS - AR05.20-P-6992MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 2: Removing Intake Camshaft Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

cam haft (2) for

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 707 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-7201MCU

10 cam haft (2) for wear; replace intake camshaft (1) or exhaust camshaft (2) if necessary

11 Install in the reverse order

CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1001- 01M Bolt, camshaft bearing bridge to cylinder head Nm 20 BA05.20-P-1002- 01M Bolt connecting camshaft bearing cap to cylinder head Nm 11 TESTING & REPAIR > REMOVE/INSTALL CAMSHAFTS - AR05.20-P-7201MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install

1 Remove inlet camshaft (2)

AR05.20- P- 6992MCU 2 Clamp intake camshaft (2) on hexagon into a vise Use protective jaws otherwise the intake camshaft (2) can be damaged.

3 Remove bolt (3) and camshaft adjuster (1) from intake camshaft (2) Installation: Place camshaft adjuster (1) in such a way that the pin on the intake camshaft (2) coincides with the respective bore in the camshaft adjuster (1).

*BA05.20- P-1004- Fig 1: Identifying Camshaft Adjuster, Intake Camshaft & Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install in the reverse

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 708 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-7295MCU

01M 4 Install in the reverse order

CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1004- 01M Bolt connecting camshaft adjuster to intake camshaft Nm 90 TESTING & REPAIR > REMOVE/INSTALL SOLENOID CHAMSHAFT - AR05.20-P-7295MCU

ENGINE 132.910 in MODEL 451.3/4

Remove/install

1 Remove interior flap above engine

AR88.40- P-1100- 03MCC 2 Disconnect electrical connector (1) on adjustable camshaft timing solenoid (Y49)

3 Unscrew bolt (2) *BA05.20- P-1006- 01M 4 Pull adjustable camshaft timing solenoid (Y49) out of cylinder Ensure that no dirt can find its way into oil holes on the adjustable camshaft timing solenoid (Y49) or in the bore in the cylinder head otherwise damage can occur on the engine. Installation:

Fig 1: Identifying Adjustable Camshaft Timing Solenoid, Electrical Connector And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

head

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 709 · Applies to: 450, 451, 452, 454 · AR: AR05.30-P-3510MCC

Check sealing ring on the adjustable camshaft timing solenoid (Y49); replace if necessary. 5 Install in the reverse order

6 Read out fault memory, erase if necessary When replacing the adjustable camshaft timing solenoid (Y49).

Connect STAR DIAGNOSIS and read out fault memory

AD00.00- P-2000- 04MCC Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 7 Conduct engine test run and check leaktightness of adjustable camshaft timing solenoid (Y49)

CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1006- 01M Bolt, camshaft solenoid to cylinder head Nm 11 TESTING & REPAIR > REPLACE VALVE STEM SEALS. - AR05.30-P-3510MCC > ENGINES 132.9 in MODEL 451.3/4

Remove

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 710 · Applies to: 450, 451, 452, 454 · AR: AR01.30-P-5800MCC, AR01.30-P-5800MCU

1 Remove cylinder head * Not for USA AR01.30-P-5800MCC

• For USA only AR01.30-P-5800MCU 2 Cut fuel hose with an inside diameter of 6 mm to a length of about 5 cm

3 Lay cylinder head on the wooden plate and lay the cut to length fuel hose in the combustion chamber under the valves

4 Screw in thread extension (1) and counter stay (2) in the area of the respective valves into a threaded hole on the cylinder head Valve assembly tool case *111589256100 Fig 1: Identifying Valve Spring Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Replacing Valve Stem Seal Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Depressor

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 712 · Applies to: 450, 451, 452, 454 · AR: AR01.30-P-5800MCC, AR01.30-P-5800MCU

*272589006100 14 Position depressor (4) in the middle on the valve spring retainer (6) and press together valve spring (7) through pressing down the lever handle, insert the valve conical pieces (5) on the valve stem (10) in the cutout and then relieve the valve spring retainer (6) Check for correct seating of the valve conical pieces (5); repeat the operation step if necessary.

Valve assembly tool case *111589256100

Depressor 272589006100 15 Remove thrust fork (3) with depressor (4) and lever handle Valve assembly tool case 111589256100

Depressor 272589006100 16 Remove thread extension (1) and counter stays (2) on the cylinder head Valve assembly tool case 111589256100

Thread extension for retaining fork *451589011600 17 Repeat operation steps 3 to 16 until all valve stem seals (9) have been replaced by new valve stem seals (11)

18 Install cylinder head * Not for USA AR01.30-P-5800MCC

• For USA only AR01.30-P-5800MCU Fig 3: Identifying Case For Valve Installation Tools (111 589 25 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL VALVES - AR05.30-P-3511MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 713 · Applies to: 450, 451, 452, 454 · AR: AR05.30-P-3511MCC

ENGINES 132.9 in MODEL 451.3/4 Fig 4: Identifying Drift (132 589 00 43 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Depressor (272 589 00 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Thread Extension For Retaining Fork (451 589 01 16 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 714 · Applies to: 450, 451, 452, 454 · AR: AR05.30-P-3510MCC

1 Remove valve stem seals (5)

AR05.30-P-3510MCC 2 Remove valve spring retainer (4) from cylinder head (1)

3 Turn over cylinder head (1) and remove intake valves (2) and exhaust valves (3) with the valve grinding tool (6) out of the cylinder head (1) Check surfaces of valve stems, valve seats and valve guides by means of a visual inspection for roughness and ridging, replace intake valves (2), exhaust valves (3) or cylinder head (1) if necessary.Mark installation position if the removed intake valves (2) and exhaust valves (3) are reinstalled.

Repair tools for valves *452589019900 Install

4 Insert intake valves (2) and exhaust valve (3) into cylinder head (1) If removed intake valves (2) and exhaust valves (3) are used again then these should be reinserted in the same position.

5 Turn over the cylinder head

Fig 1: Removing/Installing Valves Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

(1) and in ert valve pring

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 715 · Applies to: 450, 451, 452, 454 · AR: AR05.30-P-3510MCC, AR05.30-P-3512MCC

retainer (4) in the cylinder head 6 Replace valve stem seals (5).

AR05.30-P-3510MCC TESTING & REPAIR > REPLACE VALVE STEM SEALS WITH CYLINDER HEAD INSTALLED - AR05.30-P-3512MCC > ENGINES 132.9 in MODEL 451.3/4 Fig 2: Identifying Repair Tools For Valves (452 589 01 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Removing Valve Tappet Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

* not for USA

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 717 · Applies to: 450, 451, 452, 454 · AR: AR15.30-P-7100MCC, AR15.30-P-7100MCU, AP15.10-P-1580MCC, AP15.10-P-1580MCU

451.334/380/480)

• not for USA AR15.30-P-7100MCC

• for USA only AR15.30-P-7100MCU 5.2 Remove transmission cover Model 451.334/380/480 AR26.30-P-0310- 01MCC

• not for USA

6 Install retaining lock for engine

AR03.30-P-1600- 06MCE

Retaining lock *451589014000 7 Remove spark plugs * not for USA AP15.10-P-1580MCC

• for USA only AP15.10-P-1580MCU 8 Screw adaptation (2) into the respective spark plug bore and attach compressed air hose Adaptation *450589019100 9 Apply compressed air to cylinder This avoids the valve falling into the combustion chamber.

10 Screw in thread extension (3) and counter stay (4) in the area of the respective valves into a threaded hole on the cylinder head Thread extension for retaining fork *451589011600

Repair tools for valves *452589019900 11 Remove valve tappet (1) to the respective valves from the basic bore in the cylinder head Do not use magnets. Gathering of the smallest metal shavings can occur due to magnetization of the valve tappet (1) which can lead to damage of valve tappet (1) and camshaft. When recycling the valve tappet (1), it must be reinstalled at the same location. The valve tappets (1) are designed in various thicknesses to compensate for the valve clearance. The dimension for the thickness of the valve tappet (1) is located on its underside.

12 Attach lever handle and depressor (6) to the thrust fork (5) and hook into the counter stay (4) Depressor *272589006100

through pressing down the

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 719 · Applies to: 450, 451, 452, 454 · AR: AP15.10-P-1580MCC, AP15.10-P-1580MCU, AR15.30-P-7100MCC, AR15.30-P-7100MCU

lever handle, insert the valve conical pieces (7) on the valve stem (12) in the cutout and then relieve the valve spring retainer (8)

Depressor *272589006100

Repair tools for valves 452589019900 22 Remove thrust fork (5) with depressor (6) and lever handle Depressor 272589006100

Repair tools for valves *452589019900 23 Insert valve tappet (1) on the respective valve in the basic bore in the cylinder head When recycling the valve tappet (1), it must be reinstalled at the same location. The valve tappets (1) are designed in various thicknesses to compensate for the valve clearance. The dimension for the thickness of the valve tappet (1) is located on its underside.

24 Remove thread extension (3) and counter stays (4) on the cylinder head Thread extension for retaining fork *451589011600

Repair tools for valves *452589019900 25 Repeat operation steps 8 to 24 until all valve stem seals (11) have been replaced by new valve stem seals (13)

26 Disconnect compressed air hose and remove adaptation (2) from the spark plug bore Adaptation *450589019100 27 Install spark plugs * not for USA AP15.10-P-1580MCC

• for USA only AP15.10-P-1580MCU 28 Remove retaining lock for engine

AR03.30-P-1600- 06MCE

Retaining lock *451589014000 29.1 Install starter Model 451.3/4 except 451.334/380/480

• not for USA AR15.30-P-7100MCC

• for USA only AR15.30-P-7100MCU 29.2 Install transmission cover Model 451.334/380/480* not for USA AR26.30-P-0310- 01MCC

Install intake camshaft and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 720 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-6992MCC, AR05.20-P-6992MCU, AP05.30-P-0560MCC, AP05.30-P-0560MCU, AR01.00-P-3050MCC (+4 more)

30 Install intake camshaft and exhaust camshaft The timing chain is not yet installed since the valve clearance should be checked before assembly.

• not for USA AR05.20-P-6992MCC

• for USA only AR05.20-P-6992MCU 31 Check valve clearance, set if necessary

• not for USA AP05.30-P-0560MCC

• for USA only AP05.30-P-0560MCU 32 Lift and fasten rear drive module

• not for USA AR01.00-P-3050MCC

• for USA only AR01.00-P-3050MCU 33 Install CBS rear end

AR88.20-P-1900MCC 34 Install fender liner in the left and right rear fender * not for USA AR88.10-P-1400MCC

• for USA only AR88.10-P-1400MCU Fig 4: Identifying Drift (132 589 00 43 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Depressor (272 589 00 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

1000-01P >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 723 · Applies to: 450, 451, 452, 454 · AR: BE05.00-Z-9999CZ

Model 451.3/4 with engine 132.9 TIMING CHAIN DRIVER Number Designation Engine 132.9 BA05.10-P-1001- 01P Bolt, timing chain tensioning rail to cylinder head Nm 23 BA05.10-P-1002- 01P Bolt, timing chain slide rail to cylinder head Nm 10 BA05.10-P-1003- 01P Bolt, timing chain slide rail to crankcase Nm 10 BA05.10-P-1004- 01P Bolt, cam chain tensioner to crankcase Nm 9 TORQUE SPECIFICATIONS > CAMSHAFT - BA05.20-P-1000-01M > Model 451.3/4 with engine 132.9 CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1001- 01M Bolt, camshaft bearing bridge to cylinder head Nm 20 BA05.20-P-1002- 01M Bolt connecting camshaft bearing cap to cylinder head Nm 11 BA05.20-P-1004- 01M Bolt connecting camshaft adjuster to intake camshaft Nm 90 BA05.20-P-1005- 01M Bolt connecting camshaft sprocket to exhaust camshaft Nm 90 BA05.20-P-1006- 01M Bolt, camshaft solenoid to cylinder head Nm 11 TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: ENGINE TIMING - BE05.00-Z-9999CZ > MODEL all Test values for valve seat rings ENGINE 160.910 /920 /921 /922 BE05.30-P-1000-03D Valve clearance ENGINE 132.9, 134, 135 BE05.30-P-1000-06C TEST & ADJUSTMENT VALUES > VALVE CLEARANCE - BE05.30-P-1000-06C > Engine 132.9, 134, 135 CHECK VALUES FOR VALVE CLEARANCE

Number

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 724 · Applies to: 450, 451, 452, 454 · AR: GF05.20-P-1110MCC, GF05.20-P-2100MCC

Designation Engine 132.9 Engine 134 Engine 135 BE05.30-P- 1001-06C Intake valve on cold engine (approx. 20°C) mm 0.18 to 0.26 0.22 ± 0.04 0.22 ± 0.04 BE05.30-P- 1002-06C Exhaust valve on cold engine (approx. 20°C) mm 0.26 to 0.34 0.30 ± 0.04 0.30 ± 0.04 BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE CAMSHAFT ADJUSTER - GF05.20-P-1110MCC > ENGINE 132.9 in MODEL 451.3/4 Location The camshaft adjuster is located on the side on the engine on the intake camshaft. Task The camshaft adjuster allows the intake camshaft to be turned in the direction "advanced" (large valve overlap) or "retarded" (low valve overlap). BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR ADJUSTABLE CAMSHAFT TIMING SOLENOID - GF05.20-P-2100MCC > ENGINE 132.9 in MODEL 451.3/4 Fig 1: Locating Camshaft Adjuster And Adjustable Camshaft Timing Solenoid Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MAINTENANCE > SET VALVE CLEARANCE - AP05.30-P-0560MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 740 · Applies to: 450, 451, 452, 454 · AR: AP05.30-P-0560MCU

ENGINE 132.910 in MODEL 451.3 /4 Removing

1 Remove cylinder head cover

Remove, install cylinder head cover

AR01.10- P-1000- 01MCU 2 Detach right rear wheel

Remove/install wheels

AR01.20- P- 5014MCU Checking

3 Turn engine into the TDC position

Turn engine into the TDC position

AR40.10- P- 1100MCU 4 Lower vehicle with lifting platform

Check whether the valves of the 1st cylinder are relieved of load, Fig 1: Identifying Intake And Exhaust Camshaft Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install valve tappets

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 742 · Applies to: 450, 451, 452, 454 · AR: AR05.00-P-2310MCU

AR05 00 P- 2310MCU 11 Recheck valve clearance and adjust if necessary

Install

12 Position V-belt cover and install expansion clips

13 Attach right rear wheel

Remove/install wheels

AR40.10- P- 1100MCU 14 Install cylinder head cover

Remove, install cylinder head cover

AR01.20- P- 5014MCU CHECK VALUES FOR VALVE CLEARANCE Number Designation Engine 132.9 BE05.30-P-1001-06C Intake valve on cold engine (approx. 20°C) mm 0,18 to 0,26 BE05.30-P-1002-06C Exhaust valve on cold engine (approx. 20°C) mm 0,26 to 0,34 TESTING & REPAIR INDEX > REMOVE/INSTALL VALVE TAPPETS - AR05.00-P-2310MCU

ENGINE 132.910 in MODEL 451.3/4 Remove/install

Remove intake camshaft (2) or AR05.20- Fig 1: Identifying Valve Tappet With Intake And Exhaust Camshaft Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

exhaust

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 743 · Applies to: 450, 451, 452, 454 · AR: AR05.00-Z-9132CB, AR05.20-P-6010MCC, AR05.20-P-6010MCU, AR05.20-P-6025MCC, AR05.10-P-8127MCC (+5 more)

1 exhaust camshaft (3) over the relevant valve tappet (1)

P- 6992MCU 2 Remove valve tappet (1) from basic bore in cylinder head Do not use magnets. Magnetization of the valve tappet (1) can lead to gathering of the smallest metal chips which can lead to damage to the valve tappet (1) and intake camshaft (2) or exhaust camshaft (3) Installation: When recycling the valve tappet (1), it must be reinstalled at the same location. The valve tappets (1) are designed in various thicknesses to compensate for the valve clearance. The dimension for the thickness of the valve tappet (1) is located on its underside.

Checking

3 Check basic bores in cylinder head In case of damage to the basic bore in the cylinder head, the cylinder head must be replaced, see: ↓

Remove/install cylinder head AR01.30- P- 5800MCU 4 Install in the reverse order

TESTING & REPAIR INDEX > TESTING AND REPAIR WORK: SMART: ENGINE TIMING - AR05.00-Z-9132CB > ENGINE 132 Check basic position of camshafts ENGINES 132.9 in MODEL 451.3 /4 AR05.20-P-6010MCC Check basic position of camshafts ENGINES 132.910 in MODEL 451.3 /4 AR05.20-P-6010MCU Correct basic position of camshafts ENGINES 132.9 in MODEL 451.3 /4 AR05.20-P-6025MCC Remove, install tensioning rail ENGINE 132.9 in MODEL 451.3 /4 AR05.10-P-8127MCC Remove, install tensioning rail ENGINE 132.910 in MODEL 451.3 /4 AR05.10-P-8127MCU Remove/install camshaft sprocket ENGINE 132.9 in MODEL 451.3 /4 AR05.20-P-6040MCC Remove/install camshaft sprocket ENGINE 132.910 in MODEL 451.3 /4 AR05.20-P-6040MCU Remove/install camshafts ENGINE 132.9 in MODEL 451.3 /4 AR05.20-P-6992MCC Remove/install camshafts ENGINE 132.910 in MODEL 451.3 /4 AR05.20-P-6992MCU

Remove/install camshafts

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 744 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-7201MCC, AR05.20-P-7201MCU, AR05.10-P-7800MCC, AR05.10-P-7800MCU, AR05.10-P-8128MCC (+5 more)

ENGINE 132.9 in MODEL 451.3 /4 AR05.20-P-7201MCC Remove/install camshafts ENGINE 132.910 in MODEL 451.3 /4 AR05.20-P-7201MCU Remove/install chain tensioner ENGINE 132.9 in MODEL 451.3 /4 AR05.10-P-7800MCC Remove/install chain tensioner ENGINE 132.910 in MODEL 451.3 /4 AR05.10-P-7800MCU Remove/install slide rail of timing chain ENGINE 132.9 in MODEL 451.3 /4 AR05.10-P-8128MCC Remove/install slide rail of timing chain ENGINE 132.910 in MODEL 451.3 /4 AR05.10-P-8128MCU Remove/install solenoid camshaft ENGINE 132.9 in MODEL 451.3 /4 AR05.20-P-7295MCC Remove/install solenoid camshaft ENGINE 132.910 in MODEL 451.3 /4 AR05.20-P-7295MCU Remove/install valve tappets ENGINE 132.9 in MODEL 451.3 /4 AR05.00-P-2310MCC Remove/install valve tappets ENGINE 132.910 in MODEL 451.3 /4 AR05.00-P-2310MCU Remove/install valves ENGINES 132.9 in MODEL 451.3 /4 AR05.30-P-3511MCC Replace timing chain ENGINE 132.9 in MODEL 451.3 /4 AR05.10-P-7601MCC Replace timing chain ENGINE 132.910 in MODEL 451.3 /4 AR05.10-P-7601MCU Replace valve stem seals. ENGINES 132.9 in MODEL 451.3 /4 AR05.30-P-3510MCC Replace valve stem seals with cylinder head installed ENGINES 132.9 in MODEL 451.3 /4 AR05.30-P-3512MCC Set basic position of camshafts ENGINES 132.9 in MODEL 451.3 /4 AR05.20-P-6020MCC Set basic position of camshafts ENGINES 132.910 in MODEL 451.3 /4 AR05.20-P-6020MCU TESTING & REPAIR INDEX > REPLACE TIMING CHAIN - AR05.10-P-7601MCU > ENGINE 132.910 in MODEL 451.3/4

Checking

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 753 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-6010MCU, AR05.20-P-6025MCC

1 Check basic position of camshafts AR05.20-P-6010MCU

Adjust

2 Correct basic position of intake camshaft and exhaust camshaft AR05.20-P-6025MCC 3 Install in the reverse order

TESTING & REPAIR INDEX > CORRECT BASIC POSITION OF CAMSHAFTS - AR05.20-P- 6025MCC > ENGINES 132.9 in MODEL 451.3/4 Fig 1: Identifying Crankshaft Belt Pulley And Timing Case Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

8. Loosen bolts (12 to 17) for bearing cap (18) in a number of stages according to the represented

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 762 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-6992MCU

sequence until the back pressure is dissipated. Installation: Screw in bolts (12 to 17) in the reverse order in a number of stages all the way and tighten using the prescribed torque. 9. Remove bolts (12 to 17) and take off bearing cap (18). Installation: Clean contact surfaces of bearing cap (18) and wet with engine oil. Pay attention to installation position. The arrows on the bearing caps (18) must be aligned straight to the control side. The bearing caps (18) are numbered in ascending order starting from the control side. 10. Install in the reverse order. TESTING & REPAIR INDEX > REMOVE/INSTALL CAMSHAFTS - AR05.20-P-6992MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 2: Position For Intake Camshaft Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

cam haft (2) for

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 765 · Applies to: 450, 451, 452, 454 · AR: AR05.20-P-7201MCU

10 cam haft (2) for wear; replace intake camshaft (1) or exhaust camshaft (2) if necessary

11 Install in the reverse order

CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1001- 01M Bolt, camshaft bearing bridge to cylinder head Nm 20 BA05.20-P-1002- 01M Bolt connecting camshaft bearing cap to cylinder head Nm 11 TESTING & REPAIR INDEX > REMOVE/INSTALL CAMSHAFTS - AR05.20-P-7201MCU > ENGINE 132.910 in MODEL 451.3/4 Remove/install

1 Remove inlet camshaft (2)

AR05.20- P- 6992MCU 2 Clamp intake camshaft (2) on hexagon into a vise Use protective jaws otherwise the intake camshaft (2) can be damaged.

3 Remove bolt (3) and camshaft adjuster (1) from intake camshaft (2) Installation: Place camshaft adjuster (1) in such a way that the pin on the intake camshaft (2) coincides with the respective bore in the camshaft adjuster (1).

*BA05.20- P-1004- Fig 1: Identifying Camshaft Adjuster, Intake Camshaft With Mounting Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

camshaft timing solenoid (Y49); replace if

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 767 · Applies to: 450, 451, 452, 454 · AR: AR05.30-P-3510MCC

necessary. 5 Install in the reverse order

6 Read out fault memory, erase if necessary When replacing the adjustable camshaft timing solenoid (Y49).

Connect STAR DIAGNOSIS and read out fault memory

AD00.00- P-2000- 04MCC Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 7 Conduct engine test run and check leaktightness of adjustable camshaft timing solenoid (Y49)

CAMSHAFT Number Designation Engine 132.9 BA05.20-P-1006-01M Bolt, camshaft solenoid to cylinder head Nm 11 TESTING & REPAIR INDEX > REPLACE VALVE STEM SEALS. - AR05.30-P-3510MCC > ENGINES 132.9 in MODEL 451.3 /4 Fig 1: Identifying Valve Stem Seals (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > REMOVE/INSTALL VALVES - AR05.30-P-3511MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 771 · Applies to: 450, 451, 452, 454 · AR: AR05.30-P-3511MCC

ENGINES 132.9 in MODEL 451.3 /4 Remove

1 Remove valve stem seals (5)

AR05.30- P- 3510MCC 2 Remove valve spring retainer (4) from cylinder head (1)

Turn over cylinder head Check surfaces of valve stems, valve seats and valve guides by means of a visual inspection for Fig 6: Identifying Thread Extension For Retaining Fork (451 589 01 16 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Valves Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BA05.20-P-1005-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 774 · Applies to: 450, 451, 452, 454 · AR: BE05.00-Z-9999CZ, GF05.20-P-1110MCC

01M BA05.20-P-1005- 01M Bolt connecting camshaft sprocket to exhaust camshaft Nm 90 BA05.20-P-1006- 01M Bolt, camshaft solenoid to cylinder head Nm 11 TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: ENGINE TIMING - BE05.00-Z-9999CZ > MODEL all

Test values for valve seat rings ENGINE 160.910 /920 /921 /922 BE05.30-P-1000-03D

Valve clearance ENGINE 132.9, 134, 135 BE05.30-P-1000-06C TEST & ADJUSTMENT VALUES > VALVE CLEARANCE - BE05.30-P-1000-06C > Engine 132.9, 134, 135 CHECK VALUES FOR VALVE CLEARANCE Number Designation Engine 132.9 Engine 134 Engine 135 BE05.30-P- 1001-06C Intake valve on cold engine (approx. 20°C) mm 0.18 to 0.26 0.22 ± 0.04 0.22 ± 0.04 BE05.30-P- 1002-06C Exhaust valve on cold engine (approx. 20°C) mm 0.26 to 0.34 0.30 ± 0.04 0.30 ± 0.04 BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE CAMSHAFT ADJUSTER - GF05.20-P-1110MCC > ENGINE 132.9 in MODEL 451.3/4 Location The camshaft adjuster is located on the side on the engine on the intake camshaft. Task The camshaft adjuster allows the intake camshaft to be turned in the direction "advanced" (large valve overlap) or "retarded" (low valve overlap).

BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR ADJUSTABLE CAMSHAFT

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 775 · Applies to: 450, 451, 452, 454 · AR: GF05.20-P-2100MCC

TIMING SOLENOID - GF05.20-P-2100MCC > ENGINE 132.9 in MODEL 451.3/4 Location The adjustable camshaft timing solenoid is located at the upper right on the cylinder head. Task The adjustable camshaft timing solenoid controls the oil pressure for the camshaft adjuster. Fig 1: Identifying Camshaft Adjuster And Adjustable Camshaft Timing Solenoid Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: EXHAUST MANIFOLD,

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 792 · Applies to: 450, 451, 452, 454 · AR: AR14.00-Z-9132CB, AR14.10-P-3915MCB, AR14.10-P-3915MCC, AR14.30-P-7150MCU, AR14.30-P-8000MCU (+2 more)

ENGINE BRAKE, EMISSION CONTROL SYSTEM - AR14.00-Z-9132CB > ENGINE 132 Remove/install exhaust manifold ENGINES 132.930 in MODEL 451.3/4 AR14.10-P-3915MCB Remove/install exhaust manifold ENGINES 132.910 in MODEL 451.3/4 up to 30.8.10 AR14.10-P-3915MCC Remove/install pipework for secondary air system ENGINE 132.910 in MODEL 451.3/4 AR14.30-P-7150MCU Remove/install secondary air injection pump ENGINE 132.910 in MODEL 451.3/4 AR14.30-P-8000MCU Remove/install secondary air injection pump switchover valve ENGINE 132.910 in MODEL 451.3/4 AR14.30-P-8100MCU Remove/install valve for secondary air system ENGINE 132.910 in MODEL 451.3/4 AR14.30-P-8200MCU TESTING & REPAIR > REMOVE/INSTALL PIPEWORK FOR SECONDARY AIR SYSTEM - AR14.30-P-7150MCU > ENGINE 132.910 in MODEL 451.3/4

SWITCHOVER VALVE - AR14.30-P-8100MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 796 · Applies to: 450, 451, 452, 454 · AR: AR14.30-P-8100MCU, AR14.30-P-8200MCU

ENGINE 132.910 in MODEL 451.3/4

Remove/install

1 Remove interior flap above engine AR88.40-P-1100- 03MCC 2 Unlock (arrow) and remove secondary air injection pump switchover valve (Y32) on holder (1)

3 Disconnect electrical connector (3) at secondary air injection pump switchover valve (Y32)

4 Detach vacuum hoses (3) on secondary air injection pump switchover valve (Y32) and remove secondary air injection pump switchover valve (Y32)

5 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL VALVE FOR SECONDARY AIR SYSTEM - AR14.30-P-8200MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 1: Identifying Secondary Air Injection Pump Switchover Valve Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

head

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 801 · Applies to: 450, 451, 452, 454 · AR: GF14.30-P-2050MCU, GF14.30-P-2055MCU

03C head BA14.30-P-1003- 03C Bolt, pipe for secondary air injection to valve for secondary air injection Nm 8 BASIC KNOWLEDGE > SECONDARY AIR INJECTION PUMP, COMPONENT DESCRIPTION - GF14.30-P-2050MCU > ENGINES 132.9 in MODEL 451.3/4 Location The secondary air injection pump is located at the rear right on the engine support. Task The secondary air injection pump delivers fresh air from the air filter to the secondary air valve when air injection is enabled. Function The secondary air injection pump is actuated via the secondary air injection pump relay (K64) by the ME-SFI [ME] control unit (N3/10) when air injection is enabled. BASIC KNOWLEDGE > SECONDARY AIR INJECTION PUMP SWITCHOVER VALVE, COMPONENT DESCRIPTION - GF14.30-P-2055MCU > ENGINES 132.9 in MODEL 451.3/4 Fig 1: Locating Secondary Air Injection Pump Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Function

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 803 · Applies to: 450, 451, 452, 454 · AR: GF14.30-P-2060MCU

The secondary air injection pump switchover valve is directly actuated by the ME-SFI [ME] control unit (N3/10) with a ground signal when air injection is enabled. As a result, the armature plate (a) is attracted by the solenoid (d) and the rubber seal (f) shuts off the aeration connection (1). The connection between the vacuum supply connection (2) and the secondary air valve connection (3) is released and the vacuum is created from the intake manifold to the secondary air valve. In a deenergized state, the connection between the aeration connection (1) and the secondary air valve connection (3) is reestablished, vacuum actuation up to the secondary air valve is interrupted. BASIC KNOWLEDGE > SECONDARY AIR INJECTION PUMP RELAY, COMPONENT DESCRIPTION - GF14.30-P-2060MCU > ENGINES 132.9 in MODEL 451.3/4 Location The secondary air injection pump relay is located in the driver footwell above the accelerator pedals. Task The ME-SFI [ME] control unit (N3/10) actuates the secondary air injection pump (M33) via the secondary air injection pump relay. SPECIAL TOOLS > 450 589 04 09 00 SOCKET WRENCH BIT - WS14.00-P-0005B > FG 14/Set B MODEL 450, 452, 454 MODEL 451 with ENGINE 132 Fig 1: Locating Secondary Air Injection Pump Relay Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: EXHAUST MANIFOLD,

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 806 · Applies to: 450, 451, 452, 454 · AR: AR14.00-Z-9132CB, AR14.10-P-3915MCB, AR14.10-P-3915MCC, AR14.30-P-7150MCU, AR14.30-P-8000MCU (+2 more)

ENGINE BRAKE, EMISSION CONTROL SYSTEM - AR14.00-Z-9132CB > ENGINE 132 Remove/install exhaust manifold ENGINES 132.930 in MODEL 451.3 /4 AR14.10-P-3915MCB Remove/install exhaust manifold ENGINES 132.910 in MODEL 451.3 /4 up to 30.8.10 AR14.10-P-3915MCC Remove/install pipework for secondary air system ENGINE 132.910 in MODEL 451.3 /4 AR14.30-P-7150MCU Remove/install secondary air injection pump ENGINE 132.910 in MODEL 451.3 /4 AR14.30-P-8000MCU Remove/install secondary air injection pump switchover valve ENGINE 132.910 in MODEL 451.3 /4 AR14.30-P-8100MCU Remove/install valve for secondary air system ENGINE 132.910 in MODEL 451.3 /4 AR14.30-P-8200MCU TESTING & REPAIR > REMOVE/INSTALL PIPEWORK FOR SECONDARY AIR SYSTEM - AR14.30-P-7150MCU > ENGINE 132.910 in MODEL 451.3/4

remove e pan ion clip (10) and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 810 · Applies to: 450, 451, 452, 454 · AR: AR14.30-P-8100MCU

8 remove e pan ion clip (10) and remove rubber disks between the holder (7) and the noise damper (11)

9 Remove secondary air injection pump (M33) with noise damper (11) from holder (7)

10 Detach molded hose (12) on secondary air injection pump (M33) and remove together with the noise damper (11)

11 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL SECONDARY AIR INJECTION PUMP SWITCHOVER VALVE - AR14.30-P-8100MCU > ENGINE 132.910 in MODEL 451.3 /4

Remove/install

1 Remove interior flap above engine AR88.40-P-1100- 03MCC 2 Unlock (arrow) and remove secondary air injection pump switchover valve (Y32) on holder (1)

3 Disconnect electrical connector (3) at secondary air injection pump switchover valve (Y32)

Fig 1: Identifying Secondary Air Injection Pump Switchover Valve Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Detach vacuum hoses (3) on secondary air

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 811 · Applies to: 450, 451, 452, 454 · AR: AR14.30-P-8200MCU

4 Detach vacuum hoses (3) on secondary air injection pump switchover valve (Y32) and remove secondary air injection pump switchover valve (Y32)

5 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL VALVE FOR SECONDARY AIR SYSTEM - AR14.30-P-8200MCU > ENGINE 132.910 in MODEL 451.3 /4 Remove/install

1 Remove interior flap above engine

AR88.40- P-1100- 03MCC 2 Detach vacuum hose (2) at secondary air injection pump switchover valve (1)

3 Detach supply line (3) at secondary air injection pump switchover valve (1)

4 Disconnect connector O2 for sensor upstream of TWC (G3/2x1) and unclip from holder to the cylinder head cover

Fig 1: Identifying Secondary Air System Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BA14.30-P-1001-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 815 · Applies to: 450, 451, 452, 454 · AR: GF14.30-P-2050MCU, GF14.30-P-2055MCU

03C Bolt, valve for secondary air injection to cylinder head Nm 20 BA14.30-P-1002- 03C Bolt, pipe for secondary air injection to cylinder head Nm 8 BA14.30-P-1003- 03C Bolt, pipe for secondary air injection to valve for secondary air injection Nm 8 BASIC KNOWLEDGE > SECONDARY AIR INJECTION PUMP, COMPONENT DESCRIPTION - GF14.30-P-2050MCU > ENGINES 132.9 in MODEL 451.3 /4 Location The secondary air injection pump is located at the rear right on the engine support. Task The secondary air injection pump delivers fresh air from the air filter to the secondary air valve when air injection is enabled. Function The secondary air injection pump is actuated via the secondary air injection pump relay (K64) by the ME-SFI [ME] control unit (N3/10) when air injection is enabled. BASIC KNOWLEDGE > SECONDARY AIR INJECTION PUMP SWITCHOVER VALVE, COMPONENT DESCRIPTION - GF14.30-P-2055MCU > Fig 1: Identifying Secondary Air Injection Pump Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Function

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 817 · Applies to: 450, 451, 452, 454 · AR: GF14.30-P-2060MCU

The secondary air injection pump switchover valve is directly actuated by the ME-SFI [ME] control unit (N3/10) with a ground signal when air injection is enabled. As a result, the armature plate (a) is attracted by the solenoid (d) and the rubber seal (f) shuts off the aeration connection (1). The connection between the vacuum supply connection (2) and the secondary air valve connection (3) is released and the vacuum is created from the intake manifold to the secondary air valve. In a deenergized state, the connection between the aeration connection (1) and the secondary air valve connection (3) is reestablished, vacuum actuation up to the secondary air valve is interrupted. BASIC KNOWLEDGE > SECONDARY AIR INJECTION PUMP RELAY, COMPONENT DESCRIPTION - GF14.30-P-2060MCU > ENGINES 132.9 in MODEL 451.3 /4 Fig 2: Cutaway View Of Secondary Air Injection Pump Switchover Valve Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

WIRING DIAGRAMS > WIRING DIAGRAM OF CENTRAL LOCKING (CL) - PE80.20-P-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 946 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU

2000MCU > MODEL 451 Wiring diagram of central locking (CL) PE80.20-P-2000-97MCU Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and plug connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in GF00.19-P-3000MCU Fig 2: Central Locking (CL) - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

WIRING DIAGRAMS > WIRING DIAGRAM OF CENTRAL LOCKING (CL) - PE80.20-P-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 978 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU

2000MCU > MODEL 451 PE80.20-P-2000- 97MCU Wiring diagram of central locking (CL)

PE80.20-P-2000- 97MCU OV00.01-P-1901- 03MCC Use of wiring diagrams

OV00.01-P-1901- 03MCC OV00.01-P-1901MCU Search aid for all wiring diagram groups

OV00.01-P-1901MCU OV00.01-P-1001- 27MC Abbreviations for wiring diagrams

OV00.01-P-1001- 27MC OV00.01-P-1001- 28MC Abbreviations of signal and circuit

OV00.01-P-1001- 28MC Fig 2: Central Locking (CL) - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

designations for wiring

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 979 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU

diagrams GF00.19-P-1000MCU Location and assignment of line and plug connectors

GF00.19-P-1000MCU GF00.19-P-2000MCU Location and assignment of ground points

GF00.19-P-2000MCU GF00.19-P-3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)

GF00.19-P-3000MCU PE54.00-P-1100MCU

Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > LEGEND OF FUNCTION SCHEMATIC FOR ANTI-THEFT ALARM (ATA) ELECTRICAL SYSTEM - PE80.50-P-2050-60MCU > MODEL 451 Code Designation Coordinates A1 Instrument cluster 3C A1e1 Left tern signal indicator lamp 1B A1e2 Right turn signal indicator lamp 1B B32 Microwave sensor 7L E1e5 Left turn signal lamp 10C E2e5 Right turn signal lamp 10D E3e11 Left brake/turn signal light 10D E4e11 Right brake/turn signal light 10D E22/1 Left additional turn signal lamp 10E E22/2 Right additional turn signal lamp 10E H3/2 Alarm siren with inclination sensor 13L L11 Transponder coil 9G M14/5s1 Right door CL [ZV] microswitch 12D M14/6s1 Left door CL [ZV] microswitch 12E N3/10 ME-SFI [ME] control unit 3K N10/10 SAM control unit 8G S2/1 Ignition/starter switch 9G S6/1s1 Hazard warning switch 7D

OV00.01-P-1001-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 982 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE07.00-P-1100MCU, PE54.00-P-1100MCU (+1 more)

27MC Abbreviations for wiring diagrams

OV00.01-P-1001- 27MC OV00.01-P-1001- 28MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P-1001- 28MC GF00.19-P-1000MCU Location and assignment of line and connectors

GF00.19-P-1000MCU GF00.19-P-2000MCU Location and assignment of ground points

GF00.19-P-2000MCU GF00.19-P-3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)

GF00.19-P-3000MCU PE07.00-P-1100MCU

Further wiring diagrams PE07.00-P-1100MCU PE54.00-P-1100MCU

Further wiring diagrams PE54.00-P-1100MCU SPECIAL TOOLS > SPECIAL TOOLS: SMART: CENTRAL LOCKING, CONVENIENCE FEATURE, DRIVE AUTHORIZATION SYSTEM - WS80.00-Z-9999CZ > MODEL all 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P-0274K

Location and assignment of ground points

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1192 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE26.00-P-1100MCU, PE54.00-P-1100MCU

GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE26.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM OF BRAKE LIGHTS AND TURN SIGNAL/HAZARD WARNING FLASHER - PE82.10-P-2220-97MCU > Code: Designation: Position: E1 Left front headlamp unit 7L E1e5 Left turn signal lamp

E2 Right front headlamp unit 17L E21 Center high-mounted stop lamp 43L E21 Center high-mounted stop lamp 39L E22/1 Left auxiliary turn signal lamp 9L E22/2 Right auxiliary turn signal lamp 19L E2e5 Right turn signal lamp

E3 Left taillamp 15L E3e11 Left brake/turn signal light

E4 Right taillamp 24L E4e11 Right brake/turn signal light

K52/11 Left turn signal/stop lamp relay 12L K52/12 Right turn signal/stop lamp relay 21L N10/10 SAM control unit 20A N10/10 SAM control unit 10A N10/10 SAM control unit 28A N10/10 SAM control unit 4A N10/10f12 Fuse 12 13A N10/10f38 Fuse 38

N47-5 ESP control module 35L S4 Combination switch 4L S6/1 Cockpit switch group 27L S6/1s1 Hazard flasher switch

S9/1 Stop lamp switch (4-pin) 31L U23 Valid for cabriolet 41B

Location and assignment of Z connector sleeves (line connectors in

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1197 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-3000MCU, PE54.00-P-1100MCU

wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM INTERIOR ILLUMINATION - PE82.20-P-2000- 97MCU > Code: Designation: Position: E15/4 Front interior lamp 7L E15/4s1 Interior lamp switch

K116 Relay for shutoff-capable interior lamp 3L N10/10 SAM control unit 4A N10/10 SAM control unit 11A N10/10f15 Fuse 15 3A S87/6 Right door rotary tumbler microswitch 14L S87/7 Left door rotary tumbler microswitch 12L U101 Valid up to 02/2009 9E U102 Valid as of 03/2009 7E U102 Valid as of 03/2009 1E W43 Ground (outside left fire wall) 14C W43 Ground (outside left fire wall) 12C W9 Ground (left front, at lamp unit) 2H W9 Ground (left front, at lamp unit) 9F X35/1 Left door separation point 12E X35/2 Right door separation point 14E Z6/35 Left door ground connector sleeve 12G Z6/36 Right door ground connector sleeve 14G Z7/59 Tml. 30 connector sleeve 3G Z7/59 Tml. 30 connector sleeve 8G

Search aid for all wiring diagram groups

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1202 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU (+2 more)

OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and plug connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM INTERIOR ILLUMINATION - PE82.20-P-2000MCV

MODEL 451 as of 31.8.10 with CODE (876) Interior lights package Wiring diagram interior illumination PE82.20-P-2000-97MCV Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and plug connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM OF WINDSCREEN WIPER - PE82.30-P-2000MCU

MODEL 451 Wiring diagram of windscreen wiper PE82.30-P-2000-99MCU Legend for wiring diagram of windshield wiper PE82.30-P-2000-60MCU Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU

03MCC

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1222 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCC, OV00.01-P-1901MCU, GF00.19-P-1000MCC, GF00.19-P-1000MCU, GF00.19-P-2000MCC (+5 more)

Search aid for all wiring diagram groups * not for USA OV00.01-P-1901MCC Search aid for all wiring diagram groups * for USA only OV00.01-P-1901MCU Abbreviations for wiring diagrams

OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P-1001-28MC Location and assignment of line and plug connectors * not for USA GF00.19-P-1000MCC Location and assignment of line and plug connectors * for USA only GF00.19-P-1000MCU Location and assignment of ground points * not for USA GF00.19-P-2000MCC Location and assignment of ground points * for USA only GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) * not for USA GF00.19-P-3000MCC Location and assignment of Z connector sleeves (line connectors in wiring harness) * for USA only GF00.19-P-3000MCU

• not for USAFurther wiring diagrams PE54.00-P-1100MCC

• only for USAFurther wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM RADIO - PE82.60-P-2000MCF > MODEL 451 as of 31.8.10 Premium radio with Sound Premium Wiring diagram radio

PE82.60-P-2000- 97MCF Use of wiring diagrams

OV00.01-P-1901- 03MCC Search aid for all wiring diagram groups * not for USA OV00.01-P-1901MCC Search aid for all wiring diagram groups * for USA only OV00.01-P-1901MCU Abbreviations for wiring diagrams

OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P-1001-28MC Location and assignment of line and plug connectors * not for USA GF00.19-P-1000MCC Location and assignment of line and plug connectors * for USA only GF00.19-P-1000MCU Location and assignment of ground points * not for USA GF00.19-P-2000MCC Location and assignment of ground points * for USA only GF00.19-P-2000MCU

Location and assignment of Z connector sleeves

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1223 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-3000MCC, GF00.19-P-3000MCU, PE54.00-P-1100MCC, PE54.00-P-1100MCU, PE82.60-P-2000MCG (+5 more)

(line connectors in wiring harness) * not for USA GF00.19-P-3000MCC Location and assignment of Z connector sleeves (line connectors in wiring harness) * for USA only GF00.19-P-3000MCU

• not for USAFurther wiring diagrams PE54.00-P-1100MCC

• only for USAFurther wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM RADIO - PE82.60-P-2000MCG > MODEL 451 as of 31.8.10 Premium radio with Sound Basis Wiring diagram radio

PE82.60-P-2000- 97MCG Use of wiring diagrams

OV00.01-P-1901- 03MCC Search aid for all wiring diagram groups * not for USA OV00.01-P-1901MCC Search aid for all wiring diagram groups * for USA only OV00.01-P-1901MCU Abbreviations for wiring diagrams

OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P-1001-28MC Location and assignment of line and plug connectors * not for USA GF00.19-P-1000MCC Location and assignment of line and plug connectors * for USA only GF00.19-P-1000MCU Location and assignment of ground points * not for USA GF00.19-P-2000MCC Location and assignment of ground points * for USA only GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) * not for USA GF00.19-P-3000MCC Location and assignment of Z connector sleeves (line connectors in wiring harness) * for USA only GF00.19-P-3000MCU

• not for USAFurther wiring diagrams PE54.00-P-1100MCC

• only for USAFurther wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM RADIO - PE82.60-P-2000MCU > MODEL 451 up to 30.8.10 Wiring diagram radio PE82.60-P-2000-97MCU

Use of wiring diagrams

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1224 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU (+1 more)

OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and plug connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU Further wiring diagrams PE82.00-P-1100MCU Fig 1: Radio Wiring Diagram (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Location and assignment of ground points

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1228 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE07.00-P-1100MCU, PE26.00-P-1100MCU, PE54.00-P-1100MCU (+1 more)

GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE07.00-P-1100MCU Further wiring diagrams PE26.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU Further wiring diagrams PE88.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM OF COMMUNICATIONS INTERFACE (KOM) - PE82.85-P-2002-97MCU > Code: Designation: Position: A2/1 smart radio 9 3L A2/2 smart radio 10 4L A34/16 PND (personal navigation device) holder 13L A34/7 Bluetooth module 19L B25/3 Bluetooth microphone 22D N4 Communication control unit 12A N4 Communication control unit 4A N4 Communication control unit 20A U16 Valid for Bluetooth

U3 Valid for PND (Personal Navigation Device) 10C U863 Valid for external audio source 7C X39/45 External audio source separation point 8L X9 Bluetooth microphone connector 21G

03MCC

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1503 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCC, OV00.01-P-1901MCU, GF00.19-P-1000MCC, GF00.19-P-1000MCU, GF00.19-P-2000MCC (+5 more)

03MCC OV00.01-P-1901MCC Search aid for all wiring diagram groups * not for USA OV00.01-P-1901MCC OV00.01-P-1901MCU Search aid for all wiring diagram groups * for USA only OV00.01-P-1901MCU OV00.01-P-1001- 27MC Abbreviations for wiring diagrams

OV00.01-P-1001-27MC OV00.01-P-1001- 28MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P-1001-28MC GF00.19-P-1000MCC Location and assignment of line and plug connectors * not for USA GF00.19-P-1000MCC GF00.19-P-1000MCU Location and assignment of line and plug connectors * for USA only GF00.19-P-1000MCU GF00.19-P-2000MCC Location and assignment of ground points * not for USA GF00.19-P-2000MCC GF00.19-P-2000MCU Location and assignment of ground points * for USA only GF00.19-P-2000MCU GF00.19-P-3000MCC Location and assignment of Z connector sleeves (line connectors in wiring harness) * not for USA GF00.19-P-3000MCC GF00.19-P-3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) * for USA only GF00.19-P-3000MCU PE54.00-P-1100MCC

• not for USAFurther wiring diagrams PE54.00-P-1100MCC PE54.00-P-1100MCU

• only for USAFurther wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM RADIO - PE82.60-P-2000-97MCE > Code: Designation: Position: A1 Instrument cluster 15L A2/20 Radio antenna 39L A2/3 smart Entry radio 12A

GF00.19-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1506 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-3000MCU, PE54.00-P-1100MCC, PE54.00-P-1100MCU

P- 3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) * for USA only GF00.19-P-3000MCU PE54.00- P- 1100MCC

• not for USAFurther wiring diagrams PE54.00-P-1100MCC PE54.00- P- 1100MCU

• only for USAFurther wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM RADIO - PE82.60-P-2000-97MCF > Code: Designation: Position: A1 Instrument cluster 15L A2/13 Sound amplifier 28L A2/20 Radio antenna 50L A2/23 GPS antenna 48L A2/4 smart Premium radio 12A A2/4 smart Premium radio 20A A2/4 smart Premium radio 51A A2/4 smart Premium radio 5A A2/4 smart Premium radio 28A A2/4 smart Premium radio 36A A2/4 smart Premium radio 44A H4/29 Subwoofer 47L H4/33 Left tweeter 36L H4/34 Right tweeter 34L H4/64 Left door ound y tem woofer 45L H4/65 Right door sound system woofer 41L H4/68 Left door sound system tweeter 43L H4/69 Right door sound system tweeter 39L H4/7 Left rear speaker 38L H4/8 Right rear speaker 35L N10/10 SAM control unit 19L N10/10f15 Fuse 15 20L N10/10f20 Fuse 20 18L N15/6 Automated manual transmission control unit 4L

ME-SFI [ME] control unit, component

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1622 · Applies to: 450, 451, 452, 454 · AR: GF07.61-P-6000MCU, GF54.21-P-4157MCU, GF26.19-P-1010MCU, GF42.45-P-5118MCU, GF46.35-P-7100MCU (+5 more)

description N3/10 GF07.61-P-6000MCU SAM control unit, component description N10/10 GF54.21-P-4157MCU Automated manual transmission control unit, component description N15/6 GF26.19-P-1010MCU ESP control unit, component description N47-5 GF42.45-P-5118MCU Electric steering control unit, component description N68For vehicles with code (V26) Power steering, EPS (FFO) GF46.35-P-7100MCU Tire pressure monitor control unit, component description N88 GF40.15-P-5124MCU Table of contents for function description of instrument cluster (IC)

GF54.30-P-0997MCU BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS, INSTRUMENT CLUSTER (IC) COMPONENT DESCRIPTION - GF54.30-P-9996MCU > MODEL 451.3/4 Instrument cluster, component description A1 GF54.30-P-6000MCU Outside air temperature sender component description B14 GF83.57-P-4000MCC Restraint systems control unit, component description N2/7 GF91.60-P-4048MCU ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MCU SAM control unit, component description N10/10 GF54.21-P-4157MCU Automated manual transmission control unit, component description N15/6 GF26.19-P-1010MCU ESP control unit, component description N47-5 GF42.45-P-5118MCU Electric steering control unit, component description N68For vehicles with code (V26) Power steering, EPS (FFO) GF46.35-P-7100MCU Tire pressure monitor control unit, component description N88 GF40.15-P-5124MCU Table of contents for function description of instrument cluster (IC)

GF54.30-P-0997MCU BASIC KNOWLEDGE > WIRING DIAGRAM FOR DATA LINK CONNECTOR/DIAGNOSTIC SOCKET - PE54.22-P-2000-97MCU > Code: Designation: Position: A1 Instrument cluster 9L

Abbreviations for wiring diagrams

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1659 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE07.00-P-1100MCU, PE08.00-P-1100MCC (+5 more)

OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and plug connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Engine 132Further wiring diagrams PE07.00-P-1100MCU Engine 780.009Further wiring diagrams PE08.00-P-1100MCC Transmission 717 (except model 451.391/491)Further wiring diagrams PE26.00-P-1100MCU Model 451.391 / 491Further wiring diagrams PE27.00-P-1100MCC Further wiring diagrams PE42.00-P-1100MCU Model 451.391 / 491Further wiring diagrams PE43.00-P-1100MCC Further wiring diagrams PE46.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU Further wiring diagrams PE72.00-P-1100MCU Further wiring diagrams PE80.00-P-1100MCU Further wiring diagrams PE82.00-P-1100MCU Further wiring diagrams PE83.00-P-1100MCU Further wiring diagrams PE91.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000MCV > MODEL 451 Sheet 2 Wiring diagram electrical center PE54.25-P-2000-97MCV Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and plug connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Engine 132Further wiring diagrams PE07.00-P-1100MCU Engine 780.009Further wiring diagrams PE08.00-P-1100MCC

Location and assignment of Z connector sleeves (line connectors in

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1666 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-3000MCU, PE54.00-P-1100MCU

wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM OF AUXILIARY INSTRUMENTS - PE54.30-P-2003- 97MCU > Code: Designation: Position: A15 Additional instruments 11A A15 Additional instruments 6A A15 Additional instruments 3A A15p3 Clock

A15p4 Tachometer

A15p5 Display

A15x1 Additional instruments connector 1D A15x2 Additional instruments connector 10D A34/7 Bluetooth module 11L N10/10 SAM control unit 5L N10/10f12 Fuse 12 2L U31 Valid on vehicles with Bluetooth with display 9A U32 Not valid on vehicles with Bluetooth with display 5A W9 Ground (left front, at lamp unit) 3G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 2G Z78 Cockpit LIN connector sleeve 4G

WIRING DIAGRAMS > WIRING DIAGRAM OF AUXILIARY INSTRUMENTS - PE54.30-P-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1667 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU

2003MCU > MODEL 451 / (except 451.391 /491) up to 30.8.10 Wiring diagram of auxiliary instruments PE54.30-P-2003-97MCU Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and plug connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR INSTRUMENT CLUSTER Fig 1: Auxiliary Instruments - Wiring Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1828 · Applies to: 450, 451, 452, 454 · AR: AR07.00-Z-9132CB, AR07.03-P-1450MCC, AR07.03-P-1450MCU, AR07.04-P-0100MCC, AR07.04-P-0100MCU (+5 more)

1 tips Question: DTC,S where are they TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: MIXTURE FORMATION - AR07.00-Z-9132CB > ENGINE 132 Remove fuel distributor with injection valves ENGINE 132.9 in MODEL 451.3/4 AR07.03-P-1450MCC Remove fuel distributor with injection valves ENGINE 132.910 in MODEL 451.3/4 AR07.03-P-1450MCU Remove, install intake manifold pressure sensor ENGINE 132.9 in MODEL 451.3/4 AR07.04-P-0100MCC Remove, install intake manifold pressure sensor ENGINE 132.910 in MODEL 451.3/4 AR07.04-P-0100MCU Remove/install injection system control unit ENGINE 132.9 in MODEL 451.3/4 AR07.08-P-7008MCC Remove/install injection system control unit ENGINE 132.910 in MODEL 451.3/4 AR07.08-P-7008MCU Remove/install injection valves ENGINE 132.9 in MODEL 451.3/4 AR07.03-P-6522MCC Remove/install injection valves ENGINE 132.910 in MODEL 451.3/4 AR07.03-P-6522MCU Remove/install O2 sensor ENGINES 132.9 in MODEL 451.3/4 up to 30.8.10 O2 sensor downstream of CAT [KAT] AR07.04-P-0080MCB Remove/install O2 sensor ENGINES 132.9 in MODEL 451.3/4 up to 30.8.10 O2 sensor upstream of CAT [KAT] AR07.04-P-0080MCC Remove/install O2 sensor ENGINES 132.910 in MODEL 451.3/4 as of 31.8.10 O2 sensor downstream of CAT [KAT] AR07.04-P-0080MCF Remove/install O2 sensor ENGINES 132.930 in MODEL 451.3/4 as of 31.8.10 O2 sensor upstream of CAT [KAT] AR07.04-P-0080MCG Remove/install O2 sensor ENGINES 132.930 in MODEL 451.3/4 as of 31.8.10 O2 sensor downstream of CAT [KAT] AR07.04-P-0080MCH Remove/install O2 sensor ENGINE 132.910 in MODEL 451.3/4 AR07.04-P-0080MCU

O2 sensor downstream of TWC

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1829 · Applies to: 450, 451, 452, 454 · AR: AR07.04-P-0080MCV, AR07.61-P-1401MCC, AR07.61-P-1401MCU, AR07.03-P-1450MCU

Remove/install O2 sensor ENGINE 132... AR07.04-P-0080MCV Remove/install throttle valve actuator ENGINE 132.9 in MODEL 451.3/4 AR07.61-P-1401MCC Remove/install throttle valve actuator ENGINE 132.910 in MODEL 451.3/4 AR07.61-P-1401MCU TESTING & REPAIR > REMOVE FUEL DISTRIBUTOR WITH INJECTION VALVES - AR07.03-P-1450MCU > ENGINE 132.910 in MODEL 451.3/4

Remove/install

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00- Z-0001- 01A 1 Remove interior flap above engine Installation: Only install interior flap over engine after the leak test. AR88.40- P-1100- 03MCC 2 Unlock and remove holder (2) for engine wiring harness (3) on mounts on cylinder head cover (4)

3 Disconnect electrical connectors (5)

Fig 1: Identifying Fuel Distributor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Detach clamp (6) and remove fuel

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1830 · Applies to: 450, 451, 452, 454 · AR: AR07.03-P-6522MCU

4 Detach clamp (6) and remove fuel line (7) from fuel distributor (1) Collect the e caping fuel in a suitable container.Use suitable plugs to seal the openings. Installation: Replace clamp (6). Observe correct seating of the fuel line (7) in mounts on the intake manifold (8).

5 Remove bolts (9) for fuel distributor (1) on intake manifold (8) *BA07.52- P-1001- 01D 6 Remove fuel distributor (1) together with fuel injection valves Installation: Replace sealing rings for fuel injection valves and wet slightly with engine oil for easier assembly.

7 Remove fuel injection valves When replacing fuel distributor (1). AR07.03- P- 6522MCU 8 Install in the reverse order

9 Read out fault memory, erase if necessary

Connect STAR DIAGNOSIS and read out fault memory AD00.00- P-2000- 04MCC Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself.Wear closed and snug-fitting work clothes.Do not touch hot or rotating parts. AS00.00- Z-0005- 01A 10 Conduct engine test run and check for leaktightness of fuel system in the area of the fuel distributor (1) FUEL DISTRIBUTOR Number Designation Engine 132.9 BA07.52-P-1001- 01D Bolt, fuel distributor to intake manifold Nm 9 TESTING & REPAIR > REMOVE/INSTALL INJECTION VALVES - AR07.03-P-6522MCU > ENGINE 132.910 in MODEL 451.3/4

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1831 · Applies to: 450, 451, 452, 454 · AR: AR07.04-P-0080MCU

1 Remove fuel distributor (1) together with fuel injectors (Y62/1, Y62/2, Y62/3)

AR07.03- P- 1450MCU 2 Unclip anti-twist locks (2) at fuel injectors (Y62/1, Y62/2, Y62/3) Installation: The anti-twist lock (2) must engage in the respective slot (arrow) on the fuel injection valve (Y62/1, Y62/2, Y62/3)

3 Pull fuel injection valves (Y62/1, Y62/2, Y62/3) out of fuel distributor (1) Installation: Replace seal rings (3, 4) on fuel injection valves (Y62/1, Y62/2, Y62/3) and wet with engine oil before installation.

4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL O2 SENSOR - AR07.04-P-0080MCU > ENGINE 132.910 in MODEL 451.3/4 O2 sensor downstream of TWC Fig 1: Identifying Injection Valves Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating O2 Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1832 · Applies to: 450, 451, 452, 454 · AR: AR07.04-P-0080MCV

1 Remove complete exhaust system

AR49.10-P- 7000MCU 2 Unscrew O2 sensor downstream of catalytic converter (G3/1) from catalytic converter (1) Use a suitable 22 mm socket wrench.

BA14.00-P- 1003-01B Paste BR00.45-Z- 1005-06A 3 Install in the reverse order

O2 SENSOR Number Designation Engine 132.9 BA14.00-P-1003- 01B O2 sensor downstream TWC on catalytic converter Nm 40 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1005- 06A Paste, hot lubrication 1 kg, DB supply specification 6879.20 A 000 989 76 51 TESTING & REPAIR > REMOVE/INSTALL O2 SENSOR - AR07.04-P-0080MCV > ENGINES 132.910 in MODEL 451.3/4 with CODE (494) USA version O2 sensor upstream of CAT [KAT] ENGINES 132.910 in MODEL 451.3/4 as of 31.8.10 except CODE (494) USA version O2 sensor upstream of CAT [KAT]

BR00.45-Z-1005-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1835 · Applies to: 450, 451, 452, 454 · AR: AR07.04-P-0100MCU

06A Paste, hot lubrication 1 kg, DB supply specification 6879.20 A 000 989 76 51 TESTING & REPAIR > REMOVE, INSTALL INTAKE MANIFOLD PRESSURE SENSOR - AR07.04-P-0100MCU > ENGINE 132.910 in MODEL 451.3/4

Remove/install

1 Release rear drive module

AR01.00- P- 3050MCU 2 Unscrew bolt (1).

3 Remove intake manifold pressure sensor (B28) from intake manifold (2) and disconnect electrical connector (3) Installation: Check sealing ring on intake manifold pressure sensor (B28); replace if necessary.

4 Install in the reverse order

5 Read out fault memory, erase if necessary When replacing Intake manifold pressure sensor (B28).

Connect STAR DIAGNOSIS and read out fault memory AD00.00- P-2000- 04MCC TESTING & REPAIR > REMOVE/INSTALL INJECTION SYSTEM CONTROL UNIT - AR07.08- P-7008MCU > ENGINE 132.910 in MODEL 451.3/4 Fig 1: Identifying Intake Manifold Pressure Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR FUEL INJECTION VALVES -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1840 · Applies to: 450, 451, 452, 454 · AR: GF07.03-P-6010MCC

GF07.03-P-6010MCC > ENGINE 132.9 in MODEL 451.3/4 Location The fuel injection valves are located in the cylinder head upstream of the intake valves. Task The injection valves inject the fuel in the required amount before the intake valve. Design Fig 1: Locating Fuel Injection Valves Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Function

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1841 · Applies to: 450, 451, 452, 454 · AR: GF07.04-P-6010MCC

When the solenoid coil is energized, the nozzle needle is raised about 0.1 mm by the solenoid armature against the force of the coil spring. Fuel escapes through the outlet hole and is sprayed into the intake port in a finely atomized spray. Fuel injection valves are actuated by mass impulses from the ME-SFI [ME] control unit (N3/10). BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR CRANKSHAFT POSITION SENSOR - GF07.04-P-6010MCC > ENGINE 132.9 in MODEL 451.3/4 Fig 2: Identifying Fuel Injection Valves Design Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Function

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1843 · Applies to: 450, 451, 452, 454 · AR: GF07.04-P-6020MCC

The front edge of a tooth on the clutch plate generates a positive voltage pulse and the rear edge generates a negative one. The distance from the positive to the negative voltage peak corresponds to the length of a tooth. The gap produced by 2 missing teeth results in no voltage being generated in the crankshaft position sensor. This gap is used for detecting the TDC position of cylinder 1. The distance between the crankshaft position sensor and the teeth of the drive plate is specified by the installation position. BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR CAMSHAFT HALL SENSOR - GF07.04-P-6020MCC > ENGINE 132.9 in MODEL 451.3/4 Fig 2: View Of Crankshaft Position Sensor Task Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Location

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1844 · Applies to: 450, 451, 452, 454 · AR: GF07.04-P-6030MCC

The camshaft Hall sensor is located on the left on the cylinder head in the area of the intake camshaft. Task The camshaft Hall sensor transmits the respective position of the intake camshaft as a square wave signal to the ME-SFI [ME] control unit (N3/10). Function Detection of the positions of the camshafts takes place through recognition of the positions of the quadrants mounted on the intake camshaft Signals are generated according to the camshaft revolution. Here the signals switch between about 5 V (high) and about 0 V (low). If there is a Hall sensor opposite the "cutout in the pulse wheel" the signal is about 5 V. Signal failure is compensated for by the ME-SFI [ME] control unit by the signal from the crankshaft position sensor (L5). However, a precise calculation of the injection timing point is no longer possible. BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE KNOCK SENSOR - GF07.04-P-6030MCC > ENGINE 132.9 in MODEL 451.3/4 Fig 1: Locating Camshaft Hall Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > COOLANT TEMPERATURE SENSOR, COMPONENT

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1846 · Applies to: 450, 451, 452, 454 · AR: GF07.04-P-6040MCC

DESCRIPTION - GF07.04-P-6040MCC > ENGINE 132.9 in MODEL 451.3/4 Location The coolant temperature sensor is screwed onto the left side on the cylinder head. Task The coolant temperature sensor detects the coolant temperature and transmits a corresponding voltage signal to the ME-SFI [ME] control unit (N3/10). Function The NTC resistor integrated within the coolant temperature sensor changes its electrical resistance according to the coolant temperature. The ME-SFI [ME] control unit applies a sensor voltage of 5 V to pin 1 (1) and evaluates signal voltage at pin 2 (2) according to the coolant temperature. Fig 1: Locating Coolant Temperature Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE INTAKE MANIFOLD

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1847 · Applies to: 450, 451, 452, 454 · AR: GF07.04-P-6062MCC

PRESSURE SENSOR - GF07.04-P-6062MCC > ENGINE 132.9 in MODEL 451.3/4 Shown on engine 132.910 Fig 2: Identifying Coolant Temperature Sensor Connector Function Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Location

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1849 · Applies to: 450, 451, 452, 454 · AR: GF07.10-P-1016MCC

The O2 sensor upstream of TWC is located in the exhaust system upstream of the three-way catalytic converter. The O2 sensor downstream of TWC is located in the exhaust system downstream of the three-way catalytic converter. Task The O2 sensors detect the residual oxygen content in the exhaust and transmit this as a voltage signal to the ME-SFI [ME] control unit (N3/10). Body Installed O2 sensors are voltage planar sensors. The sensor tip consists of a gas-tight ceramic (zirconium dioxide) which is coated on both sides with a porous platinum layer. Both platinum layer are connected together and act as electrodes. Function The outer sides of the O2 sensors lie in the exhaust flow while the inner sides aerated with oxygen in the air. For a rich mixture the oxygen concentration in the exhaust drops a lot and generates a sensor voltage of about 0.8 V. The ME-SFI [ME] control unit (N3/10) regulates the fuel quantity until the value jumps back again. For a lean mixture the process operates in reverse, the voltage drops to about 0.2 V. This process is repeated once a second. In order to reach the operating temperature of about 300°C as quickly as possible the O2 sensors have an integral heater which is controlled by the ME-SFI [ME] control unit. BASIC KNOWLEDGE > CAMSHAFT ADJUSTMENT, FUNCTION - GF07.10-P-1016MCC > Fig 1: Locating O2 Sensors Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Component description for camshaft adjuster

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1851 · Applies to: 450, 451, 452, 454 · AR: GF05.20-P-1110MCC, GF18.10-P-4000MCC, GF07.15-P-2001MCU

GF05.20-P-1110MCC Component description for oil pump GF18.10-P-4000MCC BASIC KNOWLEDGE > START PROCEDURE, FUNCTION - GF07.15-P-2001MCU > ENGINES 132.9 in MODEL 451.3/4 The start process includes the following partial functions: Circuit 15 On START Start quantity control Post-start enrichment Circuit 15 ON The SAM control unit checks drive authorization and applies an appropriate signal to the CAN. The ME-SFI [ME] control unit requests the CHECK ENGINE indicator lamp in the instrument cluster to light up shortly. The fuel pump with fuel level sensor is actuated via the SAM control unit for about 25 seconds. Fig 1: Start Procedure Function Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > MOTOR ELECTRONICS (ME-SFI) FUEL INJECTION AND IGNITION

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1856 · Applies to: 450, 451, 452, 454 · AR: GF07.61-P-0001MCU

SYSTEM CONTROL UNIT, OUTPUT SIGNALS - GF07.61-P-0001-07MCU > BASIC KNOWLEDGE > MOTOR ELECTRONICS (ME-SFI) FUEL INJECTION AND IGNITION SYSTEM, FUNCTION - GF07.61-P-0001MCU > ENGINES 132.9 in MODEL 451.3/4 The ME-SFI [ME] control unit (N3/10) is the master control unit for the engine control and a subscriber on the Control Area Network (data bus/CAN bus) (CAN). Functions Start process Terminal 15 On Starting Start quantity control Post-start enrichment Fig 1: Motor Electronics Fuel Injection And Ignition System Control Unit Output Signals Reference Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Electrical function diagram for engine control ME-SFI [ME]

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1858 · Applies to: 450, 451, 452, 454 · AR: PE07.61-P-2050MCU, PE07.61-P-2000MCU, GF07.15-P-2001MCU, GF07.61-P-2005MCU, GF07.61-P-1001MCC (+2 more)

PE07.61-P-2050MCU Wiring diagram, fuel injection and ignition system ME-SFI PE07.61-P-2000MCU

Start procedure, function GF07.15-P-2001MCU

ME-SFI driving mode, function GF07.61-P-2005MCU

On-Board Diagnosis (OBD) ME function GF07.61-P-1001MCC BASIC KNOWLEDGE > TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF MOTOR ELECTRONICS (ME-SFI) FUEL INJECTION AND IGNITION SYSTEM - GF07.61-P- 0999MCU > ENGINES 132.9 in MODEL 451.3/4

Motor electronics (ME-SFI) fuel injection and ignition system, function GF07.61-P-0001MCU

(ME-SFI) motor electronics fuel injection and ignition system, location of components GF07.61-P-0001- 01MCU

Motor electronics (ME-SFI) fuel injection and ignition system control unit, input signals GF07.61-P-0001- 06MCU

Motor electronics (ME-SFI) fuel injection and ignition system control unit, output signals GF07.61-P-0001- 07MCU Electrical function diagram for engine control ME-SFI [ME] PE07.61-P-2050MCU Wiring diagram, fuel injection and ignition system ME-SFI PE07.61-P-2000MCU

Start procedure, function GF07.15-P-2001MCU

ME-SFI driving mode, function GF07.61-P-2005MCU

On-Board Diagnosis (OBD) ME function GF07.61-P-1001MCC

Overview of system components motor electronics (ME- SFI) fuel injection and ignition system GF07.61-P-9997MCU BASIC KNOWLEDGE > ME-SFI DRIVING MODE, FUNCTION - GF07.61-P-2005MCU > ENGINES 132.9 in MODEL 451.3/4

Crankshaft position sensor (L5)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1869 · Applies to: 450, 451, 452, 454 · AR: GF07.61-P-9997MCU, GF49.10-P-2010MCU, GF54.30-P-6000MCU, GF83.55-P-2108MCU, GF47.30-P-2101MCU

Throttle valve actuator (M16/6) Oil pressure switch (S41/1) Fuel level sensor (M3/3b1) The following components are actuated directly by the ME-SFI [ME] control unit: Generator Heating O2 sensor downstream of TWC Heating O2 sensor upstream of TWC Secondary air injection pump relay (K64) Throttle valve actuator Cylinder 1 ignition coil (T1/1) Cylinder 2 ignition coil (T1/2) Cylinder 3 ignition coil (T1/3) Secondary air injection pump switchover valve (Y32) Adjustable camshaft timing solenoid (Y49) External air shut-off valve (Y50) Tank vent valve (Y58) Cylinder 1 fuel injection valve (Y62/1) Cylinder 2 fuel injection valve (Y62/2) Cylinder 3 fuel injection valve (Y62/3) BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS MOTOR ELECTRONICS (ME-SFI) FUEL INJECTION AND IGNITION SYSTEM - GF07.61-P-9997MCU > ENGINES 132.9 in MODEL 451.3/4 Three-way catalytic converter, component description

GF49.10-P-2010MCU Instrument cluster, component description A1 GF54.30-P-6000MCU Component description of refrigerant compressor A9For code (I01) Air conditioning Plus GF83.55-P-2108MCU Knock sensor, component description A16 GF07.04-P- 6030MCC Fuel tank pressure sensor, component description B4/3 GF47.30-P-2101MCU Camshaft Hall sensor, component B6/1 GF07.04-P-

WIRING DIAGRAMS > WIRING DIAGRAM FOR FUEL INJECTION AND IGNITION SYSTEM

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1878 · Applies to: 450, 451, 452, 454 · AR: PE07.61-P-2000MCU, OV00.01-P-1901MCU

ME-SFI - PE07.61-P-2000MCU > ENGINES 132 in MODEL 451 Wiring diagram, fuel injection and ignition system ME-SFI PE07.61-P-2000-97MCU Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Fig 5: Fuel Injection And Ignition System ME-SFI - Wiring Diagram (5 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Abbreviations for wiring diagrams

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1879 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE07.00-P-1100MCU, PE26.00-P-1100MCU (+5 more)

OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and plug connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE07.00-P-1100MCU Further wiring diagrams PE26.00-P-1100MCU Further wiring diagrams PE42.00-P-1100MCU Further wiring diagrams PE46.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU Further wiring diagrams PE83.00-P-1100MCU WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR ENGINE CONTROL ME- SFI [ME] - PE07.61-P-2050MCU > ENGINE 132 in MODEL 451 Electrical function diagram for engine control ME-SFI [ME] PE07.61-P-2050-99MCU Legend of electrical function diagram for engine control ME-SFI [ME] PE07.61-P-2050-60MCU Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE07.00-P-1100MCU Further wiring diagrams PE26.00-P-1100MCU Further wiring diagrams PE42.00-P-1100MCU Further wiring diagrams PE46.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU Further wiring diagrams PE83.00-P-1100MCU SPECIAL TOOLS > 450 589 09 21 00 PRESSURE GAUGE - WS07.00-P-0100B > FG 07/Set B

TESTING & REPAIR INDEX > TESTING AND REPAIR WORK: SMART: MIXTURE

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1883 · Applies to: 450, 451, 452, 454 · AR: AR07.00-Z-9132CB, AR07.03-P-1450MCC, AR07.03-P-1450MCU, AR07.04-P-0100MCC, AR07.04-P-0100MCU (+5 more)

FORMATION - AR07.00-Z-9132CB > ENGINE 132 Remove fuel distributor with injection valves ENGINE 132.9 in MODEL 451.3 /4 AR07.03-P-1450MCC Remove fuel distributor with injection valves ENGINE 132.910 in MODEL 451.3 /4 AR07.03-P-1450MCU Remove, install intake manifold pressure sensor ENGINE 132.9 in MODEL 451.3 /4 AR07.04-P-0100MCC Remove, install intake manifold pressure sensor ENGINE 132.910 in MODEL 451.3 /4 AR07.04-P-0100MCU Remove/install injection system control unit ENGINE 132.9 in MODEL 451.3 /4 AR07.08-P-7008MCC Remove/install injection system control unit ENGINE 132.910 in MODEL 451.3 /4 AR07.08-P-7008MCU Remove/install injection valves ENGINE 132.9 in MODEL 451.3 /4 AR07.03-P-6522MCC Remove/install injection valves ENGINE 132.910 in MODEL 451.3 /4 AR07.03-P-6522MCU Remove/install O2 sensor ENGINES 132.9 in MODEL 451.3 /4 up to 30.8.10 O2 sensor downstream of CAT [KAT] AR07.04-P-0080MCB Remove/install O2 sensor ENGINES 132.9 in MODEL 451.3 /4 up to 30.8.10 O2 sensor upstream of CAT [KAT] AR07.04-P-0080MCC Remove/install O2 sensor ENGINES 132.910 in MODEL 451.3 /4 as of 31.8.10 O2 sensor downstream of CAT [KAT] AR07.04-P-0080MCF Remove/install O2 sensor ENGINES 132.930 in MODEL 451.3 /4 as of 31.8.10 O2 sensor upstream of CAT [KAT] AR07.04-P-0080MCG Remove/install O2 sensor ENGINES 132.930 in MODEL 451.3 /4 as of 31.8.10 O2 sensor downstream of CAT [KAT] AR07.04-P-0080MCH Remove/install O2 sensor ENGINE 132.910 in MODEL 451.3 /4 O2 sensor AR07.04-P-0080MCU

downstream of TWC

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1884 · Applies to: 450, 451, 452, 454 · AR: AR07.04-P-0080MCV, AR07.61-P-1401MCC, AR07.61-P-1401MCU, AR07.03-P-1450MCU

Remove/install O2 sensor ENGINE 132... AR07.04-P-0080MCV Remove/install throttle valve actuator ENGINE 132.9 in MODEL 451.3 /4 AR07.61-P-1401MCC Remove/install throttle valve actuator ENGINE 132.910 in MODEL 451.3 /4 AR07.61-P-1401MCU TESTING & REPAIR INDEX > REMOVE FUEL DISTRIBUTOR WITH INJECTION VALVES - AR07.03-P-1450MCU > ENGINE 132.910 in MODEL 451.3 /4

Remove/install

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Only pour fuels into suitable and appropriately marked containers.Wear protective clothing when handling fuel. AS47.00- Z-0001- 01A 1 Remove interior flap above engine Installation: Only install interior flap over engine after the leak test. AR88.40- P-1100- 03MCC 2 Unlock and remove holder (2) for engine wiring harness (3) on mounts on cylinder head cover (4)

3 Disconnect electrical connectors (5)

Fig 1: Identifying Fuel Distributor With Injection Valves Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1886 · Applies to: 450, 451, 452, 454 · AR: AR07.04-P-0080MCU

1 Remove fuel distributor (1) together with fuel injectors (Y62/1, Y62/2, Y62/3)

AR07.03- P- 1450MCU 2 Unclip anti-twist locks (2) at fuel injectors (Y62/1, Y62/2, Y62/3) Installation: The anti-twist lock (2) must engage in the respective slot (arrow) on the fuel injection valve (Y62/1, Y62/2, Y62/3)

3 Pull fuel injection valves (Y62/1, Y62/2, Y62/3) out of fuel distributor (1) Installation: Replace seal rings (3, 4) on fuel injection valves (Y62/1, Y62/2, Y62/3) and wet with engine oil before installation.

4 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL O2 SENSOR - AR07.04-P-0080MCU > ENGINE 132.910 in MODEL 451.3 /4 O2 sensor downstream of TWC Fig 1: Identifying Injection Valves Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying O2 Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1887 · Applies to: 450, 451, 452, 454 · AR: AR07.04-P-0080MCV

1 Remove complete exhaust system

AR49.10-P- 7000MCU 2 Unscrew O2 sensor downstream of catalytic converter (G3/1) from catalytic converter (1) Use a suitable 22 mm socket wrench.

BA14.00-P- 1003-01B Paste BR00.45-Z- 1005-06A 3 Install in the reverse order

O2 SENSOR Number Designation Engine 132.9 BA14.00-P-1003-01B O2 sensor downstream TWC on catalytic converter Nm 40 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1005- 06A Paste, hot lubrication 1 kg, DB supply specification 6879.20 A 000 989 76 51 TESTING & REPAIR INDEX > REMOVE/INSTALL O2 SENSOR - AR07.04-P-0080MCV > ENGINES 132.910 in MODEL 451.3 /4 with CODE (494) USA version O2 sensor upstream of CAT [KAT] ENGINES 132.910 in MODEL 451.3 /4 as of 31.8.10 except CODE (494) USA version O2 sensor upstream of CAT [KAT]

TESTING & REPAIR INDEX > REMOVE, INSTALL INTAKE MANIFOLD PRESSURE

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1890 · Applies to: 450, 451, 452, 454 · AR: AR07.04-P-0100MCU, AR07.08-P-7008MCU

SENSOR - AR07.04-P-0100MCU > ENGINE 132.910 in MODEL 451.3 /4

Remove/install

1 Release rear drive module

AR01.00- P- 3050MCU 2 Unscrew bolt (1).

3 Remove intake manifold pressure sensor (B28) from intake manifold (2) and disconnect electrical connector (3) Installation: Check sealing ring on intake manifold pressure sensor (B28); replace if necessary.

4 Install in the reverse order

5 Read out fault memory, erase if necessary When replacing Intake manifold pressure sensor (B28).

Connect STAR DIAGNOSIS and read out fault memory AD00.00- P-2000- 04MCC TESTING & REPAIR INDEX > REMOVE/INSTALL INJECTION SYSTEM CONTROL UNIT - AR07.08-P-7008MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 1: Identifying Intake Manifold Pressure Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1891 · Applies to: 450, 451, 452, 454 · AR: AR07.61-P-1401MCU

Notes on avoiding damage to electronic components due to electrostatic discharge

AH54.00-P- 0001-01A 1 Turn off ignition

2 Remove right side paneling in trunk

AR68.30- P- 4800MCU 3 Release and disconnect electrical connectors (1)

4 Remove bolts (2) and ME-SFI [ME] control unit (N3/10)

5 Install in the reverse order

6 Flash ME-SFI [ME] control unit (N3/10) When replacing the ME-SFI [ME] control unit (N3/10). AR54.21- P- 0012MCU TESTING & REPAIR INDEX > REMOVE/INSTALL THROTTLE VALVE ACTUATOR - AR07.61-P-1401MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 1: Identifying Injection System Control Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Sensors

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1894 · Applies to: 450, 451, 452, 454 · AR: GF07.03-P-6010MCC

ENGINE 639.9, 660.9 BA07.04-P-1000-01J Sensors ENGINE 134.910 /911, 135.930 /950 BA07.04-P-1000-01H Vacuum system ENGINE 639.939, 660.9 BA07.09-P-1000-01A TORQUE SPECIFICATIONS > ME GASOLINE INJECTION AND IGNITION SYSTEM - BA07.61-P-1000-01B > Engine 132, 160 ME-SFI [ME] GASOLINE INJECTION AND IGNITION SYSTEM Number Designation Engine 132.9 Engine 160.910 Engine 160.920 Engine 160.921 BA07.61-P- 1001-01B Bolt at throttle valve actuator Nm - 9 - - BA07.61-P- 1002-01B Bolt, electronic accelerator adjusting motor to intake manifold Nm - - 9 9 BA07.61-P- 1003-01B Bolt, throttle valve actuator to intake manifold/ charge air manifold Nm 9 - - - ME-SFI [ME] GASOLINE INJECTION AND IGNITION SYSTEM Number Designation Engine 160.922 Engine 160.923 BA07.61-P- 1001-01B Bolt at throttle valve actuator Nm - - BA07.61-P- 1002-01B Bolt, electronic accelerator adjusting motor to intake manifold Nm 9 9 BA07.61-P- 1003-01B Bolt, throttle valve actuator to intake manifold/ charge air manifold Nm - - TORQUE SPECIFICATIONS > FUEL DISTRIBUTER - BA07.52-P-1000-01D > Engine 132 Number Designation Engine132.9

BA07.52-P-1001-01D Nm 9

BA07.52-P-1002-01D Nm 9 BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR FUEL INJECTION VALVES - GF07.03-P-6010MCC > ENGINE 132.9 in MODEL 451.3 /4

Function

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1896 · Applies to: 450, 451, 452, 454 · AR: GF07.04-P-6010MCC

When the solenoid coil is energized, the nozzle needle is raised about 0.1 mm by the solenoid armature against the force of the coil spring. Fuel escapes through the outlet hole and is sprayed into the intake port in a finely atomized spray. Fuel injection valves are actuated by mass impulses from the ME-SFI [ME] control unit (N3/10). BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR CRANKSHAFT POSITION SENSOR - GF07.04-P-6010MCC > ENGINE 132.9 in MODEL 451.3 /4 Fig 2: Identifying Fuel Injection Valves Design Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Function

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1898 · Applies to: 450, 451, 452, 454 · AR: GF07.04-P-6020MCC

The front edge of a tooth on the clutch plate generates a positive voltage pulse and the rear edge generates a negative one. The distance from the positive to the negative voltage peak corresponds to the length of a tooth. The gap produced by 2 missing teeth results in no voltage being generated in the crankshaft position sensor. This gap is used for detecting the TDC position of cylinder 1. The distance between the crankshaft position sensor and the teeth of the drive plate is specified by the installation position. BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR CAMSHAFT HALL SENSOR - GF07.04-P-6020MCC > ENGINE 132.9 in MODEL 451.3 /4 Fig 2: Identifying Crankshaft Position Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Location

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1899 · Applies to: 450, 451, 452, 454 · AR: GF07.04-P-6030MCC

The camshaft Hall sensor is located on the left on the cylinder head in the area of the intake camshaft. Task The camshaft Hall sensor transmits the respective position of the intake camshaft as a square wave signal to the ME-SFI [ME] control unit (N3/10). Function Detection of the positions of the camshafts takes place through recognition of the positions of the quadrants mounted on the intake camshaft Signals are generated according to the camshaft revolution. Here the signals switch between about 5 V (high) and about 0 V (low). If there is a Hall sensor opposite the "cutout in the pulse wheel" the signal is about 5 V. Signal failure is compensated for by the ME-SFI [ME] control unit by the signal from the crankshaft position sensor (L5). However, a precise calculation of the injection timing point is no longer possible. BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE KNOCK SENSOR - GF07.04-P-6030MCC > ENGINE 132.9 in MODEL 451.3 /4 Fig 1: Identifying Camshaft Hall Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > COOLANT TEMPERATURE SENSOR, COMPONENT

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1901 · Applies to: 450, 451, 452, 454 · AR: GF07.04-P-6040MCC

DESCRIPTION - GF07.04-P-6040MCC > ENGINE 132.9 in MODEL 451.3 /4 Location The coolant temperature sensor is screwed onto the left side on the cylinder head. Task The coolant temperature sensor detects the coolant temperature and transmits a corresponding voltage signal to the ME-SFI [ME] control unit (N3/10). Function The NTC resistor integrated within the coolant temperature sensor changes its electrical resistance according to the coolant temperature. The ME-SFI [ME] control unit applies a sensor voltage of 5 V to pin 1 (1) and evaluates signal voltage at pin 2 (2) according to the coolant temperature. Fig 1: Identifying Coolant Temperature Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE INTAKE MANIFOLD

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1902 · Applies to: 450, 451, 452, 454 · AR: GF07.04-P-6062MCC

PRESSURE SENSOR - GF07.04-P-6062MCC > ENGINE 132.9 in MODEL 451.3 /4 Shown on engine 132.910 Fig 2: Identifying Coolant Temperature Sensor Connector Terminals Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Location

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1904 · Applies to: 450, 451, 452, 454 · AR: GF07.10-P-1016MCC

The O2 sensor upstream of TWC is located in the exhaust system upstream of the three-way catalytic converter. The O2 sensor downstream of TWC is located in the exhaust system downstream of the three-way catalytic converter. Task The O2 sensors detect the residual oxygen content in the exhaust and transmit this as a voltage signal to the ME-SFI [ME] control unit (N3/10). Body Installed O2 sensors are voltage planar sensors. The sensor tip consists of a gas-tight ceramic (zirconium dioxide) which is coated on both sides with a porous platinum layer. Both platinum layer are connected together and act as electrodes. Function The outer sides of the O2 sensors lie in the exhaust flow while the inner sides aerated with oxygen in the air. For a rich mixture the oxygen concentration in the exhaust drops a lot and generates a sensor voltage of about 0.8 V. The ME-SFI [ME] control unit (N3/10) regulates the fuel quantity until the value jumps back again. For a lean mixture the process operates in reverse, the voltage drops to about 0.2 V. This process is repeated once a second. In order to reach the operating temperature of about 300°C as quickly as possible the O2 sensors have an integral heater which is controlled by the ME-SFI [ME] control unit. BASIC KNOWLEDGE > CAMSHAFT ADJUSTMENT, FUNCTION - GF07.10-P-1016MCC > Fig 1: Identifying Three-Way Catalytic Converter, O2 Sensor Downstream From Catalytic Converter And O2 Sensor Upstream TWC Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Component description for camshaft adjuster

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1906 · Applies to: 450, 451, 452, 454 · AR: GF05.20-P-1110MCC, GF18.10-P-4000MCC, GF07.15-P-2001MCU

GF05.20-P-1110MCC Component description for oil pump GF18.10-P-4000MCC BASIC KNOWLEDGE > START PROCEDURE, FUNCTION - GF07.15-P-2001MCU > ENGINES 132.9 in MODEL 451.3 /4 The start process includes the following partial functions: Circuit 15 On START Start quantity control Post-start enrichment Circuit 15 ON The SAM control unit checks drive authorization and applies an appropriate signal to the CAN. The ME-SFI [ME] control unit requests the CHECK ENGINE indicator lamp in the instrument cluster to light up shortly. The fuel pump with fuel level sensor is actuated via the SAM control unit for about 25 seconds. Fig 1: Start Procedure Function Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Ignition coils, component

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1908 · Applies to: 450, 451, 452, 454 · AR: GF15.10-P-2100MCC, GF07.03-P-6010MCC

description T1/1, T1/2, T1/3 GF15.10-P-2100MCC Fuel injection valves, component description Y62/1, Y62/2, Y62/3 GF07.03-P-6010MCC BASIC KNOWLEDGE > (ME-SFI) MOTOR ELECTRONICS FUEL INJECTION AND IGNITION SYSTEM, LOCATION OF COMPONENTS - GF07.61-P-0001-01MCU > Fig 1: Motor Electronics Fuel Injection And Ignition System Components Location (1 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > MOTOR ELECTRONICS (ME-SFI) FUEL INJECTION AND IGNITION

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1911 · Applies to: 450, 451, 452, 454 · AR: GF07.61-P-0001MCU

SYSTEM CONTROL UNIT, OUTPUT SIGNALS - GF07.61-P-0001-07MCU > BASIC KNOWLEDGE > MOTOR ELECTRONICS (ME-SFI) FUEL INJECTION AND IGNITION SYSTEM, FUNCTION - GF07.61-P-0001MCU > ENGINES 132.9 in MODEL 451.3 /4 The ME-SFI [ME] control unit (N3/10) is the master control unit for the engine control and a subscriber on the Control Area Network (data bus/CAN bus) (CAN). Functions Start process Terminal 15 On Starting Start quantity control Post-start enrichment Fig 1: Motor Electronics Fuel Injection And Ignition System Control Unit Output Signals Reference Chart Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

injection and ignition system

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1913 · Applies to: 450, 451, 452, 454 · AR: PE07.61-P-2050MCU, PE07.61-P-2000MCU, GF07.15-P-2001MCU, GF07.61-P-2005MCU, GF07.61-P-1001MCC (+2 more)

control unit, output signals Electrical function diagram for engine control ME-SFI [ME] PE07.61-P-2050MCU Wiring diagram, fuel injection and ignition system ME-SFI PE07.61-P-2000MCU

Start procedure, function GF07.15-P-2001MCU

ME-SFI driving mode, function GF07.61-P-2005MCU

On-Board Diagnosis (OBD) ME function GF07.61-P-1001MCC BASIC KNOWLEDGE > TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF MOTOR ELECTRONICS (ME-SFI) FUEL INJECTION AND IGNITION SYSTEM - GF07.61-P- 0999MCU > ENGINES 132.9 in MODEL 451.3 /4

Motor electronics (ME-SFI) fuel injection and ignition system, function GF07.61-P-0001MCU

(ME-SFI) motor electronics fuel injection and ignition system, location of components GF07.61-P-0001-01MCU

Motor electronics (ME-SFI) fuel injection and ignition system control unit, input signals GF07.61-P-0001-06MCU

Motor electronics (ME-SFI) fuel injection and ignition system control unit, output signals GF07.61-P-0001-07MCU Electrical function diagram for engine control ME-SFI [ME] PE07.61-P-2050MCU Wiring diagram, fuel injection and ignition system ME-SFI PE07.61-P-2000MCU

Start procedure, function GF07.15-P-2001MCU

ME-SFI driving mode, function GF07.61-P-2005MCU

On-Board Diagnosis (OBD) ME function GF07.61-P-1001MCC

Overview of system components motor electronics (ME-SFI) fuel injection and ignition system GF07.61-P-9997MCU BASIC KNOWLEDGE > ME-SFI DRIVING MODE, FUNCTION - GF07.61-P-2005MCU >

Cylinder 1 fuel injection valve (Y62/1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1925 · Applies to: 450, 451, 452, 454 · AR: GF07.61-P-9997MCU, GF49.10-P-2010MCU, GF54.30-P-6000MCU, GF83.55-P-2108MCU, GF07.04-P-6030MCC (+5 more)

Cylinder 2 fuel injection valve (Y62/2) Cylinder 3 fuel injection valve (Y62/3) BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS MOTOR ELECTRONICS (ME-SFI) FUEL INJECTION AND IGNITION SYSTEM - GF07.61-P-9997MCU > ENGINES 132.9 in MODEL 451.3 /4 Three-way catalytic converter, component description

GF49.10-P-2010MCU Instrument cluster, component description A1 GF54.30-P-6000MCU Component description of refrigerant compressor A9For code (I01) Air conditioning Plus GF83.55-P-2108MCU Knock sensor, component description A16 GF07.04-P-6030MCC Fuel tank pressure sensor, component description B4/3 GF47.30-P-2101MCU Camshaft Hall sensor, component description B6/1 GF07.04-P-6020MCC Coolant temperature sensor, component description B11/4 GF07.04-P-6040MCC Component description for the intake manifold pressure sensor B28 GF07.04-P-6062MCC Accelerator pedal sensor, component description B37 GF30.20-P-2010MCU Component description for O2 sensor G3/1, G3/2 GF07.04-P-6100MCU Secondary air injection pump relay, component description K64 GF14.30-P-2060MCU Crankshaft position sensor, component description L5 GF07.04-P-6010MCC Component description for fuel pump M3/3 GF47.20-P-2000MCC Fan motor, component description M4/2 GF20.20-P-1000MCU Throttle valve actuator, component description M16/6 GF30.20-P-2020MCC Secondary air injection pump, component description M33 GF14.30-P-2050MCU

PE07.61-P-2050MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1927 · Applies to: 450, 451, 452, 454 · AR: PE07.61-P-2050MCU

Electrical function diagram for engine control ME-SFI [ME] ENGINE 132 in MODEL 451 PE07.61-P-2050MCU WIRING DIAGRAMS > WIRING DIAGRAM FOR FUEL INJECTION AND IGNITION SYSTEM A16 - PE07.61-P-2000-97MCU > Code: Designation: Position: A16 Knock sensor 43L A45 Fanfare horns and airbag clock spring contact 27L A9 Refrigerant compressor 74L B11/4 Coolant temperature sensor 44L B28 Intake manifold pressure sensor 38L B37 Accelerator pedal sensor 14L B4/3 Fuel tank pressure sensor 17L B6/1 Camshaft Hall sensor 47L F36 Secondary air injection pump fuse 23H G1 Battery 24L G2 Alternator 75L G3/1 O2 sensor downstream of TWC [KAT] 65L G3/1x1 O2 sensor downstream of TWC [KAT] connector

G3/2 O2 sensor upstream of TWC [KAT] 62L G3/2x1 O2 sensor upstream of TWC [KAT] connector

K64 Secondary air injection pump relay 21L L5 Crankshaft position sensor 40L M1 Starter 77L M16/6 Throttle valve actuator 32L M3/3 Fuel pump with fuel level sensor 10L M3/3b1 Fuel level sensor 12L M33 Secondary air injection pump 19L N10/10 SAM control unit 75A N10/10 SAM control unit 5L N10/10f1 Fuse 1 76A N10/10f10 Fuse 10 73A N10/10f10 Fuse 10 5L N10/10f16 Fuse 16 9L

WIRING DIAGRAMS > WIRING DIAGRAM FOR FUEL INJECTION AND IGNITION SYSTEM

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1934 · Applies to: 450, 451, 452, 454 · AR: PE07.61-P-2000MCU

ME-SFI - PE07.61-P-2000MCU > ENGINES 132 in MODEL 451 PE07.61-P-2000- 97MCU Wiring diagram, fuel injection and ignition system ME-SFI

PE07.61-P-2000- 97MCU OV00.01-P-1901- 03MCC Use of wiring diagrams

OV00.01-P-1901- 03MCC Fig 5: Fuel Injection And Ignition System ME-SFI Wiring Diagram (5 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

OV00.01-P-1901MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1935 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE07.00-P-1100MCU (+5 more)

Search aid for all wiring diagram groups

OV00.01-P-1901MCU OV00.01-P-1001- 27MC Abbreviations for wiring diagrams

OV00.01-P-1001- 27MC OV00.01-P-1001- 28MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P-1001- 28MC GF00.19-P-1000MCU Location and assignment of line and plug connectors

GF00.19-P-1000MCU GF00.19-P-2000MCU Location and assignment of ground points

GF00.19-P-2000MCU GF00.19-P-3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)

GF00.19-P-3000MCU PE07.00-P-1100MCU

Further wiring diagrams PE07.00-P-1100MCU PE26.00-P-1100MCU

Further wiring diagrams PE26.00-P-1100MCU PE42.00-P-1100MCU

Further wiring diagrams PE42.00-P-1100MCU PE46.00-P-1100MCU

Further wiring diagrams PE46.00-P-1100MCU PE54.00-P-1100MCU

Further wiring diagrams PE54.00-P-1100MCU PE83.00-P-1100MCU

Further wiring diagrams PE83.00-P-1100MCU WIRING DIAGRAMS > LEGEND OF ELECTRICAL FUNCTION SCHEMATIC FOR ENGINE CONTROL ME-SFI [ME] - PE07.61-P-2050-60MCU > ENGINE 132 in MODEL 451 Code Designation Coordinates A1 Instrument cluster 21E A1e5 Alternator charge monitoring and warning lamp 22B A1e26 "CHECK ENGINE" MIL 22B A1e30 Oil pressure warning lamp 22B A1e54 Coolant temperature warning lamp 23B

Adjustable camshaft timing solenoid

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1937 · Applies to: 450, 451, 452, 454 · AR: PE07.61-P-2050MCU, OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU

Y49 Adjustable camshaft timing solenoid 14C Y50 Outside air shutoff valve 13B Y58 Activated charcoal filter shutoff valve 13B Y62/1 Cylinder 1 fuel injection valve 17E Y62/2 Cylinder 2 fuel injection valve 17F Y62/3 Cylinder 3 fuel injection valve 17F WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR ENGINE CONTROL ME- SFI [ME] - PE07.61-P-2050-99MCU > ENGINE 132 in MODEL 451 WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR ENGINE CONTROL ME- SFI [ME] - PE07.61-P-2050MCU > ENGINE 132 in MODEL 451 PE07.61-P-2050- 99MCU Electrical function diagram for engine control ME-SFI [ME]

PE07.61-P-2050- 99MCU PE07.61-P-2050- 60MCU Legend of electrical function diagram for engine control ME-SFI [ME]

PE07.61-P-2050- 60MCU OV00.01-P-1901- 03MCC Use of wiring diagrams

OV00.01-P-1901- 03MCC OV00.01-P-1901MCU Search aid for all wiring diagram groups

OV00.01-P-1901MCU OV00.01-P-1001- 27MC Abbreviations for wiring diagrams

OV00.01-P-1001- 27MC OV00.01-P-1001- 28MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P-1001- 28MC GF00.19-P-1000MCU Location and assignment of line and connectors

GF00.19-P-1000MCU GF00.19-P-2000MCU Location and assignment of ground points

GF00.19-P-2000MCU GF00.19-P-3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)

GF00.19-P-3000MCU

PE07.00-P-1100MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1938 · Applies to: 450, 451, 452, 454 · AR: PE07.00-P-1100MCU, PE26.00-P-1100MCU, PE42.00-P-1100MCU, PE46.00-P-1100MCU, PE54.00-P-1100MCU (+1 more)

Further wiring diagrams PE07.00-P-1100MCU PE26.00-P-1100MCU

Further wiring diagrams PE26.00-P-1100MCU PE42.00-P-1100MCU

Further wiring diagrams PE42.00-P-1100MCU PE46.00-P-1100MCU

Further wiring diagrams PE46.00-P-1100MCU PE54.00-P-1100MCU

Further wiring diagrams PE54.00-P-1100MCU PE83.00-P-1100MCU

Further wiring diagrams PE83.00-P-1100MCU SPECIAL TOOLS > 450 589 09 21 00 PRESSURE GAUGE - WS07.00-P-0100B > FG 07/Set B ENGINE 132, 160, 660 Use: Pressure gauge for checking the fuel pressure. NOTE: Fuel pressure gauge 0...10 barSmart No. 0005182. SPECIAL TOOLS > 450 589 18 21 00 VACUUM PUMP - WS07.00-P-0102B > FG 07/Set B MODEL 450, 451, 452 Fig 1: Identifying Pressure Gauge (450 589 09 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Use of wiring diagrams

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2293 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU

OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU SPECIAL TOOLS > 129 589 01 21 00 RETAINER DEVICE - WS40.00-P-0025B > FG 40/01/Set B MODEL 124, 126, 129, 140, 163, 164, 168, 169, 170, 171, 172, 197, 199, 201, 202, 203, 204, 207, 208, 209, 210, 211, 212, 215, 216, 218, 219, 220, 221, 230, 240, 245.20 /23, 251, 414, 450, 451, 452, 460, 461, 463, 636, 638, 639, 906 Part 129 589 01 21 25 Clamping nut (complete) FG 40/Set B WS40.00-P-0025-01B Use: Retainer for steering wheel in straight-ahead position.

SPECIAL TOOLS > 450 589 05 09 00 SOCKET WRENCH BIT - WS40.00-P-0060A > FG 40/Set A MODEL 450, 451, 452 Use: Fig 1: Identifying Retainer Device (129 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

OV00.01-P-1901MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2375 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU

Search aid for all wiring diagram groups

OV00.01-P-1901MCU OV00.01-P-1001- 27MC Abbreviations for wiring diagrams

OV00.01-P-1001- 27MC OV00.01-P-1001- 28MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P-1001- 28MC GF00.19-P-1000MCU Location and assignment of line and connectors

GF00.19-P-1000MCU GF00.19-P-2000MCU Location and assignment of ground points

GF00.19-P-2000MCU GF00.19-P-3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)

GF00.19-P-3000MCU PE54.00-P-1100MCU

Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM FOR TIRE PRESSURE MONITOR CONTROL UNIT - PE40.15-P-2101-99MCU > Code: Designation: Position: A1 Instrument cluster 12L A69/1 Left front TPM [RDK] wheel sensor 15L A69/2 Right front TPM [RDK] wheel sensor 17L A69/3 Left rear TPM [RDK] wheel sensor 18L A69/4 Right rear TPM [RDK] wheel sensor 20L N10/10 SAM control unit 3L N10/10f12 Fuse 12 4L N10/10f19 Fuse 19 2L N88 TPM control module 4A N88 TPM control module 11A S6/1 Cockpit switch group 8L S6/1s9 TPM [RDK] switch 8L

MAINTENANCE > CHECK POLY-V BELT FOR WEAR AND DAMAGE - AP13.22-P-1351MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2380 · Applies to: 450, 451, 452, 454 · AR: AP13.22-P-1351MCU

ENGINE 132.910 in MODEL 451.3/4 Damage profiles Fig 1: Identifying Poly-V Belt Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

(4) If nece

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2382 · Applies to: 450, 451, 452, 454 · AR: AR13.00-Z-9132CB, AR13.22-P-1202MCC, AR13.22-P-1202MCU, AR13.21-P-1202MCC, AR13.21-P-1202MCU (+5 more)

ary ↓Replace poly-V belt (5) or poly-V belt of refrigerant compressor (4) - subject to a separate repair order. Remove/install poly-V beltOn vehicles with code (I01) Air conditioning Plus AR13.22-P- 1202MCU Remove/install poly-V belt for compressor AR13.21-P- 1202MCU Install

4 Position cover (3), insert expansion clips (1) and press in pins (2)

5 Lower vehicle with lifting platform

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: AIR COMPRESSOR, BELT DRIVES - AR13.00-Z-9132CB > ENGINE 132 Remove/install poly-V belt ENGINE 132... AR13.22-P-1202MCC Remove/install poly-V belt ENGINE 132.910 in MODEL 451.3/4 AR13.22-P-1202MCU Remove/install poly-V belt for compressor ENGINE 132.9 in MODEL 451.3/4 with CODE (I01) Air conditioning Plus AR13.21-P-1202MCC Remove/install poly-V belt for compressor ENGINE 132.910 in MODEL 451.3/4 with CODE (I01) Air conditioning Plus AR13.21-P-1202MCU Remove/install poly-V belt of starter- alternator ENGINES 132.910 in MODELS 451.334 /380 /480 as of 31.8.10 AR13.22-P-0005MCB Remove/install poly-V belt of starter- alternator ENGINES 132.910 in MODEL 451.334 /380 /480 up to 30.8.10 AR13.22-P-0005MCC Remove/install poly-V belt tensioning device ENGINES 132.910 in MODELS 451.334 /380 /480 as of 31.8.10 AR13.25-P-3200MCB Remove/install poly-V belt tensioning device ENGINE 132... AR13.25-P-3200MCC Remove/install poly-V belt tensioning device ENGINES 132.910 in MODEL 451.334 /380 /480 up to 30.8.10 AR13.25-P-3200MCE Remove/install poly-V belt tensioning device ENGINE 132.910 in MODEL 451.3/4 AR13.25-P-3200MCU TESTING & REPAIR > REMOVE/INSTALL POLY-V BELT FOR COMPRESSOR - AR13.21-P-

1202MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2383 · Applies to: 450, 451, 452, 454 · AR: AR13.22-P-1202MCU

ENGINE 132.910 in MODEL 451.3/4 with CODE (I01) Air conditioning Plus Illustrated on removed engine Removing

Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities No parts of the body or limbs should be within the operating range of the mechanism when moving components. AS00.00-Z-0009-01A 1 Remove poly-V belt (1)

AR13.22-P-1202MCU 2 Place one clamp for assembly tool (5) in the marked area (arrow A) on refrigerant compressor belt pulley Place one clamp for assembly tool (5), with the long strut upwards, on the belt pulley.

451589006100 3 Turn engine at center bolt (3) through about 30° in direction of engine rotation until poly-V belt (2) lies on the first clamp for the assembly tool (5) 451589006100 4 Place a second clamp for assembly tool (5) in the marked area (arrow A) on refrigerant compressor belt pulley Place one clamp for assembly tool (5), with the long strut upwards, on the belt pulley.

Fig 1: Identifying Poly-V Belt For Compressor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Continue to turn engine at the

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2384 · Applies to: 450, 451, 452, 454 · AR: AR13.22-P-1202MCU

451589006100 5 Continue to turn engine at the center bolt (3) through a further 30° until poly-V belt (2) lies on the second clamp for the assembly tool (5) 451589006100 6 Press poly-V belt (2) using a suitable assembly lever in the upper area slightly outwards and turn engine at center bolt (3) until the poly-V belt (2) can be removed

7 Remove poly-V belt (2)

Install

8 Position poly-V belt (2) on belt pulley (4), lay in the upper area on the supercharger belt pulley and lock in place with a clamp for the assembly tool (5) in the marked area (arrow B) Check poly-V belt (2) before installing for wear and damage.

451589006100 9 Turn engine at center bolt (3) through about 30° in direction of engine rotation and lock poly-V belt (2) in place using the second clamp for the assembly tool (5) in the marked area (arrow B) 451589006100 10 Turn engine at center bolt (3) until poly-V belt (2) lies complete on the pulley Check positioning of poly-V belt (2) on the belt pulley (4) and align if necessary by guiding with the hand and by turning the engine at the center bolt (3).

11 Install poly-V belt (1)

AR13.22-P-1202MCU Fig 2: Identifying Assembly Tool (451 589 00 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL POLY-V BELT - AR13.22-P-1202MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2385 · Applies to: 450, 451, 452, 454 · AR: AR13.22-P-1202MCU

ENGINE 132.910 in MODEL 451.3/4 Removing

Risk of injury caused by moving parts that can pinch, crush or, in extreme cases, even sever extremities No parts of the body or limbs should be within the operating range of the mechanical components when moving AS00.00-Z-0009- 01A Fig 1: Identifying Expansion Clip And Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Poly-V Belt, Tensioning Device And Locking Pin Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2387 · Applies to: 450, 451, 452, 454 · AR: AR13.22-P-1202MCU, BA13.00-Z-9999CZ

1 Remove poly-V belt (2)

AR13.22-P-1202MCU 2 Remove bolt (3) and poly-V belt tensioning device (1) *BA13.25-P-1003-01K 3 Install in the reverse order

BELT TENSIONING DEVICE Number Designation Engine 132.9 BA13.25-P-1003- 01K Bolt, poly-V belt tensioning device to timing case cover Nm 49 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: AIR COMPRESSOR, BELT DRIVES - BA13.00-Z-9999CZ > MODEL all Belt tensioning device ENGINE 132.9, 160.910 /920 /921 /922 /923 BA13.25-P-1000-01K Belt tensioning device ENGINE 660.940 BA13.25-P-1000-01J Belt tensioning device ENGINE 132.910 in MODEL 451.334 /380/480 BA13.25-P-1000-01V Belt tensioning device ENGINE 639.939 BA13.25-P-1000-01S Belt tensioning device ENGINE 122.950, 134.910 /911, 135.930/950 BA13.25-P-1000-01O Belt tensioning ENGINE 160.910 /920 /921 /922 /923 BA13.25-P-1000-01N Fig 1: Identifying Poly-V Belt Tensioning Device, Poly-V-Belt And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

device

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2388 · Applies to: 450, 451, 452, 454 · AR: BE13.00-Z-9999CZ, GF13.21-P-1000MCU

Single-belt drive ENGINE 639.939 BA13.22-P-1000-01B TORQUE SPECIFICATIONS > BELT TENSIONING DEVICE - BA13.25-P-1000-01K > Engines 132, 160 BELT TENSIONING DEVICE Number Designation Engine 132.9 Engine 160.910 Engine 160.920 Engine 160.921 BA13.25-P- 1001-01K Bolt, poly-V belt tensioning device carrier to timing case Nm - 20 20 20 BA13.25-P- 1002-01K Eccentric bolt to poly-V belt tensioning device carrier Nm - 21 21 21 BA13.25-P- 1003-01K Bolt, poly-V belt tensioning device to timing case cover Nm 49 20 20 - BELT TENSIONING DEVICE Number Designation Engine 160.922 Engine 160.923 BA13.25-P-1001- 01K Bolt, poly-V belt tensioning device carrier to timing case Nm 20 20 BA13.25-P-1002- 01K Eccentric bolt to poly-V belt tensioning device carrier Nm 21 21 BA13.25-P-1003- 01K Bolt, poly-V belt tensioning device to timing case cover Nm - - TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: AIR COMPRESSOR, BELT DRIVES - BE13.00-Z-9999CZ > MODEL all Single-belt drive ENGINE 660.940 ohne KaltemittelverdichterENGINE 660.940 mit Kaltemittelverdichter BE13.22-P-1000-01J Single-belt drive ENGINE 160... BE13.22-P-1000-01I BASIC KNOWLEDGE > BELT DRIVE FUNCTION - GF13.21-P-1000MCU > ENGINE 132.9 in MODEL 451.3/4 Shown with code (I01) Air conditioning Plus

Function

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2389 · Applies to: 450, 451, 452, 454 · AR: GF13.21-P-6000MCU

Driving of the alternator (G2) and coolant pump is by means of a poly-V belt which is tensioned by a spring- loaded tensioning device. Transfer of the spring force on the V-belt takes place via the tensioner pulley mounted on the clamping device. For vehicles with code (I01) Air conditioning Plus the drive for the refrigerant compressor is by means of a stretch belt. Component description for the clamping device Model 451.33/43 GF13.25-P- 3202MCC Component description for stretch belts For code (I01) Air conditioning Plus GF13.21-P-6000MCU BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR STRETCH BELTS - GF13.21-P- 6000MCU > ENGINE 132.9 in MODEL 451.3/4 with CODE (I01) Air conditioning Plus Fig 1: Poly-V-Belt Routing Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Location

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2390 · Applies to: 450, 451, 452, 454 · AR: GF13.25-P-3202MCC

The stretch belt is located seen in the direction of travel on the right side on the engine and connects the crankshaft belt pulley with the refrigerant compressor belt pulley. Task The stretch belt transfers the rotational movement of the crankshaft via the crankshaft belt pulley to the refrigerant compressor belt and thus drives the refrigerant compressor (A9). The stretch belt does not need a tensioning device and must be replaced after a specified mileage. BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE CLAMPING DEVICE - GF13.25-P-3202MCC > ENGINE 132.9 in MODEL 451.33 /43 (except 451.334) Fig 1: Identifying Stretch Belt, Crankshaft Belt Pulley And Belt Pulley On Refrigerant Compressor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MAINTENANCE > CHECK POLY-V BELT FOR WEAR AND DAMAGE - AP13.22-P-1351MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2396 · Applies to: 450, 451, 452, 454 · AR: AP13.22-P-1351MCU

ENGINE 132.910 in MODEL 451.3 /4 Damage profiles Fig 1: Identifying Poly-V Belt Of Refrigerant Compressor, Poly-V-Belt, Center Bolt And Expansion Clip Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

V belt (5) and poly V

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2398 · Applies to: 450, 451, 452, 454 · AR: AR13.00-Z-9132CB, AR13.22-P-1202MCC, AR13.22-P-1202MCU, AR13.21-P-1202MCC, AR13.21-P-1202MCU (+5 more)

belt of refrigerant compressor (4) for wear and damage Remove/install poly-V beltOn vehicles with code (I01) Air conditioning Plus AR13.22- P- 1202MCU Remove/install poly-V belt for compressor AR13.21- P- 1202MCU Install

4 Position cover (3), insert expansion clips (1) and press in pins (2)

5 Lower vehicle with lifting platform

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: AIR COMPRESSOR, BELT DRIVES - AR13.00-Z-9132CB > ENGINE 132 Remove/install poly-V belt ENGINE 132... AR13.22-P-1202MCC Remove/install poly-V belt ENGINE 132.910 in MODEL 451.3 /4 AR13.22-P-1202MCU Remove/install poly-V belt for compressor ENGINE 132.9 in MODEL 451.3 /4 with CODE (I01) Air conditioning Plus AR13.21-P-1202MCC Remove/install poly-V belt for compressor ENGINE 132.910 in MODEL 451.3 /4 with CODE (I01) Air conditioning Plus AR13.21-P-1202MCU Remove/install poly-V belt of starter-alternator ENGINES 132.910 in MODELS 451.334 /380 /480 as of 31.8.10 AR13.22-P-0005MCB Remove/install poly-V belt of starter-alternator ENGINES 132.910 in MODEL 451.334 /380 /480 up to 30.8.10 AR13.22-P-0005MCC Remove/install poly-V belt tensioning device ENGINES 132.910 in MODELS 451.334 /380 /480 as of 31.8.10 AR13.25-P-3200MCB Remove/install poly-V belt tensioning device ENGINE 132... AR13.25-P-3200MCC Remove/install poly-V belt tensioning device ENGINES 132.910 in MODEL 451.334 /380 /480 up to 30.8.10 AR13.25-P-3200MCE Remove/install poly-V belt tensioning device ENGINE 132.910 in MODEL 451.3 /4 AR13.25-P-3200MCU TESTING & REPAIR > REMOVE/INSTALL POLY-V BELT FOR COMPRESSOR - AR13.21-P- 1202MCU > ENGINE 132.910 in MODEL 451.3 /4 with CODE (I01) Air conditioning Plus Illustrated on removed engine

poly V belt (2) u ing a uitable

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2400 · Applies to: 450, 451, 452, 454 · AR: AR13.22-P-1202MCU

6 Pre poly V belt (2) u ing a uitable assembly lever in the upper area slightly outwards and turn engine at center bolt (3) until the poly-V belt (2) can be removed

7 Remove poly-V belt (2)

Install

8 Position poly-V belt (2) on belt pulley (4), lay in the upper area on the supercharger belt pulley and lock in place with a clamp for the assembly tool (5) in the marked area (arrow B) Check poly-V belt (2) before installing for wear and damage.

Fig 2 9 Turn engine at center bolt (3) through about 30° in direction of engine rotation and lock poly-V belt (2) in place using the second clamp for the assembly tool (5) in the marked area (arrow B) Fig 2 10 Turn engine at center bolt (3) until poly- V belt (2) lies complete on the pulley Check positioning of poly-V belt (2) on the belt pulley (4) and align if necessary by guiding with the hand and by turning the engine at the center bolt (3).

11 Install poly-V belt (1)

AR13.22- P- 1202MCU TESTING & REPAIR > REMOVE/INSTALL POLY-V BELT - AR13.22-P-1202MCU > ENGINE 132.910 in MODEL 451.3 /4 Fig 2: Identifying Assembly Tool (451 589 00 61 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2403 · Applies to: 450, 451, 452, 454 · AR: AR13.22-P-1202MCU, BA13.00-Z-9999CZ

1 Remove poly-V belt (2)

AR13.22-P-1202MCU 2 Remove bolt (3) and poly-V belt tensioning device (1) *BA13.25-P-1003-01K 3 Install in the reverse order

BELT TENSIONING DEVICE Number Designation Engine 132.9 BA13.25-P-1003- 01K Bolt, poly-V belt tensioning device to timing case cover Nm 49 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: AIR COMPRESSOR, BELT DRIVES - BA13.00-Z-9999CZ > MODEL all Belt tensioning device ENGINE 132.9, 160.910 /920 /921 /922 /923 BA13.25-P-1000-01K Belt tensioning device ENGINE 660.940 BA13.25-P-1000-01J Belt tensioning device ENGINE 132.910 in MODEL 451.334 /380/480 BA13.25-P-1000-01V Belt tensioning device ENGINE 639.939 BA13.25-P-1000-01S Belt tensioning device ENGINE 122.950, 134.910 /911, 135.930/950 BA13.25-P-1000-01O Belt tensioning ENGINE 160.910 /920 /921 /922 /923 BA13.25-P-1000-01N Fig 1: Identifying Poly-V Belt Tensioning Device, Poly-V-Belt And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

device

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2404 · Applies to: 450, 451, 452, 454 · AR: BE13.00-Z-9999CZ, GF13.21-P-1000MCU

Single-belt drive ENGINE 639.939 BA13.22-P-1000-01B TORQUE SPECIFICATIONS > BELT TENSIONING DEVICE - BA13.25-P-1000-01K > Engines 132, 160 BELT TENSIONING DEVICE Number Designation Engine 132.9 Engine 160.910 Engine 160.920 Engine 160.921 BA13.25-P- 1001-01K Bolt, poly-V belt tensioning device carrier to timing case Nm - 20 20 20 BA13.25-P- 1002-01K Eccentric bolt to poly-V belt tensioning device carrier Nm - 21 21 21 BA13.25-P- 1003-01K Bolt, poly-V belt tensioning device to timing case cover Nm 49 20 20 - BELT TENSIONING DEVICE Number Designation Engine 160.922 Engine 160.923 BA13.25-P- 1001-01K Bolt, poly-V belt tensioning device carrier to timing case Nm 20 20 BA13.25-P- 1002-01K Eccentric bolt to poly-V belt tensioning device carrier Nm 21 21 BA13.25-P- 1003-01K Bolt, poly-V belt tensioning device to timing case cover Nm - - TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: AIR COMPRESSOR, BELT DRIVES - BE13.00-Z-9999CZ > MODEL all Single-belt drive ENGINE 660.940 ohne KaltemittelverdichterENGINE 660.940 mit Kaltemittelverdichter BE13.22-P-1000- 01J Single-belt drive ENGINE 160... BE13.22-P-1000-01I BASIC KNOWLEDGE > BELT DRIVE FUNCTION - GF13.21-P-1000MCU > ENGINE 132.9 in MODEL 451.3 /4 Shown with code (I01) Air conditioning Plus

Function

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2405 · Applies to: 450, 451, 452, 454 · AR: GF13.25-P-3202MCC, GF13.21-P-6000MCU

Driving of the alternator (G2) and coolant pump is by means of a poly-V belt which is tensioned by a spring- loaded tensioning device. Transfer of the spring force on the V-belt takes place via the tensioner pulley mounted on the clamping device. For vehicles with code (I01) Air conditioning Plus the drive for the refrigerant compressor is by means of a stretch belt. Component description for the clamping device Model 451.33/43 GF13.25-P-3202MCC Component description for stretch belts For code (I01) Air conditioning Plus GF13.21-P-6000MCU BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR STRETCH BELTS - GF13.21-P- 6000MCU > ENGINE 132.9 in MODEL 451.3 /4 with CODE (I01) Air conditioning Plus Fig 1: View Of Poly-V-Belt Routing Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Location

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2406 · Applies to: 450, 451, 452, 454 · AR: GF13.25-P-3202MCC

The stretch belt is located seen in the direction of travel on the right side on the engine and connects the crankshaft belt pulley with the refrigerant compressor belt pulley. Task The stretch belt transfers the rotational movement of the crankshaft via the crankshaft belt pulley to the refrigerant compressor belt and thus drives the refrigerant compressor (A9). The stretch belt does not need a tensioning device and must be replaced after a specified mileage. BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE CLAMPING DEVICE - GF13.25-P-3202MCC > ENGINE 132.9 in MODEL 451.33 /43 (except 451.334) Fig 1: Identifying Stretch Belt, Crankshaft Belt Pulley And Belt Pulley On Refrigerant Compressor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Inspect expansion valve

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2436 · Applies to: 450, 451, 452, 454 · AR: AR01.00-P-3050MCU, AR88.20-P-1900MCC, AR88.00-P-1010MCC, AR83.30-P-1760MCC

10 Inspect expansion valve with air conditioning leak detector If leaks are found, the expansion valve must be replaced.Refer to: ↓

Remove/install expansion valve AR83.30-P- 5520MCU 11 Inspect refrigerant compressor with air conditioning leak detector If leaks are found, the refrigerant compressor must be replaced.Refer to: ↓

Remove/install expansion valve ar83.30-P-5300MCU 12 Inspect condensation water drain hose (1) with air conditioning leak detector If leaks are found, the evaporator must be replaced.Refer to: ↓

Remove/install air conditioner housing AR83.30-P- 5200MCU 13 Inspect refrigerant lines with air conditioning leak detector If leaks are found, the refrigerant lines affected must be replaced.Refer to: ↓

Remove/install refrigerant lines at refrigerant compressor AR83.30-P- 7810MCU Remove/install refrigerant line between refrigerant compressor and evaporator AR83.30-P- 7811MCU Remove/install refrigerant line between evaporator and condenser AR83.30-P- 7812MCU Remove/install refrigerant line between condenser and refrigerant compressor AR83.30-P- 7813MCU Install

14 Position rear drive module

AR01.00-P-3050MCU 15 Lift vehicle using the vehicle lift and install underfloor paneling

16 Install CBS rear

AR88.20-P-1900MCC 17 Install front CBS

AR88.00-P-1010MCC 18 Install maintenance flap

TESTING & REPAIR > DRAIN, EVACUATE AND REFILL AIR CONDITIONING, CHECK FUNCTION AND CHECK FOR LEAKS - AR83.30-P-1760MCC > MODEL 451.3/4 with CODE (I01) Air conditioning Plus

Search aid for all wiring diagram groups

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2695 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU (+1 more)

OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU SPECIAL TOOLS > SPECIAL TOOLS: SMART: DETACHABLE BODY COMPONENTS, EXTERIOR FLAPS - WS88.00-Z-9999CZ > MODEL all 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P- 0274K 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P- 0027K 452 589 01 21 00 Feeler gauge FG 60/62/63/64/65/67 72/77/82/88/Set K WS60.00-P- 0107K 452 589 01 63 00 Clip remover FG 61/67/68/72/82/88/ 91/ Set K WS68.00-P- 0012K

Search aid for all wiring diagram groups

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2830 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU

OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU SPECIAL TOOLS > 450 589 00 39 00 RIVETER - WS72.00-P-0029B > FG 72/Set B MODEL 451, 454 Use: Riveter for riveting blind rivets on power windows NOTE: Electro-mechanical blind riveter tool smart no.: 000 5030 V001 0000 00 SPECIAL TOOLS > 451 589 01 39 00 NOSEPIECE EXTENDED - WS72.00-P-0036B > Group 72/Set B MODEL 451 Use: Nosepiece extended for installing rivet for power window Fig 1: Identifying Riveter (450 589 00 39 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

60MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2909 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU

diagram for power windows 60MCU OV00.01-P-1901- 03MCC Use of wiring diagrams

OV00.01-P-1901- 03MCC OV00.01-P-1901MCU Search aid for all wiring diagram groups

OV00.01-P-1901MCU OV00.01-P-1001- 27MC Abbreviations for wiring diagrams

OV00.01-P-1001- 27MC OV00.01-P-1001- 28MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P-1001- 28MC GF00.19-P-1000MCU Location and assignment of line and connectors

GF00.19-P-1000MCU GF00.19-P-2000MCU Location and assignment of ground points

GF00.19-P-2000MCU GF00.19-P-3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)

GF00.19-P-3000MCU PE54.00-P-1100MCU

Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM FOR POWER WINDOWS - PE72.29-P-2001- 99MCU > Code: Designation: Position: A1 Instrument cluster 7L M10/3 Left power window motor 17L M10/4 Right power window motor 19L N10/10 SAM control unit 3L N10/10f3 Fuse 3 2L N57/2 Power window convenience feature control unit 20A N57/2 Power window convenience feature control unit 12A N57/2 Power window convenience feature control unit 4A S21/1 Left power window switch 11L S21/2 Right power window switch 21L

Location and assignment of ground points

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3654 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU, PE91.00-P-2050MCU, OV00.01-P-1901MCU (+3 more)

GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR AIRBAG (AB), EMERGENCY TENSIONING RETRACTOR (ETR) - PE91.00-P-2050MCU > MODEL 451 Electrical function diagram for airbag (AB), emergency tensioning retractor (ETR) PE91.00-P-2050- 99MCU Legend of electrical function diagram for airbag (AB), emergency tensioning retractor (ETR) PE91.00-P-2050- 60MCU Use of wiring diagrams OV00.01-P-1901- 03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE07.00-P-1100MCU Further wiring diagrams PE42.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM OF SEAT HEATER (SIH) - PE91.30-P-2000- 97MCU > Code: Designation: Position: N10/10 SAM control unit 4L N10/10f12 Fuse 12 6L N10/10f20 Fuse 20 3L N10/10f44 Fuse 44 (slot R9) 2L N25/5 Front HS [SIH] control unit 12A N25/5 Front HS [SIH] control unit 4A R13/1 Left seat heated cushion 11L R13/3 Right seat heated cushion 14L

Abbreviations for wiring diagrams

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3657 · Applies to: 450, 451, 452, 454 · AR: GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU

OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU SPECIAL TOOLS > 450 589 07 99 00 ASSEMBLY TOOL SET - WS91.00-P-0031B > FG 68/91/Set B MODEL 450, 451, 452, 454 Use: Model 450; 451; 452 Assembly tool set for seat repair. Model 454 Pulling hook from assembly tool set for removal of air outlets from instrument panel. NOTE: Set consists of three individual tools smart no. 001 0475 V001 0000 00. SPECIAL TOOLS > 211 589 00 32 00 PLATES - WS91.00-P-0034B > FG 91/Set B Fig 1: Identifying Assembly Tool Set (450 589 07 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Search aid for all wiring diagram groups

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4241 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU (+1 more)

OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU SPECIAL TOOLS > 129 589 01 98 00 WELDING BEAD CATCHER - WS77.00-P-0010K > Group 00/63/77/Set K MODEL all Use: Welding bead catcher for covering vehicle parts during welding

SPECIAL TOOLS > SPECIAL TOOLS: SMART: SLIDING ROOF, SOFT TOP, TOP ATTACHMENTS - WS77.00-Z-9999CZ > MODEL all 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P- 0274K 129 589 01 98 00 Welding bead catcher Group 00/63/77/Set K WS77.00-P- 0010K 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P- 0027K 450 589 02 23 00 Gage FG 77/Set K WS77.00-P- Fig 1: Identifying Welding Bead Catcher (129 589 01 98 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODEL 451

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4317 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE54.00-P-1100MCU (+1 more)

Electric wiring diagram for heated rear window PE67.29-P-2000-99MCU Legend of wiring diagram for heated rear window PE67.29-P-2000-60MCU Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU Further wiring diagrams PE83.00-P-1100MCU SPECIAL TOOLS > 450 589 08 63 00 CUTTING WIRE - WS67.00-P-0020B > FG 65/67/Set B MODEL 450, 451, 452, 454 Use: Cutting wire for cutting out glued windows and glass roof NOTE: Cutting wiresmart no.: 000 5177 V001 0000 00 SPECIAL TOOLS > 452 589 00 99 11 STONE CHIPPING CRACKER - WS67.00-P-0022-11B Fig 1: Identifying Cutting Wire (450 589 08 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Use of wiring diagrams

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4450 · Applies to: 450, 451, 452, 454 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE07.00-P-1100MCU (+4 more)

OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE07.00-P-1100MCU Further wiring diagrams PE26.00-P-1100MCU Further wiring diagrams PE42.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM OF AUTOMATED MANUAL TRANSMISSION (SEQ) CONTROL UNIT - PE26.19-P-2101MCU > TRANSMISSION 717 in MODEL 451 / (except 451.391 /491) Wiring diagram of automated manual transmission (SEQ) control unit PE26.19-P-2101-97MCU Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and plug connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU SPECIAL TOOLS > 000 589 52 37 00 PLIERS - WS26.00-P-0005C > FG 26/Set C TRANSMISSION 711.101 /11 /202 /640 /641 /68, 716.0 /1 /2 /6, 717.0 /40 /41 /42 /43 /44 /45 /46, 711.67, 717.48 Further use FG 27/Set C WS27.00-P-0001C

FG 46/Set C WS46.00-P-0093C

FG 47/ Set B WS47.00-P-0036B