2008 Smart Fortwo Tech Manual

,
Introduction of the smart fortwo Model series 451

Introduction into Service Manual
www.smartusa.com
Introduction of the smart fortwo Model series 451
SN_Typ 451_us.book Seite 1 Freitag, 30. November 2007 1:56 13
Introduction of the smart fortwo Model Series 451

Introduction into Service Manual
smart USA
Copyright
smart USA, 2007 All rights reserved. Reproduction by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from the publisher.
Published by smart USA, 2007 Printed in U.S.A. www.smartusa.com
Content
Preface
7
Complete vehicle Overview Technical data Maintenance Safety concept

8 10 13 17
Electrical system On board electrical system/power supply Complete networking Wiring harnesses Diagnosis SAM control unit
20 22 24 26 28
Engine M132 Engine description Performance graph Engine data Valve assembly Valve timing Gasoline injection and ignition system Belt drive Cooling system Engine mount
Introduction of the smart fortwo, Model Series 451 30 30 32 33 34 35 38 39 41
Content
Fuel system Fuel supply
42
Exhaust system Overview Secondary air injection

45 46
Automated manual transmission Transmission description Transmission data Shift mechanism Synchronization Transmission control Park pawl Clutch
47 48 49 54 55 61 62
Chassis Front axle Rear axle Rear module Tire pressure monitor Brakes Steering
64 65 66 67 69 75
Introduction of the smart fortwo, Model Series 451
Content
Body Interior Doors/flaps Roof systems Central locking Anti theft alarm system (ATA [EDW]) Exterior lights Audio system Climate control Customized Bodypanel System (CBS) Seats Supplemental restraint system Body
82 86 90 96 99 101 102 104 106 108 109 113
Accessories smart accessories

116
Index
120
Content
Preface
Dear reader, This Introduction into Service Manual presents the new smart fortwo in model series 451. The purpose of this manual is to inform you of the technical features of this new vehicle. This brochure is intended to provide information for people employed in service, maintenance and repair as well as for aftersales staff. In terms of the contents, the emphasis in this Intro duction into Service manual is on presenting the major assemblies and systems. This Introduction into Service manual is not intended as an aid for repairs or for the diagnosis of technical problems. For such needs, more extensive information is available in the Workshop Information System (WIS) and in the Diagnosis Assistance System (DAS). WIS is updated monthly. Therefore, the information available there reflects the latest technical status. This Introduction into Service Manual presents initial information relating to the new smart fortwo in model series 451 and, as such, is not stored in WIS. The contents of this brochure are not updated. No provi sion is made for supplements. We will publicize modifications and new features in the relevant WIS documents. The information presented in this Introduction into Service Manual may therefore differ from the more up to date information found in WIS. All information relating to technical data, equipment and options is valid as of the copy deadline in September 2007 and may therefore differ from the current production configuration.
smart USA aftersales
Complete vehicle
Overview
smart fortwo coup

P00.10-4192-00
smart fortwo cabrio

P00.10-4198-00
Overview
Vehicle concept
Externally, the smart fortwo is immediately distin guishable by its compactness with the tridion safety cell and its two tone design. The smart fortwo is avail able in a variety of colors. The tridion safety cell in black or silver can be combined with six different basic colors. The model series can be ordered as the smart fortwo coup or the smart fortwo cabrio. Despite its compact appearance, the smart fortwo provides the occupants with a generous amount of legroom and sufficient trunk capacity. The interior compartment has a classic design. The instrument panel was designed with straight lines and the colors have been kept refined. Repeated aluminum accent trim on the air vents and the inside door handles gives the interior design a harmonic yet modern aspect.
Vehicle characteristics
Overall vehicle exterior External dimensions to suitably accommodate the occupants and provide sufficient the trunk capacity. Plastic panoramic sunroof or full roof on the smart fortwo coup. Tritop soft top on the smart fortwo cabrio. Overall vehicle interior Numerous color and pattern variants in the interior. Ergonomic instrument cluster in the instrument panel. Clearly arranged and user friendly center console. Rear end door with integral stowage compartment for the smart fortwo coup or tight fitting stowage areas without retaining straps for the roof side supports in the smart fortwo cabrio. Engine/injection system 3 cylinder gasoline engine with 52 kW. Fuel injection system with Bosch Multi Point Injection. Transmission 5 speed automated manual transmission AMT 2 (2nd generation). Suspension MacPherson front suspension with torsion stabilizer bars. DeDion rear axle. Brake Hydraulic 2 circuit brake system with ESP and TT (front/rear) split, version 8.1 from Bosch. Steering Equipped with rack and pinion steering as standard. Electromechanical power steering with active steering centering and adaptation of the steering forces available as special equipment. Maintenance Maintenance concept: Maintenance service only every two years, with only the Oil Service Plus once a year in between. Service flap at front for easy access to the maintenance points. Safety Restraint system with airbags and emergency tensioning retractors. Bodyshell made of high strength steels. Door reinforcements made of high strength steels. Full length knee guard for driver and passenger.
Complete vehicle
Complete vehicle
Technical data
60.7
50.5 69.0
54.5 61.4
39.7
27.7
21.0 21.0 11.5
19.7 24.4
28.7
16.7
73.5 106.1
15.9
50.0
48.0
P00.10-4259-00
Dimensions smart fortwo coup
Dimensions Vehicle length Vehicle width Vehicle height Wheelbase Front track width Rear track width
Unit in (mm) in (mm) in (mm) in (mm) in (mm) in (mm)
smart fortwo coup (model 451) 106.1 (2695) 61.4 (1559) 60.7 (1542) 73.5 (1867) 50.5 (1283) 54.5 (1385)
10
Technical data
60.7
50.5 69.0
54.5 61.4
39.7
27.7
21.0 21.0 11.5
19.7 24.4
28.7
16.7
73.5 106.1
15.9
50.0
48.0
P00.10-4260-00
Dimensions smart fortwo cabrio
Dimensions Vehicle length Vehicle width Vehicle height Wheelbase Front track width Rear track width
Unit in (mm) in (mm) in (mm) in (mm) in (mm) in (mm)
smart fortwo cabrio (model 451) 106.1 (2695) 61.3 (1559) 60.7 (1542) 73.5 (1867) 50.5 (1283) 54.5 (1385)
11
Complete vehicle
Complete vehicle
Technical data
Models and major assemblies
smart fortwo smart fortwo coup smart fortwo cabrio Model 451.331 451.431 132.910 (52 kW) 717.482 Engine Transmission
Loads, weights and other data

Unit Powerplant Permissible front axle load kW lb (kg) lb (kg) lb (kg) lb (kg) lb (kg) lb (kg) 1652 (820) 2247 (1050) 595 (230) 110 (50) smart fortwo coup 52 969 (440) 1458 (660) 1740 (840) 2247 (1050) 507 (210) smart fortwo cabrio 52
Permissible rear axle load
Curb weight as per DIN
Permissible gross vehicle weight
Payload
of which max. in luggage compart ment
Max. seating capacity Luggage compartment volume up to belt line up to roof in3 (l) in3 (l) Turning circle yd (m) US gal (l)
7.8 (220) 12 (340) 9.57 (8.75) 8.72/1.32 33/5
Tank capacity/including reserve
12
Maintenance
Ma xintenance concept
Consistent product development has enabled a future oriented servicing concept to be implemented in model series 451. The servicing concept of the smart fortwo has allowed the service intervals to be extended significantly, as shown below.
Maintenance intervals
smart fortwo Gasoline engine kW 52 Interval Every 2 years or 20,000 miles*
* depending on first occurrence
Oil Service Plus

In combustion engines with a high engine output per unit of displacement, the engine oil is subjected to extreme loads. With 3.7 US qt (3.5 liters), the smart fortwo has a relatively small quantity of engine oil, meaning that it has to be replaced at regular time/mileage intervals. To help optimize operating costs, the "Oil Service Plus" has been introduced, which is due every 10 000 miles or once per year. It comprises merely an engine oil change and inspection of the safety relevant components and functions. This servicing concept has benefits for both the workshops and the customers: Customers have lower vehicle operating costs due to the reduced maintenance costs as a whole. This improves customer satisfaction. The workshops improve their competitiveness in the servicing business especially. Longer lasting customer loyalty and better chances of follow up business are possible with this concept.
13
Complete vehicle
Complete vehicle
Maintenance
Maintenance interval display (WIA)
The maintenance interval display is located in the multifunction display of the instrument cluster. The maintenance intervals are indicated by the lighting of one or two wrench symbols. In addition, approximately one month in advance of a scheduled service date the multifunction display shows the remaining time (in days) until it is due. After engine start the range (in miles) is displayed for about ten seconds.
P54.32-5676-00
Instrument cluster A1 A1p13 Instrument cluster Multifunction display
i Note When the Oil Service Plus or a maintenance service has been performed, the maintenance interval display can be reset to the starting distance on the instrument cluster itself or via STAR DIAGNOSIS. (See WIS for a detailed description.)
Meaning of wrench symbols: 1 wrench means Oil Service Plus 2 wrenches mean maintenance service
P54.32-5677-00
Multifunction display with maintenance interval display
14
Maintenance
Service flap
The smart fortwo is equipped with a detachable service flap which allows convenient access to all maintenance points in the front section. Customer relevant maintenance items can be performed by the customer accordingly. To remove the service flap, levers located in the air grille on each side must be operated to unlock the service flap. The service flap can then be removed and suspended by two brackets on the front of the vehicle. A check strap prevents the service flap from falling down.
Maintenance points at front end

The most important maintenance points at the front of the car are: Brake fluid reservoir Windshield washer fluid reservoir Coolant expansion reservoir Lamp units for bulb replacement
P00.20-2629-00
Maintenance points at front end 1 Brake fluid reservoir 2 Windshield washer fluid reservoir 3 Coolant expansion reservoir 4 Lamp unit for bulb replacement 5 Service flap 6 Check strap
15
Complete vehicle
Complete vehicle
Maintenance
Maintenance points in engine compartment
The maintenance points in the engine compartment can be accessed once the engine compartment cover in the luggage compartment floor has been removed. The most important maintenance points in the engine compartment are: Oil filler neck Oil dipstick Air filter housing Spark plugs
P00.20-2630-00
Maintenance points in engine compartment 7 Oil filler neck 8 Oil dipstick 9 Air filter housing 10 Ignition coils (spark plugs)
16
Safety concept
In the smart fortwo, high levels of active safety are provided by both tried and tested and newly devel oped systems and components.
Active safety
Active safety includes measures and equipment that help to prevent detected dangers from occurring in the first place, or that warn the driver of dangers in advance, or that assist him in critical driving situa tions: A distinction is drawn between the following safety aspects: Driving safety Stress reducing safety Perceptual safety Operating safety High levels of stress reducing safety are due to: Comfortable seats with integral head restraints Temperature regulated air conditioning High levels of perceptual safety are assured by the following components: Auto on/off headlamps (SA) Center high mounted brake lamp in the roof spoiler Operating safety is provided by: Ergonomically designed driver area Clearly arranged and easily reachable controls
The components responsible for maintaining driving safety include: Electromechanical power steering (SA) 5 speed automated manual transmission Vehicle dynamics systems: ABS (antilock brake system) ASR (acceleration skid control) ESP (electronic stability program)
17
Complete vehicle
Complete vehicle
Safety concept
Passive safety
The goal of a vehicle's passive safety is to minimize as much as possible the effects of an accident on the people involved. Some of the most important aspects of this are the preservation of the survival space (rigid passenger cell), high energy dissipation in the event of an accident thanks to exploitable crumple zones at the front and rear, and energy absorbing restraint systems in the interior. The passive safety concept includes: tridion safety cell consisting of 50% high strength steel Crash management system (CMS) at the front and rear, which absorbs energy at low vehicle speeds and prevents expensive bodyshell damage Front end with no major assemblies, for effective exploitation of the short overhang as a crumple zone Inclusion of the wheels and axles/frame type integral support in the crumple zone and for force application Front and rear structures with several impact planes and large cross sections to transfer and disperse the crash energy that is generated Long forward displacement area for the driver and passenger with restraint systems adapted to compensate for the "short" crumple zone Sturdy steel seat structures for effective protection against shifting cargo and for specific deformation in rear end collisions Side doors made of solid steel frame profiles including side impact protection Safe positioning of the fuel tank in the underfloor area between the axles Deformable steering column to dissipate energy, prevent intrusion and lengthen the forward displacement distance in a frontal collision Full interior lining to reduce head injuries The occupant restraint systems comprise: 2 stage driver airbag in steering wheel 2 stage top mounted passenger airbag with deployment opening on the top surface of the instrument panel Head/thoraxbags in the backrests Three point seat belts with emergency tensioning retractors, belt force limiters and belt guides on the backrests Seat belt reminders for driver and passenger Belt tension sensor on passenger side Passenger seat with Weight Sensing System (WSS) with automatic passenger airbag deactivation for the corresponding weight classes and airbag OFF indicator lamp Full length knee guard Two frontal acceleration sensors on front crossmember Two satellite sensors on inner side wall in area of left and right B pillar Restraint systems control unit
P91.60-3663-00
1 Driver airbag 2 Passenger airbag 3 Head/thoraxbag
18
Safety concept
Protective measures for pedestrians and cyclists comprise: Single piece front end module Main headlamps with predetermined fracture point Concealed and retracting windshield wiper shafts Energy absorbing covering on the center piece in front of the windshield Large, soft plastic surfaces at the front
The extended range of functions following an accident includes: Automatic engine off feature Interruption of the fuel supply Unlocking of the doors Activation of the hazard warning system
19
Complete vehicle
Electrical system
On board electrical system/power supply

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

Alternator
The alternator supplies the electrical consumers while the engine is running and recharges the battery so that a subsequent engine start is possible. The alternator is equipped with an overvoltage protection function that limits the on board power supply voltage in the event of a defect in the governor. The alternator is monitored by the ME SFI [ME] control unit. The alternator is pre excited via a direct line. The alternator load is reported back to the ME SFI [ME] control unit over a separate line and monitored.
Instrument cluster
The on board power supply voltage is monitored by the engine control. If the voltage is < 11.5 V for a period of over 3 min, a signal is sent over CAN to the instrument cluster and the alternator charge moni toring and warning lamp (A1e5) lights up.
P54.10-2891-00
P54.32-5684-00
G2
Alternator
A1 A1e5
Instrument cluster Alternator charge monitoring and warning lamp
21
Electrical system
Electrical system
Complete networking
Overall network location of components
P00.19-4338-00
Overall network full equipment
A1 A15p4
B24/15
B32
Instrument cluster on the left side of the instrument panel Tachometer (with code (V31) Cockpit clock and tachome ter package) in the center of the instrument panel Yaw rate, lateral and longitudinal accelera tion sensor under the floor covering near the driver seat ATA [EDW] microwave sensor (with code (V01) Anti theft alarm system (FFO)) under the center console near the handbrake lever
B38
H3/2
N2/7 N3/10 N10/10 N15/5
Rain sensor/light sensor (with code (V54) Rain/light sensor) in the middle of the windshield near the in side rearview mirror Alarm siren with inclination sensor (with code (V01) Anti theft alarm system (FFO)) on the right in front of the fuel tank Restraint systems control unit in the center under the instrument panel ME SFI [ME] control unit behind the right side paneling in the rear SAM control unit on the left under the instrument panel Electronic selector lever module control unit
(Legend continued on the next page)
22
Complete networking
Overall network CAN bus/LIN bus
P00.19-4339-00
Block diagram Full equipment
N15/6
N23
N25/5
N47 5 N49
Automated manual transmission control unit under the floor covering near the driver seat Heater/AC operating unit (with code (I01) Air conditioning Plus and code (V30) Outside temperature sensor (FFO)) in the center of the instrument panel Front HS [SIH] control unit (with code (S17) Seat heaters (FFO)) in the center under the instrument panel ESP control unit on ESP hydraulic unit Steering angle sensor in steering wheel
N57/2
N68
N88 N110 X11/4
Power window convenience feature control unit (with code (V43) Power windows) on the left under the instrument panel Power steering control unit (with code (V26) Power steering, EPS (FFO)) in interior compartment on left of firewall TPM [RDK] control unit on left below instrument panel Weight Sensing System (WSS) control unit on underside of passenger seat Data link connector on the bottom of the instrument panel on the driver side Controller Area Network bus (data bus/CAN bus) Controller Area Network bus class B (interior compartment) Interior Local Interconnect Network 1 Interior Local Interconnect Network 2
CAN CAN B LIN B LIN C
23
Electrical system
Electrical system
Wiring harnesses
P54.18-4507-00
Wiring harness groups
The wiring harness is divided into the following groups: 1 Main wiring harness 2 Engine wiring harness 3 Transmission wiring harness 4 Battery wiring harness
Not illustrated: Door wiring harness Soft top wiring harness (in smart fortwo cabrio) Rear end door wiring harness
24
Wiring harnesses
General
The wiring harness variants result from the basic standard equipment, the special equipment items and the national versions.
Repair capability
A basic wiring harness repair kit in a case is available for repairing individual lines, wiring harnesses and connectors without sealed plugs. All the above repairs can be carried out using this kit. It is also possible to expand the kit with a supple mental repair set to allow wiring harnesses with sealed plugs to be repaired.
i Note W000 589 13 99 00 Basic wiring harness repair kit. Tools for repairing individual lines, wiring harnesses and connectors in combination with the wiring harness repair kit supplement for passenger cars (W220 589 04 99 00). W220 589 04 99 00 Wiring harness repair kit supplement for passenger cars Tools for repairing individual lines, wiring harnesses and connectors in combination with the basic wiring harness repair kit (W000 589 13 99 00).
P54.18-4140-00
Wiring harness repair kit
25
Electrical system
Electrical system
Diagnosis
General
The network architecture in model 451 allows external access to individual control units in the CAN bus system.
Diagnostic tester
By connecting the diagnostic tester, the vehicle with all its equipment variants can be precisely identified. This enables accurate fault evaluation and rectifica tion and the analysis of vehicle specific values and parameters.
Data link connector

The CAN bus is accessed by means of a diagnostic tester that is connected to the vehicle via the data link connector. The data link connector is linked directly to the CAN bus and can therefore access all the control units that have diagnostic or programming capability. The data link connector is located in the vehicle interior on the underside of the instrument panel on the driver side.
P54.22-2048-00
Location of data link connector (X11/4)
26
Diagnosis
Diagnosis capability
The following control units have diagnosis capability: Instrument cluster Restraint systems control unit WSS control unit ME SFI [ME] control unit SAM control unit Automated manual transmission control unit Heater/AC operating unit ESP control unit Steering assist control unit TPM [RDK] control unit Electronic selector lever module control unit
TAN generator
For the following applications a TAN (transaction number) must be generated: Retrofitting the steering wheel gearshift (SAL) Replacing the ME SFI [ME] control unit Replacing the SAM control unit Teach in of transmitter keys (after loss or detection of additional transmitter keys)
Fault memory Each of the control units listed above has a fault memory that provides information about the associ ated systems. The stored faults are displayed by the diagnostic tester and must be rectified. When all the faults have been eliminates, the fault memory must be erased and read out again. There should be no fault entries left afterwards. Maintenance intervals The diagnostic tester is used to reset the mainte nance interval in the instrument cluster following an Oil Service Plus or a maintenance service.
i Note Up to six transmitter keys in total can be taught in at the same time.
SCN (Software Calibration Number) coding

The following control units can be coded via the SCN coding process: ME SFI [ME] control unit*) SAM control unit ESP control unit Automated manual transmission control unit*) Restraint systems control unit Instrument cluster
Programming control units

The following control units can be programmed: ME SFI [ME] control unit SAM control unit Automated manual transmission control unit ESP control unit
*) The control unit is relevant to exhaust emissions, i.e. the SCN is written in the control unit and can be interrogated. For the other control units a virtual SCN is generated during the coding process, but this is not written to the control unit.
27
Electrical system
Electrical system
SAM control unit

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

The SAM control unit also communicates over: LIN B with the tachometer and the rain sensor/light sensor LIN C with the ATA [EDW] microwave sensor and the alarm siren with inclination sensor. The fuse and relay box is integrated in the SAM control unit. The following relays are not accommodated on the SAM control unit: Left turn signal/brake light relay (K52/11) Right turn signal/brake light relay (K52/12) Secondary air injection pump relay (K64) Soft top opening relay (K66/1) (only cabrio) Soft top closing relay (K66/2) (only cabrio)
i Note Up to six transmitter keys can be stored in the SAM control unit.
P54.21-2703-00
SAM control unit (rear)
29
Electrical system
Engine M132
Engine description
Engine M132
At market launch, the smart fortwo is available with a 3 cylinder gasoline engine with 61 in3 (999 cm3) displacement and 52 kW
P01.10-2942-00
3 cylinder gasoline engine (M132)
30
Performance graph
Power and torque graph
The red characteristic represents the power curve (P) in relation to the engine speed (n). The blue characteristic represents the torque curve (M) in relation to the engine speed (n).
M (lb-ft)
180 160 140
P (kW)
70 60 50
120 100 80 60 20 40 20 0 0 1000 2000 3000 4000 5000 6000 10 0 7000 40 30
n (1/min)
P01.00-2999-00
Power and torque graph M132
M Torque (lb ft) P Engine power (kW) n Engine speed (rpm)
31
Engine M132
Engine M132
Engine data
M132
Engine model designation
132.910
Rated output
kW at rpm lb ft (Nm) at rpm e
52 5800 68 (92) 4500 10.0:1
Rated torque
Compression ratio
Engine configuration/no. of cylinders
Inline/3
Camshaft configuration/number in3 (cm3) in (mm) in (mm)
Overhead/2
Displacement
61 (999) 2.83 (72) 3.22 81.8 45
Bore
Stroke
Cylinder angle
Fuel
* Premium gasoline unleaded ULEV
Emission regulations
* Fuel requirements: Only unleaded premium fuel may be used. The octane number (shown on the gasoline pump) should be at least 91. This is an average value based on tests of the octane number (RON) and motor octane number (MON) (RON+MON/2). It is also known as the anti knock index.
32
Valve assembly
Valve assembly
The timing chain is driven by the crankshaft via the crankshaft gear and thus drives the intake camshaft via the camshaft adjuster and the exhaust camshaft via the exhaust camshaft sprocket. The timing chain is guided by a slide rail. A tensioning rail and chain tensioner ensure that the chain is at the right tension to prevent wear and noises. The intake and exhaust camshafts control the gas exchange in the engine via the intake and exhaust valves. Variable camshaft adjustment allows for greater torque at low engine speeds and better response time in the idle and partial load ranges. At the same time, the camshaft adjustment helps to achieve the stipulated exhaust emissions limits.
P05.00-2082-00
Valve assembly
1 2 3 4 5 6
Exhaust camshaft sprocket Exhaust camshaft Camshaft adjuster Intake camshaft Crankshaft gear Crankshaft
7 8 9 10 11
Timing chain Intake valve Exhaust valve Valve spring Cup tappet
33
Engine M132
Engine M132
Valve timing
General
Engine M132 is equipped with mechanical cup tappets. The mechanical stress on the cams and cup tappets makes it necessary to check and adjust the valve clea rance. The cup tappets must be measured using a micro meter. Find and insert the appropriate cup tappet by refer ence to its markings. The valve clearance is adjusted by exchanging the cup tappets. These are available in various thicknesses.
P05.30-2151-00
1 2 3 4 5 6
Cylinder head Camshaft bearing cap Intake camshaft Exhaust camshaft Cup tappet Intake valve
7 8 9 10 11 12
Exhaust valve Valve spring retainer Valve locks Valve spring Valve stem seal Valve seat
34
Gasoline injection and ignition system

Injection control
Engine M132 features an ME (motor electronics) gasoline injection and ignition system. The central control unit of this system is the ME SFI [ME] control unit. It is networked over CAN with the following components: Instrument cluster SAM control unit Automated manual transmission control unit Heater/AC operating unit ESP control unit Steering assist control unit Data link connector Direct output signals go to: Fuel pump relay Fuel pump with fuel level sensor Secondary air injection pump relay Secondary air injection pump Secondary air injection pump switchover valve Throttle valve actuator Cylinder 1 ignition coil Cylinder 2 ignition coil Cylinder 3 ignition coil Outside air shutoff valve Adjustable camshaft timing solenoid Cylinder 1 fuel injection valve Cylinder 2 fuel injection valve Cylinder 3 fuel injection valve Fuel tank vent valve
The ME SFI [ME] control unit puts its information on the CAN, making it accessible to all the other networked components on the CAN. The information from other components reaches the ME SFI [ME] control unit in the same way. For example, the signal from the clutch motor, which is read directly by the automated manual transmission control unit, reaches the ME SFI [ME] control unit in this way. Direct input signals come from: Knock sensor Fuel tank pressure sensor Camshaft Hall sensor Coolant temperature sensor Accelerator pedal sensor O2 sensor downstream of TWC [KAT] O2 sensor upstream of TWC [KAT] Crankshaft position sensor Throttle valve actuator Oil pressure switch
There are also the following inputs on the ME SFI [ME] control unit: Circuit 15 Circuit 30 Circuit 31
Function
The engine is controlled according to load by the performance map based on the signals arriving either directly or over CAN. The actuators are actuated via direct lines in accordance with the values computed by the ME SFI [ME] control unit. Information intended for other components is put on the CAN. The ME SFI [ME] control unit has an integral fault memory and can exchange information with STAR DIAGNOSIS via a data link connector that is connected to the CAN.
35
Engine M132
Engine M132
P07.61-3578-00
Data flow chart of M132 injection system
36

N10/10 N15/6 N23 N47 5 N68 S41/1 T1/1 T1/2 T1/3 X11/4 Y32 Y49 Y50 Y58 Y62/1 Y62/2 Y62/3 CAN SAM control unit Automated manual transmission control unit Heater/AC operating unit ESP control unit Steering assist control unit Oil pressure switch Cylinder 1 ignition coil Cylinder 2 ignition coil Cylinder 3 ignition coil Data link connector Secondary air injection pump switchover valve Adjustable camshaft timing solenoid Outside air shutoff valve Tank vent valve Cylinder 1 fuel injection valve Cylinder 2 fuel injection valve Cylinder 3 fuel injection valve Controller Area Network (data bus/CAN bus)
15/30/31 Circuit status A1 A16 B4/3 B6/1 B11/4 B28 B37 G3/1 G3/2 K27 K64 L5 M3/3 M16/6 M33 N3/10 Instrument cluster Knock sensor Fuel tank pressure sensor Camshaft Hall sensor Coolant temperature sensor Intake manifold pressure sensor Accelerator pedal sensor O2 sensor downstream of TWC [KAT] O2 sensor upstream of TWC [KAT] Fuel pump relay Secondary air injection pump relay Crankshaft position sensor Fuel pump with fuel level sensor Throttle valve actuator Secondary air injection pump ME SFI [ME] control unit
37
Engine M132
Engine M132
Belt drive
Belt adjustment and description of stretch belt Self tensioning belt drive
The alternator and coolant pump are driven by a poly V belt with tensioning device. The poly V belt is tensioned via a new spring loaded tensioning device. To install and remove the poly V belt the tensioning device must be rotated clockwise using a special tool to slacken the tension in the belt drive. The tensioning device can then be locked in place and the poly V belt removed.
Stretch belt
The refrigerant compressor is driven by a stretch belt. The stretch belt does not need a tensioning device, but it must be replaced after a specified mileage. It is removed and installed with the aid of a special tool that guides the stretch belt over the belt pulley of the refrigerant compressor. The stretch belt can be pulled on or off the belt pulley by cranking the engine in its normal direction of rotation.
P13.20-2055-00
Belt drive
1 2 3 4
Alternator belt pulley Poly V belt Coolant pump belt pulley Refrigerant compressor belt pulley
5 6 7 8
Crankshaft pulley Tensioning device Tensioning device belt pulley Stretch belt
38
Cooling system
Coolant circuit
In the small cooling circuit, the coolant is pumped through the engine, the heater heat exchanger and back to the engine via the expansion reservoir by the coolant recirculation pump. In the large coolant circuit, the coolant flows from the thermostat straight to the radiator and on to the coolant recirculation pump. The switchover between the small and large coolant circuit is performed by the thermostat depending on the coolant temperature. In the expansion reservoir the circuit is split again, with one stream flowing direct to the coolant recircu lation pump and the other passing through the radi ator. The coolant fan motor is switched on or off depending on the engine temperature recorded by the coolant temperature sensor and cools the coolant.
P20.00-2339-00
1 2 3 4 5 6 7
Radiator Expansion reservoir Coolant return line Coolant feed line (large circuit) Coolant pump Coolant pump belt pulley Thermostat
8 9 10 B11/4 M4/2
Coolant feed line (small circuit) Heater heat exchanger Coolant pipe Coolant temperature sensor Coolant fan motor
39
Engine M132
Engine M132
Cooling system
Bleeding cooling system General
If some or all of the coolant has been drained, the cooling system must be bled after refilling.
Bleeding
Unfasten the clamp, pull off the coolant hose and wait until coolant emerges from the coolant hose and the cylinder head. Then reconnect the coolant hose and fasten it with the clamp. Top up the expansion reservoir to the "MAX" mark again and screw on the cooling system cap. Warm up the engine until the thermostat opens. Switch off the engine and check the coolant level in the expansion reservoir.
Fill
Unscrew the cooling system cap and fill the cooling system up to the "MAX" mark in the expansion reser voir.
i Note The cooling system must be filled and bled only when the engine is cold.
P20.00-2340-00
1 Cooling system cap 2 Expansion reservoir
3 Coolant hose 4 Clamp
40
Engine mount
Engine mount/torque support
The engine with transmission is mounted on two mounts and a torque support. They were designed to dampen inherent engine vibrations. They also consid erably reduce the rocking of the drive assemblies during load changes. The reduction in vibrations and in the tendency to rock provides a higher level of driving safety and ride comfort.
P22.10-2299-00
Engine mount, transmission mount and torque support
1 Frame type integral support 2 Engine mount
3 Transmission mount 4 Torque support
41
Engine M132
Fuel system
Fuel supply
Fuel supply
A non return fuel system is used for the fuel supply. The fuel is pumped by a flow pump via the fuel filter in the fuel tank into the fuel distributor rail according to requirements. Any surplus fuel is pumped via the fuel pressure regulator straight into the buffer of the fuel pump. The fuel pressure regulator is designed to ensure that there is always a pressure of 46 psi (3.24 bar) at the fuel distributor rail. The fuel tank fill level is measured by a float and lever sensor.
Leak test
The leak test for the fuel evaporation control system must detect leaks with a diameter as of 0.02 in (0.5 mm) and must take place in three stages (function chain): Test for gross leaks (equal to or greater than 0.12 in (3 mm)) Test for fine leaks (equal to or greater than 0.04 in (1 mm)) Test for very fine leaks (equal to or greater than 0.02 in (0.5 mm)) Test for gross leaks The outside air shutoff valve is closed and the tank vent valve is opened. Intake manifold vacuum present in fuel tank. This vacuum is measured by the tank pressure sensor. If no vacuum is built up in the fuel tank (approx. 0.1 psi ( 6 mbar) within approx. 12 seconds) there is a major leak (e.g. tank cap open, hose line loose). The test will be interrupted and the "gross leak" fault will be registered. If the ME SFI [ME] control unit detects a system with a gross leak, the fuel reserve warning lamp in the instrument cluster flashes and the message "CHECK FILLER CAP" appears in the multifunction display. Test for fine leaks The tank vent valve is closed at a vacuum of around 0.1 psi ( 6 mbar). The system is closed and thereby airproof. The vacuum is then measured for approx. 30 seconds. The vacuum must not reduce more rapidly than 0.004 to 0.007 psi/s (0.3 to 0.5 mbar/s) (depends on fuel level). If the vacuum drops more rapidly, there is a fine leak. The test will be interrupted and the "fine leak" fault will be registered.
Fuel tank
The fuel tank is located in front of the rear axle under the seats. It is made of polyethylene and is formed such that the available installation space is used to an optimum. The capacity of the fuel tank is 8.72 gallons (33 liters), including a 1.32 gallon (5 liter) reserve. The intank fuel supply system consists of a fuel pump with fuel level sensor, fuel pressure regulator and an integrated fuel filter.
Evaporative emission control system (purging)

The evaporative emission control system prevents fuel vapors escaping to the atmosphere. The fuel vapors are stored in the activated charcoal filter and then sent later to the engine for combustion.
42
Fuel supply
Check for very fine leaks
If no fine leak is recognized then purging is briefly enabled and then the vacuum of about 0.1 psi ( 6 mbar) is built up again. The vacuum must not reduce more rapidly than 0.0014 to 0.002 psi/s (0.1 to 0.15 mbar/s) in the closed system (depends on fuel level). If the vacuum drops more rapidly, the fault "very fine leak" will be registered. The reduction in vacuum depends on the fuel level in the fuel tank and on outgassing of the fuel. The outgassing of the fuel is measured just before the test by the fuel tank pressure sensor and is allowed for during fault determination. The test for fine and very fine leaks is aborted if an excessive lean correction of the lambda control takes place during the build up of the vacuum. The function of the tank vent valve is checked at the same time by the actuation. If the closed tank vent valve jams, the fault "gross leak" is stored.
Test requirements
Engine at idle Vehicle stationary Drive position "D" or "R" is engaged Off period after engine start elapsed (approx. 16 minutes) or mixture adaptation performed Lambda control enabled Intake air temperature <113 F (<45 C) Coolant temperature at engine start <212 F (<100 C) Air injection not active Air pressure >1.12 psi (>780 hPa) (i.e. no tests performed above approx. 2735 yd (2500 m) altitude) Low loading of activated charcoal canister Fuel level in fuel tank between approx. and No fault in outside air shutoff valve No fault in the fuel tank pressure sensor No fault in tank vent valve Battery voltage > 11 V
The outside air shutoff valve is reopened after the tests.
43
Fuel system
Fuel system
Fuel supply
P47.-10-2433-00
Fuel system 1 2 3 4 5 6 7 Fuel tank Activated charcoal filter Vent line Filler neck Filler neck hose connection Purge line Fuel distributor rail B4/3 M3/3 Y50 Y58 Fuel tank pressure sensor Fuel pump with fuel level sensor Outside air shutoff valve Tank vent valve
44
Overview
Design
The exhaust system is made of stainless steel and consists of the following components: Exhaust manifold Catalytic converter Main muffler
Muffler system
When designing the muffler systems, it was important both to minimize the exhaust back pressure and achieve optimum acoustic tuning. The muffler system is rigidly fixed to the vehicle body.
Exhaust aftertreatment
A control sensor and a diagnostic sensor are installed for exhaust aftertreatment. Aftertreatment of the exhaust gases is performed by a catalytic converter with monolithic coating.
P49.00-2109-00
Exhaust system
1 Exhaust manifold 2 Catalytic converter 3 Main muffler
G3/1 G3/2
O2 sensor downstream of TWC [KAT] O2 sensor upstream of TWC [KAT]
45
Exhaust system
Exhaust system
Secondary air injection

Engine 132 is fitted with a secondary air injection pump (electric air pump), which injects additional fresh air in order to reduce exhaust gas emissions after a cold start and to accelerate the warming of the catalytic converter to its reaction temperature. The necessary air is injected into the exhaust ports in the cylinder head by the secondary air injection pump via the combination valve. The secondary air injection pump is actuated by the ME SFI [ME] control unit via a relay. The secondary air injection pump switchover valve is supplied with vacuum from the vacuum reservoir at the intake manifold via a check valve. When actuated, the secondary air injection pump switchover valve releases vacuum to the combination valve. This opens and the air injected by the secondary air injection pump passes through to the exhaust ports in the cylinder head. The injected air reacts with the hot exhaust gases in the outlet port. The carbon monoxide (CO) and hydro carbon (HC) are oxidized. This "afterburning" process increases the exhaust temperature and reduces pollutants. The duration of secondary air injection is dependent on the coolant temperature. The secondary air injection pump is only actuated at a coolant temperature of 45 F to 97 F (7 C to 36 C) and for a maximum duration of 33 seconds.
P14.30-2183-00
1 2 3 4
Cylinder head Combination valve Air hose Vacuum hose
M33 Y32
Secondary air injection pump Secondary air injection pump switchover valve
46
Transmission description
5 speed automated manual transmission (AMT 2)
The smart fortwo is fitted with the newly developed 2nd generation 5 speed automated manual transmis sion (AMT 2). Advantages of the 5 speed automated manual trans mission: Greater shift comfort Reduced fuel consumption Features: 5 speed transmission Two drum control Potentiometer free position sensor system Mechanical park pawl
The driver can choose between two operating modes: Automatic mode (selector lever in position D) Manual mode (selector lever in position M +/ ) with operation via the selector lever or paddle shifts on the steering wheel (SAL)
P26.10-2167-00
5 speed manual transmission (AMT 2)
47
Automated manual transmission
Transmission description
AMT 2 in model 451
Unit Transmission model Number of forward/reverse gears Max. transferable torque lb ft (Nm) G 717.482 5/1 88 (120) Single plate dry clutch in (mm) 14.3 (364) Aluminum alloy lb (kg) US qt (l) Approx. 74.9 (34) 2.4 (2.3) Two piece with bell housing
Clutch Overall length (including 3 in (75 mm) for clutch)
Housing material Weight (without oil charge)
Oil charge (permanent charge)
Housing
48
Shift mechanism
Shift mechanism
The central components of the shift mechanism are two selector drums for moving the shift forks. Each selector drum is driven by a separate electric motor via two sintered spur gear sets. One selector drum shifts the odd gears, while the other shifts the even gears and reverse gear. The position of the selector drum, and thus the current shift position, is determined by two incre mental sensors in each electric motor. Both electric motors and the spur gears are located in a common aluminum housing, the actuator unit, which is mounted on the transmission. The two selector drums are arranged to allow over lapping shift operations to minimize shift times. It is possible to skip gears (e.g. double downshifts).
P26.60-2320-00
Design of shift mechanism
1 2 3 4 5
Shift fork for shift collar 5 Shift fork for reverse gear sliding gear Shift fork for shift collar 1/3 Shift fork for shift collar 2/4 Main shaft
6 7 8 M17/3 M17/4
Selector drum 1/3, 5 Selector drum 2/4, R Input shaft Transmission motor 1 Transmission motor 2
49
Shift mechanism
Function
The shift forks are displaced by the selector drums parallel to the transmission shafts. They in turn slide the shift collars on the input shaft or the main shaft towards the respective idler gears. The actuation of the shift forks is conducted by two independent selector drums, each of which has a groove. The sliding blocks for two shift forks run in each groove. Selector drum 1/3, 5: Sliding block of shift fork for shift collar 1/3 Sliding block of shift fork for shift collar 5 Selector drum 2/4, R: Sliding block of shift fork for shift collar 2/4 Sliding block of shift fork for sliding gear, reverse gear The positions of both sliding blocks in the same groove are offset to each other by 120. If a sliding block displaces a shift fork from the center position, the other sliding block is in the straight area of the groove (in center position of respective shift fork).
Shift positions
Neutral (N) and reverse gear (R) a Selector drum 1/3, 5 b Selector drum 2/4, R c Selector drum adjustment (1 grid square = 40) d Sliding block deflection (1 grid square = 0.3 in (7.5 mm)) Neutral position (N) The sliding blocks in the grooves of the selector drum are in the neutral position. No gear is engaged. Reverse gear (R) The selector drum 2/4, R rotates through 120 downwards. This displaces the upper sliding block by 0.89 in (22.5 mm) to the left. The reverse gear sliding gear engages in the outer teeth of shift collar 1/3. The sliding blocks in the selector drum 1/3, 5 are in the neutral position.
P26.60-2356-00
50
Shift mechanism
Shift positions
1st gear (1) and 2nd gear (2) a Selector drum 1/3, 5 b Selector drum 2/4, R c Selector drum adjustment (1 grid square = 40) d Sliding block deflection (1 grid square = 0.3 in (7.5 mm)) 1st gear (1) The selector drum 1/3, 5 rotates through 40 down wards. This displaces the upper sliding block by 0.3 in (7.5 mm) to the left. The shift collar 1/3 is slid into the idler gear of the first gear. The sliding blocks in the selector drum 2/4, R are in the neutral position. 2nd gear (2) For the change from 1st gear to 2nd gear, the two selector drums rotate through 40 upwards. This in turn displaces the lower sliding block in the selector drum 2/4, R by 0.3 in (7.5 mm) to the left. The shift collar 2/4 is slid into the idler gear of the second gear. The sliding blocks in the selector drum 1/3, 5 are in the neutral position.,
P26.60-2357-00
51
Shift mechanism
Shift positions
3rd gear (3) and 4th gear (4) a Selector drum 1/3, 5 b Selector drum 2/4, R c Selector drum adjustment (1 grid square = 40) d Sliding block deflection (1 grid square = 0.3 in (7.5 mm)) 3rd gear (3) For the change from 2nd gear to 3rd gear, the two selector drums rotate through 40 upwards. The upper sliding block in the selector drum 1/3, 5 is displaced by 0.3 in (7.5 mm) to the right. It presses the shift collar 1/3 into the idler gear of the third gear. The other sliding blocks are in the neutral position. 4th gear (4) For the change from 3rd gear to 4th gear, the two selector drums rotate through 40 upwards. The lower sliding block in the selector drum 2/4, R is displaced by 0.3 in (7.5 mm) to the right. It presses the shift collar 2/4 into the idler gear of the fourth gear. The other sliding blocks are in the neutral position.
P26.60-2358-00
52
Shift mechanism
Shift positions
5th gear (5) a Selector drum 1/3, 5 b Selector drum 2/4, R c Selector drum adjustment (1 grid square = 40) d Sliding block deflection (1 grid square = 0.3 in (7.5 mm)) 5th gear (5) For the change from 4th gear to 5th gear, the selector drum 1/3, 5 rotates through 40 upwards. The lower sliding block in the selector drum 1/3, 5 is displaced by 0.3 in (7.5 mm) to the left. It presses shift collar 5 into the idler gear of the fifth gear. The selector drum 2/4, R is rotated through 40 downwards. The sliding blocks in the selector drum 2/4, R are in the neutral position.
P26.60-2362-00
53
Synchronization
Borg Warner synchronization
All forward gears are equipped with a Borg Warner synchronization. Reverse gear is not synchronized. Function Before the shift collar (3) positively connects the sleeve carrier with the corresponding idler gear, the tapered pairs of faces contact the clutch body (1), synchronizer ring (2) and, where applicable, an intermediate ring. The engine's gear is run at the speed of the corresponding drive side gear; only then do the locking splines (4) release the remaining travel of the shift collar. The shift collar travel from neutral to complete engagement in the relevant idler gear is approx. 0.3 in (7.7 mm).
P26.50-2173-00
1 2 3 4
Clutch body Synchronizer ring Shift collar Locking splines
54
Transmission control
Transmission rpm sensor (L2)
Location The transmission rpm sensor is mounted to the transmission housing. Task The rpm sensor determines the rotational speed of the input shaft. The recorded speeds of the crank shaft and input shaft are used to monitor the clutch operation. The speeds of the input shaft and the drive wheels are used to determine the actual gear engaged. The diagram illustrates the oscilloscope picture of an rpm sensor.
P26.19-2104-00
1 L2
Input shaft Transmission rpm sensor
55
Transmission motors 1 and 2 (M17/3 and M17/4)
Location The transmission motors are located on the trans mission housing. Task Depending on the shift request from the automated manual transmission control unit (N15/6), the transmission motors adjust the selector drums via a two stage spur gear transmission. Actuation is pulse width modulated by two output stages with four electronic switches each. Upon reaching the specified position the transmission motor is braked. It can, if necessary, be actuated with opposing voltage, if an overshoot beyond the spec ified position is to be prevented or reversed. Actuation of the transmission motors is monitored by the incremental sensors, which are located on each motor shaft. These detect the rotation angle and rotation direction of the respective transmis sion motor using the integrated Hall sensors. The transmission motors are only actuated to execute the shift operations. Once a target position is reached, a pin engages in the locking groove of the selector drum to maintain the selected gear.
P26.60-2321-00
1 2 M17/3 M17/4
Transmission motor 1 selector drum Transmission motor 2 selector drum Transmission motor 1 Transmission motor 2
56
Automated manual transmission control unit (N15/6)
Location The automated manual transmission control unit is located in the passenger compartment under the driver seat. General The transmission control converts the driver's shift requests into corresponding control signals to the clutch and the 5 speed automated manual transmission. This is done by relaying the shift signal about the shift request at the electronic selector lever module control unit over a direct line to the auto mated manual transmission control unit. The automated manual transmission control unit checks the plausibility of the shift request in relation to the vehicle speed, the load (acceler ator pedal position) and the engine speed. If the plausibility check is passed, the automated manual transmission control unit sends the signal to initiate the selected shift operation to the two actuator motors for the two selector drums and to the clutch motor to open or close the clutch. Task The automated manual transmission control unit controls the following functions depending on the input information: Engaging first gear at vehicle standstill Gear change Compulsory upshift just before maximum engine speed is reached Compulsory downshift when engine idle speed is approached Downshift for kickdown Disengaging the gear after 1 s when a door is opened without the service brake or accelerator pedal being actuated Crawl function Clutch operation Monitoring of clutch load
N15/6
P26.19-2145-00
Automated manual transmission control unit
The automated manual transmission control unit directly reads the signals from the following compo nents: Transmission rpm sensor (L2) Transmission motor 1 (M17/3) Transmission motor 2 (M17/4) Clutch motor (M18) Electronic selector lever module control unit (N15/5) Park pawl switch (S16/2)
57
The following components are actuated directly by the automated manual transmission control unit: Transmission motor 1 (M17/3) Transmission motor 2 (M17/4) Clutch motor (M18) Communication via CAN takes place with the following components: Instrument cluster (A1) ME SFI [ME] control unit (N3/10) SAM control unit (N10/10) Electronic selector lever module control unit (N15/5) ESP control unit (N47 5)
Electronic selector lever module control unit (N15/5)

Location The electronic selector lever module control unit is located in the center console. Task The electronic selector lever module control unit records the shift requests of the driver. The shift positions N, R, + and are detected by Hall sensors in the electronic selector lever module control unit and are read and evalu ated by the electronics in the electronic selector lever module control unit. The signals corre sponding to the shift lever positions are trans ferred to the automated manual transmission control unit. The release button on the selector lever must be actuated in order to move the selector lever to the following positions: From P to R, N or D From R to P From N to R or P The transmitter key can only be removed in position 0 if the selector lever is in position P. When the transmitter key is removed, the selector lever is locked in position P. i Note When reverse gear is requested, the backup light is actuated directly by the electronic selector lever module control unit.
P26.60-2375-00
1 Unlock button N15/5 Electronic selector lever module control unit P R N D M + Park Reverse gear Neutral position Automatic mode Manual mode Upshift Downshift
58
Manual mode In manual mode (selector lever in position M), the gears are shifted either using the selector lever or using the paddle shifts on the steering wheel (SAL). The gear which is currently selected is displayed on the multifunction display in the instrument cluster. The gear indicator may change to provide gearshift recommendations (arrow up or down). The gearshift recommendations are based on a driving style which optimizes fuel consumption. Automatic mode In automatic mode (selector lever in position D), the automated manual transmission control unit deter mines the gear changes. The selected gear range D is displayed on the multifunction display in the instrument cluster.
P54.32-5683-00
1 2
Gear range display (automatic mode) Gear display (manual mode)
A1 Instrument cluster A1p13 Multifunction display
59
Data flow chart of transmission control

P26.19-2141-00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Circuit status Shift request Transmission speed Clutch request Clutch motor status Gear change request Transmission motor status Engine speed Backup light actuation Vehicle speed Shift program selection Accelerator pedal position Brake pedal status Door status Engaged gear Gear indicator actuation Park pawl status
A1 A45 E3e3 E4e3 L2 M17/3 M17/4 M18 N3/10 N10/10 N15/5 N15/6 N47 5 S16/2 S112s1 S112s2 CAN
Instrument cluster Fanfare horns and airbag clock spring con tact Left backup light Right backup light Transmission rpm sensor Transmission motor 1 Transmission motor 2 Clutch motor ME SFI [ME] control unit (gasoline engine) SAM control unit Electronic selector lever module control unit Automated manual transmission control unit ESP control unit Park pawl switch Steering wheel gear shifter PLUS (SAL) Steering wheel gear shifter MINUS (SAL) Controller Area Network (data bus/CAN bus)
60
Park pawl
Mechanical park pawl In addition to the parking brake, the 5 speed auto mated manual transmission is equipped with a mechanical park pawl to prevent the vehicle from rolling away. The mechanical park pawl is operated by the electronic selector lever module control unit via a cable. The status of the park pawl is reported to the auto mated manual transmission control unit via the park pawl switch (S16/2).
P26.60-2377-00
1 2 3
Transmission Cable Park pawl
N15/5 Electronic selector lever module control unit S16/2 Park pawl switch
61
Clutch
Single plate dry clutch
A single plate dry clutch, consisting of clutch plate and pressure plate, is installed on model 451. An internal computer in the automated manual trans mission control unit evaluates the clutch load. If a threshold value is exceeded, the clutch starts to pulse as an overload warning to the driver. If the overloading continues, e.g. if the car is being held with the clutch on a gradient, the clutch is closed in order to provoke a stall.
P25.00-2010-00
Single plate dry clutch
1 Pressure plate 2 Clutch plate 3 Flywheel with starter ring gear
62
Clutch
Clutch motor General
Model 451 is fitted with a 5 speed automated manual transmission. This means that a single plate dry clutch is installed instead of the torque converter that is usual with conventional automatic transmissions. The single plate dry clutch is actuated by the clutch motor.
Function
When the automated manual transmission control unit issues a request for a gear change, the clutch motor is actuated at the same time. The electric motor inte grated in the clutch motor operates the clutch via the actuating plunger. The power flow is interrupted and the shift operation can be performed.
P25.19-2010-00
4 Electric motor 5 Electric motor connector 6 Actuating plunger
M18
Clutch motor
63
Chassis
Front axle
Front axle
The front axle has a classic McPherson design. The supporting ball joint is press fitted with the transverse control arm forming a single component unit. If repairs are necessary, the supporting ball joint must be replaced complete with the cross member since a satisfactory press fit cannot be guaranteed in the repair shop. The wheel bearing in the steering knuckle is not available separately either because it is pressed into the steering knuckle and can only be ordered as a complete unit with the steering knuckle. Adjustment capabilities On the front axle it is only possible to adjust the toe; the camber can only be corrected by utilizing the "play" at the attachment points of the front axle.
P33.00-2086-00
Front axle smart fortwo model 451
1 Front axle crossmember 2 Stabilizer bar 3 Transverse control arm with press fitted support ing ball joint
4 Coil spring 5 Two tube shock absorber 6 Wheel carrier, cast iron with pressed in wheel bearing
64
Rear axle
Rear axle with suspension
The rear axle consists of: Axle tube Frame type integral support Coil springs Bar link Single tube shock absorbers Center bearing The frame type integral support supports the rear wheel drive module. The coil springs are located at the outsides and support the body against rolling move ments. The single tube shock absorbers are fixed in place at the top with pin bearings.
P35.00-2075-00
Rear axle smart fortwo model 451
7 8 9 10
Axle tube Frame type integral support Coil spring Bar link
11 Single tube shock absorber pin bearing 12 Single tube shock absorber 13 Center bearing
65
Chassis
Chassis
Rear module
Lowering the rear module
On model 451, the rear wheel drive module can be lowered. This shortens removal/installation time for various major assemblies such as the refrigerant compressor, starter, alternator etc., because all the attached parts on the engine and the engine itself can be reached very quickly and with relatively little effort. This shortens repair times and reduces costs while improving customer satisfaction at the same time.
P35.00-2085-00
Lowered rear drive module
66
Tire pressure monitor

General
The tire pressure monitoring system (TPM [RDK]) monitors the air pressure in the individual tires and improves active safety. A previously stored tire pres sure is used as a comparative value. If a relevant loss of pressure occurs, the tire pressure monitor warning lamp in the instrument cluster warns the driver. The tire pressure measuring range is p = 0 to 78 psi (p = 0 to 5.5 bar). The TPM [RDK] system has the following subfunctions: Tire pressure sensing Warning display Manual restart Function requirements Circuit 15 ON Tire pressure monitor (TPM [RDK]) system functional Tire pressure sensing The TPM [RDK] control unit is permanently opera tional. Each time the CAN wakes up, the control unit performs a re initialization. While driving, the tire pressure monitoring (TPM [RDK]) system continuously monitors the tire pressure of all rotating wheels (with circuit 15 OFF for a further t = 19 min). When the vehicle is parked for t > 19 min, on board wheel detection and axle assignment must first be completed via the TPM [RDK] wheel sensors. While driving, the TPM [RDK] wheel sensors transmit data telegrams every 60 seconds. These data telegrams contain the following informa tion: Tire pressure Tire air temperature Individual serial number Status information (manufacturer, direction of rotation, operating mode etc.) In addition the TPM [RDK] control unit takes into account the outside temperature and the vehicle speed for the tire pressure determination. These data are provided via CAN by the instrument cluster. Warning indicator A warning is issued when a relevant loss of pressure has been detected in at least one of the tires. The warning is issued in the instrument cluster via the tire pressure monitor warning lamp, but the specific tire where pressure loss has occurred is not specified. Manual restart The tire pressure to be monitored can be reset via the TPM [RDK] switch on the cockpit switch panel. When the TPM [RDK] switch is pressed, the current tire pressure is stored in the memory of the TPM [RDK] control unit and is then used as the reference pres sure, as long as it is within the permissible limits. The tire pressure monitor warning lamp in the instru ment cluster flashes to indicate that a manual restart has taken place.
i Note A manual restart must be performed each time the tire inflation pressure is changed and when a wheel, wheel sensor or the TPM [RDK] control unit is replaced. If the nut on the valve element of a wheel sensor is loosened, all components of the valve element must be replaced. See the Workshop Information System (WIS) for further instructions and information.
67
Chassis
Chassis
Tire pressure monitor
P40.15-2424-00
Location of TPM [RDK] components
A1 A1e66 A69/1 A69/2 A69/3 A69/4
Instrument cluster Tire pressure monitor warning lamp Left front TPM [RDK] wheel sensor Right front TPM [RDK] wheel sensor Left rear TPM [RDK] wheel sensor Right rear TPM [RDK] wheel sensor
B14 N10/10 N88 S6/1 S6/1s9
Outside temperature display temperature sensor SAM control unit TPM [RDK] control unit Cockpit switch group TPM [RDK] switch
68
Brakes
Task
The task of the brake system is to brake the vehicle or hold it at a standstill. The system includes the service brake, which brakes the vehicle while it is being driven, and the parking brake, which secures the vehicle when it is at a stand still.
Components of the service brake

Disk brakes with brake calipers on front axle Drum brakes with aluminum wheel brake cylinders on rear axle Brake fluid reservoir Brake lines and brake hoses Brake pedal module ESP unit, consisting of ESP control unit and ESP hydraulic unit
Components of the parking brake

Hand brake lever with hand brake cables Parking brake mechanism integrated into rear drum brake
Function of service brake

The service brake is a hydraulic 2 circuit brake system with TT (front/rear) split. The force applied to the brake pedal is transferred to the brake booster via a linkage. The brake booster multiplies this forces and uses it to pressurize the master brake cylinder. The brake pressure is built up via the master brake cylinder. The brake force is distributed to the disk brakes and drum brakes by the ESP unit via the integrated antilock brake system (ABS) and the electronic brake force distribution (EBD) system.
Function of parking brake

When the handbrake lever is actuated, a relay lever is actuated at the rear brake shoes of the left and right drum brakes via the handbrake cables. This presses the brake shoes of the drum brakes against the insides of the brake drums to build up the required brake force.
69
Chassis
Chassis
Brakes
P40.10-2711-00
Brake system
Brake pedal module Brake disk Brake caliper Expansion reservoir ESP unit Hand brake cables Drum brake (consisting of: anchor plate, wheel brake cylinder, brake shoe, springs and brake drum) 8 Hand brake lever
1 2 3 4 5 6 7
B24/15 L6/1 L6/2 L6/3 L6/4 N47 5 N49
Yaw rate, lateral and longitudinal accelera tion sensor Left front rpm sensor Right front rpm sensor Left rear rpm sensor Right rear rpm sensor ESP control unit Steering angle sensor
70
Brakes
Brake pedal module
The brake pedal module is located on the underfloor and consists of the following assemblies: Pedals Carrier Brake booster Master brake cylinder Pedals The pedals consist of: Pedal head Perforated boot Pedal assembly seal Housing Linkage rod Brake pedal module cover Seal for brake pedal module cover Brake light switch
P42.10-2712-00
Brake pedal module
9 10 11 12 13 14 15
Pedal head Housing Carrier Brake booster Master brake cylinder Grommet Brake pedal module cover
16 17 18 19 20 S9/1
Linkage Seal Pedal assembly seal Perforated boot Bolt Brake light switch
71
Chassis
Chassis
Brakes
Pedals The seals and the boot on the pedals may not be damaged otherwise moisture can penetrate into the interior compartment. To ensure that the pedals remain leaktight, the brake pedal module cover must be replaced each time the pedals are disassembled. Brake light switch The brake light switch in the pedal assembly is only accessible after the brake pedal module cover has been removed. The brake light switch is actuated via the linkage in the pedal assembly when the brake is actuated. The signal from the brake light switch is read by the ESP control unit. The free travel of the brake light switch must be correctly adjusted to ensure that the brake light switch operates properly. Brake lines All brake lines may only be retightened twice at the most when work is performed on the vehicle. If a threaded connection on a brake line is loosened and then retightened, this must be documented. The respective threaded connection must be marked in color with a suitable safety paint. The following color codings are specified: First retightening: yellow marking Second retightening: red marking If the respective threaded connection is loosened again after being retightened for a second time, the detached brake line must be replaced. This also applies if it is not possible to trace how often the threaded connection has previously been loosened. Brake system bleeding Whereas the brake fluid can be replaced by one person, the hydraulic brake system can only be bled by two people working together. When bleeding the primary and secondary circuit, one person must build up the pressure required by the brake fluid changer by repeatedly actuating the brake pedal. The second person is needed to: Actuate the ESP hydraulic unit via diagnosis at the same time and perform the bleeding procedure when bleeding the primary circuit Perform the bleeding procedure when bleeding the secondary circuit i Note To ensure that the brake system is not damaged, the filling pressure on the brake fluid changer may be set to max. 2.8 psi (2 bar).
Basic adjustment of brake shoes After brake shoes are replaced or removed/installed, basic adjustment of the drum brake must be performed. To do so, the brake shoes are measured and adjusted using the slack adjuster. Drum brake adjustment Manual adjustment of the clearance between brake shoe and brake drum is not permissible. Adjustment may only be performed via the automatic slack adjuster of the brake shoes to prevent grinding or locking of the drum brake.
i Note See the Workshop Information System (WIS) for the exact procedure for repairing the brake system and for the relevant safety information.
72
Brakes
ESP system
The latest ESP system (version 8.1) is installed next to the brake pedal module on the underfloor and features the following functions: ABS ASR HBA EBD ESP EBR Start off assist Electronic stability program (ESP) Minimizes oversteer or understeer by means of specific intervention by the brake system at each wheel on the front and rear axles. There may also be intervention in the engine and transmission control systems if necessary. Engine braking regulation (EBR) Reduces slip of the drive wheels in deceleration mode and thereby improves directional stability and road adhesion. Start off assist Maintains the brake pressure for approx. 0.7 s after the brake pedal is released to facilitate start off on uphill slopes. Rpm sensors The rpm sensors are active sensors, i.e. they must be connected to a voltage source in order to operate. They deliver a signal with an rpm independent, constant amplitude, and utilize the Hall effect to detect the rpm signal. Yaw rate, lateral and longitudinal acceleration sensor The yaw rate, lateral and longitudinal acceleration sensor is a combined sensor of micromechanical design. It registers the yaw rate (yaw angle velocity) of the vehicle about the vertical axis, the longitudinal acceleration and the lateral acceleration.
Antilock brake system (ABS) Prevents individual wheels from locking up by regu lating the brake pressure at the relevant wheel brakes. The vehicle remains steerable, enabling the driver to take evasive action himself to avoid sudden obstacles during emergency braking. Acceleration skid control (ASR) Prevents the drive wheels from spinning by inter vening in the engine management and brake pressure regulation. ASR provides good traction and improves vehicle stability and steerability when moving off and accelerating. Hydraulic brake assist (HBA) Regulates the pressure buildup in the brake system in relation to the vehicle speed and the actuation speed of the brake pedal. When emergency braking is detected by means of characteristics defined before hand, the ESP control unit actuates the return flow pump that is integrated in the hydraulic unit. The maximum brake pressure is built up. Electronic brake force distribution (EBD) Regulates the brake pressure at the rear wheels in the partial braking range in order to improve the stability of the vehicle and the braking effect.
i Note In the event of an emergency stop in which the vehicle is braked to a standstill from a speed in excess of 43 mph (70 km/h), the SAM control unit automatically activates the hazard warning system. Deactivation of the hazard warning func tion occurs automatically when the vehicle speed is detected to have risen above 6 mph (10 km/h) or manually by actuation of the hazard warning system switch.
73
Chassis
Chassis
Brakes
P42.45-2662-00
Data flow chart of Electronic Stability Program ESP
1 2 3 4 5 6 7 8 9 10 11 12 13 14 A1 A1e41
ESP/ABS/ASR status ESP/ABS/ASR display status Wheel speed signal Steering angle Steering rate Lateral and longitudinal acceleration Yaw rate Engine torque control Transmission control intervention Brake pedal status Emergency stop reference speed Driver door closed status Handbrake status Brake fluid status Instrument cluster ESP warning lamp
B24/15 L6/1 L6/2 L6/3 L6/4 N3/10 N10/10 N15/6 N47 5 N49 S9/1 S11 S12 CAN
Yaw rate, lateral and longitudinal accelera tion sensor Left front rpm sensor Right front rpm sensor Left rear rpm sensor Right rear rpm sensor ME SFI [ME] control unit SAM control unit Automated manual transmission control unit ESP control unit Steering angle sensor Brake light switch Brake fluid indicator switch Parking brake indicator switch Controller Area Network (data bus/CAN bus)
74
Steering
Rack and pinion steering
The smart fortwo features rack and pinion steering as standard. The steering ratio is 22:1.
General
Electric Power Steering (EPS) is a direct steering system with integral speed dependent power assis tance and active steering centering. This ensures that steering wheel forces remain low when the vehicle is being maneuvered. An electromechanical system offers the following advantages compared to a conventional hydraulic power steering system: Less weight and smaller installation space Greater degree of freedom to adjust the steering assistance Reduced fuel consumption. EPS operates without hydraulic components such as pumps, reservoirs, coolers, lines and hydraulic fluid, and is therefore a dry, environmentally compatible system.
Electric power steering EPS (special equipment)

Electric Power Steering (EPS) is available as special equipment. The steering ratio is 21:1. The tasks of the EPS system are as follows: Power assistance with Servotronic Adaptation of the steering forces Active steering centering
P46.10-2935-00
Electric power steering EPS
75
Chassis
Chassis
Steering
Design
The main components of the electric power steering (EPS) system are the power steering motor, a DC brush type electric motor with maximum 35 Ampere power consumption and the power steering control unit. The power steering control unit communicates via the CAN data bus and is located in the vehicle interior on the left of the firewall. The rack and pinion mechanical components for the electric power steering (EPS) are accommodated in a steering housing made of diecast aluminum, to which the power steering motor is also flange mounted. To provide steering assistance, the steering gear pinion shaft transmits the rotational movement of the steering gear input shaft to the teeth of the toothed rack. The power steering motor transmits force for steering assistance to the spur toothing of the hyper bolic gear via a worm shaft. The hyperbolic gear is fixed to the pinion of the steering gear pinion shaft. The power steering torque sensor is located in the steering gear housing between the steering gear input shaft and hyperbolic gear.
P46.10-2933-00
Components of the electric power steering (EPS)
1 2 3 4 5 6 B23 M19 N68
Steering gear housing Steering gear pinion shaft Steering gear input shaft Toothed rack Worm shaft Hyperbolic gear Power steering torque sensor Power steering motor Steering assist control unit
76
Steering
Function
Function requirement Steering assistance is activated after engine start and at a minimum engine speed of 500 rpm. Steering power assistance As the driver turns the steering wheel, a steering torque is produced at the drag link which is regis tered by the power steering torque sensor and forwarded to the power steering control unit. The steering torque is used as an actuating variable for the electric assistance force. It is derived from the rotation of the torsion bar, which is located between the steering gear input shaft and steering gear pinion shaft on the same axis. The power steering torque sensor is located around the torsion bar. This determines the torque over a range of +/ 8.1 lb ft (11 Nm) and at a resolution of 0.037 lb ft (0.05 Nm). The power steering control unit uses the steering torque measurement to determine the level of torque that needs to be provided to supplement the steering force. Based on this information and depending on the vehicle speed signal from the ESP control unit and the engine speed signal from the ME SFI [ME] control unit, the power steering control unit determines the current requirement of the power steering motor as per the programmed characteristic field. The power steering motor transmits the appropriate supplementary steering torque to the face of the hyperbolic gear via the worm shaft.
P46.10-2934-00
Steering torque of the electric power steering (EPS)
2 3 5 6 7 B23 M19 N68
Steering gear pinion shaft Steering gear input shaft Worm shaft Hyperbolic gear Torsion bar Power steering torque sensor Power steering motor Steering assist control unit
77
Chassis
Chassis
Steering
Steering centering This function returns the steering to the center posi tion once the driver stops applying steering torque. The power steering motor is actuated accordingly by the power steering control unit. "Active center feeling" function When the steering wheel is registered in the center position and there are no steering movements, the power steering motor is energized by the steering assist control unit so that a sufficient torque is produced to hold the steering in the straightahead position. This actuation conveys an improved steering center feel to the driver. The system is continuously calibrated and learns the center position automati cally. The long term calibration is performed via the ESP wheel sensor system. Limp home function The steering assist control unit constantly checks all the input signals for plausibility. In the case of a faulty component the steering, power assistance is shut down and a fault is stored in the steering assist control unit. The steering then continues to function as a conventional rack and pinion steering. i Note If the electric steering suffers a function failure, the electric steering indicator lamp in the instru ment cluster lights up to indicate this.
To comply with EMC requirements, the energy line from the power steering control unit to the power steering motor is 85 % shielded against external influ ences. The power steering control unit is a CAN bus subscriber in the overall network. The vehicle speed, the steering angle and other data are read in over CAN.
i Note The steering power assistance is at a maximum at low speeds and when the vehicle is stationary and decreases as the vehicle speed increases. Once the vehicle stops and the engine is switched off, the steering power assistance is deactivated in stages after approx. 3 s.
78
Steering
P46.35-2034-00
Data flow chart of electric power steering EPS
1 2 3 4 5 6
Vehicle speed Steering torque Warning and fault message output Power steering motor actuation Steering angle, steering rate Engine speed
A1 A1e18 B23 M19 N3/10 N47 5 N49 N68 CAN
Instrument cluster Electric steering indicator lamp Power steering torque sensor Power steering motor ME SFI [ME] control unit ESP control unit Steering angle sensor Steering assist control unit Controller Area Network (data bus/CAN bus)
79
Chassis
Chassis
Steering
Steering wheel
Two steering wheel variants are available for model series 451. Variants Leather two spoke steering wheel of dia. 14.6 in (370 mm) as standard equipment on the pure Three spoke sport steering wheel with integrated paddle shift of dia. 13.8 in (350 mm) as standard equipment on the passion
Paddle shifts on steering wheel

In vehicles that are fitted with a three spoke sport steering wheel, the paddle shifts on each side of the steering wheel can be used to shift up and down through the gears. It is therefore possible to select a gear on the steering wheel as well as via the gear selector lever. The left hand paddle shift is used to downshift and the right hand paddle shift is for upshifts. The gear which is currently engaged is displayed on the multifunction display in the instrument cluster.
P46.10-2839-00
Two spoke steering wheel
P46.10-2840-00
Three spoke sport steering wheel with paddle shifts
80
Steering
Steering wheel removal and installation
The following components of the steering wheel are replaceable: Contact unit with steering angle sensor Airbag module Paddle shifts (three spoke sport steering wheel only) The steering wheel must be detached first before replacing or removing/installing any of the above components. Care must be taken to ensure that the front wheels are in the straightahead position, the battery is discon nected and the handbrake is applied before the steering wheel is removed. The exact procedure for removal/installation of the steering wheel and its components is described in the Workshop Information System (WIS). i Note Care must be taken to ensure that the turn signal is not set when removing/installing the steering wheel otherwise the trigger tab may be damaged. i Note All control units must be de energized before the steering wheel is removed. For this reason, at least 15 minutes must elapse after the battery is disconnected before it is removed.
P46.10-2841-00
81
Chassis
Body
Interior
Interior design
The interior compartment has a classic look while still displaying modern, typical smart features. This well balanced overall concept helps the smart fortwo create an exclusive overall impression with high perceived quality. This is helped by the lines of the instrument panel, the door linings and the seats shaped to match. The harmonized color scheme of the interior also gives a positive impression in combination with the passenger compartment as a whole.
P68.00-5039-00
Shown on the smart coup pure
82
Interior
Instrument panel
For the design of the instrument panel, particular emphasis was placed on the following criteria: Ergonomics Clear layout Passenger safety The instrument panel is designed with straight lines and equipped with airbags and a full length knee bolster to improve passenger protection. Two additional instruments (tachometer and clock) are available as special equipment (SA) and are posi tioned above the center console. The air vents on the instrument panel have a cylindrical shape.
P68.10-3852-00
Shown on the smart coup passion
83
Body
Body
Interior
Instrument cluster
In the center of the instrument cluster is the speed ometer scale with the multifunction display under neath. On each side is a strip with indicators and warning displays, as well as the control buttons for the multi function display. The task of the instrument cluster is to provide the driver with information about the various operating states and to provide acoustic or visual warnings in the event of critical operating conditions. It is the display unit for the vehicle speed and for other systems. In addition, the instrument cluster computes the maintenance intervals and shows them in the multifunction display. The instrument cluster is a device on the data bus/CAN bus in the overall network. Most of the signals are transmitted or received over CAN. The following signals are supplied to the instrument cluster over direct lines: Signal from outside temperature indicator temperature sensor Signal from "Fanfare horns and airbag clock spring contact (only on variant with SAL). The vehicle speed is displayed by an electronic speedometer that is driven by a stepper motor. The ESP control unit reads the information for the speed display from the wheel speed sensors in the form of signals, and forwards it over CAN to the instrument cluster. The instrument cluster processes the incoming signals and uses them to calculate the vehicle speed and distance traveled.
Multifunction display The task of the multifunction display is to provide the driver with information about variable changes in the vehicle, the ambient conditions and the road. The variable displays include: Outside temperature Main odometer Trip odometer Gear indicator (in manual mode) Automatic transmission indicator (in automatic mode) Fuel reserve indicator (US gal) Maintenance interval display with symbol Fuel level and reserve indicator Clock
P54.32-5677-00
Multifunction display
84
Interior
P54.30-9683-00
Instrument cluster
1 2
Left button, select multiple display / set clock Right button, instrument illumination / set clock Instrument cluster Left turn signal indicator lamp Right turn signal indicator lamp High beam indicator lamp Alternator charge monitoring and warning lamp Brake fluid and parking brake warning lamp
A1 A1e1 A1e2 A1e3 A1e5 A1e7
A1e9 A1e15 A1e17 A1e18 A1e26 A1e30 A1e41 A1e54 A1e66 A1e67 A1p8 A1p13
Seat belt warning lamp Airbag indicator and warning lamp ABS indicator lamp Electric steering indicator lamp CHECK ENGINE indicator lamp Oil pressure warning lamp ESP warning lamp Coolant temperature warning lamp Tire pressure monitor warning lamp Low beam indicator lamp Electronic speedometer Multifunction display
85
Body
Body
Doors/flaps
Side doors
The doors of the new smart fortwo follow the typical smart brand construction principle with a metal carrier part and the plastic CBS door paneling. The doors of the smart coup and the smart cabrio are identical. The triangular windows located above each door handle are stationary windows held in place by bolts. Crash requirements The door support structure in model 451 is made of steel. In addition, panels and sections of high strength steel are used at strategically important points. This is the case, for example, with the diagonal struts and the side window slot frames.
Door structure
P72.00-2185-00
In combination with the cockpit crossmember, this makes the passenger compartment highly resistant to side impacts in this section of the vehicle.
1 2 3 4
Door carrier module Diagonal strut Side window slot frame Cockpit crossmember
Emergency opening Normally, the smart fortwo is opened from outside via the standard equipment central locking system using the transmitter key. If the battery in the transmitter key cannot supply enough power, a lock cylinder installed behind a small cover under the handle of the left door can be used to open the driver door manually in an emergency.
P80.20-3225-00
1 Lock cylinder for emergency opening
86
Doors/flaps
P72.10-3403-00
Design of driver door with power window and electric outside mirror
1 2 3 4 5 6 7 8 9 10
Door carrier module Window lifter mechanism Diagonal strut Top door hinge assembly Bottom door hinge assembly Inner door lining CBS door paneling Curved handle Side window Triangular window
H4/9 M10/3 M14/6 M14/6s1 M21/1 S21/1 S21/2 S50 S87/7
Left front speaker Left power window motor Left door CL [ZV] motor Left door CL [ZV] microswitch Left electrically adjustable and heated out side mirror Left power window switch Right power window switch Outside mirror adjustment switch Left door rotary tumbler microswitch
87
Body
Body
Doors/flaps
Rear end door
P72.20-2599-00
Design of rear end door shown on the smart fortwo coup
1 2 3 4 5 6 7 8 9 10
Upper rear end door Upper rear end door paneling Rear spoiler Upper rear end door hinges Gas operated strut Rear window CBS rear end door paneling Lower rear end door Right door lock of lower rear end door Left door lock of lower rear end door
11 12 13 14
Door lock of upper rear end door Door panel lining Lower rear end door hinges Seal
E21 M6/4 S88/9
Center high mounted brake lamp Rear end door wiper motor Rear end door handle switch
88
Doors/flaps
Emergency unlocking of rear end door
The rear end door in the smart fortwo can be unlocked from the inside in an emergency, if the trunk lid central locking motor for operating the rotary tumbler is defective or de energized. Emergency unlocking in smart fortwo coup To do this, a small tab at the side of the trunk lid lock paneling must be carefully bent over or broken off to produce a small hole. A shop made wire must then be inserted through the small hole so that enough downward pressure is exerted on the relay lever in the door lock to unlock the rear end door at the top. A description of the procedure for manufacturing the emergency release wire in the workshop is given in the Workshop Information System (WIS). Emergency unlocking in smart fortwo cabrio In order to open the two door locks in the cabrio, a hole must be accurately marked on the inside of the rear end door on each side. Then a hole of 0.2 in (5 mm) diameter is drilled through the paneling on each side of the rear end door.. A suitable screwdriver is inserted into each hole and the rear end door is unlocked by moving the screw driver handles simultaneously in the directions of the arrows. The exact dimensions for the holes and a detailed description of the procedure can be found in the Workshop Information System (WIS).
P72.20-2583-00
P72.20-2582-00
A Actuation direction 1 Tab/paneling hole on trunk lid lock 2 Emergency release wire
B Actuation direction 3 Hole (0.2 in (5 mm)) 4 Screwdriver
89
Body
Body
Roof systems
Variants of roof system
Two roof variants are available for the model series 451 coup. A fully electric Tritop fabric soft top is installed in the cabrio. smart fortwo coup Full roof made of glass fiber reinforced polyurethane (PU) Panoramic sunroof made of polycarbonate (PC) smart fortwo cabrio Fully electric Tritop fabric soft top
P65.00-2119-00
Vehicle with PU roof
P77.21-2226-00
Vehicle with panoramic sunroof
P77.00-2338-00
Vehicle with fully electric Tritop fabric soft top
90
Roof systems
Hard roofs on smart fortwo coup Full roof
In the standard equipment pure version the smart fortwo coup is supplied with the polyurethane (PU) full roof. The PU roof is only available in pitted matt black. The PU full roof sits on the body and is bonded to the bodyshell structure.
Panoramic sunroof
A polycarbonate (PC) panoramic sunroof with step lessly variable roller sun blind is available for some equipment variants. The roof module is bonded to the tridion safety cell. The latest in plastics technology makes it possible to use breakproof material extensively in the vehicle. The material is covered with a scratch resistant coating and the light transmission of the tint is approx. 13 %. The material also provides 100 % protection against UV light. The steplessly adjustable inside roller blind can be used to block out the sun. The roller sun blind is made of a polyester fabric and covers the entire trans parent area of the panoramic sunroof. The roof and roller blind can be replaced separately. The panoramic sunroof is manufactured by a two component injection molding process in which the second component material serves to blacken the edges.
P77.21-2225-00
Panoramic sunroof with roller sun blind
91
Body
Body
Roof systems
Tritop fabric soft top
The Tritop fabric soft top of the smart fortwo cabrio is the only one in the world that can be opened and closed while driving up to the maximum speed. The name TRITOP comes from the three main components of the soft top: Folding top open Rear soft top stowed Side supports removed The soft top control system is fully electronic and features the following functions: Opening the folding top Closing the folding top Lowering the rear soft top Raising the rear soft top
P77.30-2390-00
Components of Tritop textile soft top
1 Folding top 2 Rear soft top
3 Left and right side supports
92
Roof systems
Soft top operation
The folding top and rear soft top are opened and closed using the power soft top switch on the elec tronic selector lever module control unit. The folding top can also be opened remotely and auto matically by means of a button on the transmitter key. To operate the soft top via the power soft top switch the vehicle's ignition must be switched on. A short press of the power soft top switch in the "Open" direction causes the folding top to open all the way to its end position. The folding top must always be fully opened before the rear soft top can be opened. If the power soft top switch is then pressed again and held in the "Open" direction, the rear soft top is folded away for as long as the switch is actuated. As soon as the rear soft top has been stowed in its end position, its motors cut out and the switch can be released. To close the soft top, the power soft top switch is pressed and held in the "Close" direction until the rear soft top has reached its upper end position and the motors of the rear soft top cut out; the switch can then be released. If the power soft top switch is pressed and held again, the folding top closes until it reaches its own end position and the motor cuts out; then the switch can be released again. The rear soft top and folding top lock automatically as soon as they reach their end positions.
P80.35-2333-00
3 A
Folding top automatic open button Transmitter key
P77.00-2332-00
S84
Power soft top switch
i Note For safety reasons, it is not possible to close the folding top automatically. There would be a risk of injury during the closing process because limbs of vehicle occupants could become trapped between the roof frame and folding top in the area of the windshield.
93
Body
Body
Roof systems
Targa roof position
In the targa roof position, the folding top is fully opened, the side supports are removed and the rear soft top is closed. The targa roof position is important with regard to the operation of the folding top because the side supports must be inserted before the folding top can be closed. The side supports are detected by a mechanical catch in the roof cassette lock.
Soft top control

The central controller unit of the soft top is the SAM control unit. The SAM control unit reads in the actuation request from the power soft top switch and actuates the appropriate motors depending on the position and status of the soft top. The soft top is powered by a total of three motors. A central motor in the roof cassette is responsible for opening and closing the folding top. The folding and raising of the rear soft top is carried out by two motors in the left and right main bearings of the soft top. The soft top also incorporates the center high mounted brake lamp and a glass rear window with an integral rear window heater, which is also activated by the SAM control unit. Function sequence of soft top actuation Function requirements: Switch circuit 15 ON Pressing the power soft top switch sends a direct signal to open or close to the SAM control unit. The SAM control unit reads in the signal, checks whether the function requirements are satisfied and deter mines the status of the soft top via the microswitches installed on the soft top. If all the preconditions are met, the SAM control unit actuates the appropriate motor(s) for the desired operation.
P77.00-2340-00
Targa roof position
94
Roof systems
P77.39-2210-00
Data flow chart of soft top control
1 2 3 4 5 6 7 8 9
Circuit 15 ON Request to open folding top Request to open rear soft top Request to close rear soft top Request to close folding top Status of soft top Status of roof cassette latch Status of rear soft top Vehicle speed
A1 K66/1 K66/2 M12/6 M12/7 M12/8 N10/10 S2/1 S84 S84/37 S84/38 S84/39 S84/40 S84/41 A CAN
Instrument cluster Open soft top relay Close soft top relay Electric soft top motor Left soft top drive Right soft top drive SAM control unit Ignition/starter switch Power soft top switch Folding top microswitch Left roof cassette microswitch Right rear soft top microswitch Right roof cassette microswitch Left rear soft top microswitch Transmitter key Controller Area Network (data bus/CAN bus)
95
Body
Body
Central locking
Central locking (CL [ZV])
The central locking in the smart fortwo includes the locking and unlocking of both doors and the fuel filler flap, and the opening of the rear end door in the smart coup or the opening of the soft top on the smart cabrio. A distinction is drawn between manual and automatic functions. Manual functions: Remote control with the transmitter key Door opening from the inside Operation via the interior CL [ZV] locking and unlocking switches in the cockpit switch group Manual unlocking with the transmitter key at the driver side door lock Automatic functions: Speed dependent locking Emergency opening after crash detection Relocking Unlocking or locking via the transmitter key When the Unlock or Lock button on the transmitter key is pressed, it sends a radio signal to the SAM control unit. The SAM control unit checks the access authori zation of the transmitter key. If the access authoriza tion is valid, it actuates the following motors directly to unlock or lock the vehicle: Right door CL [ZV] motor Left door CL [ZV] motor Fuel filler flap CL [ZV] motor When the vehicle is globally unlocked, the rear end door handle switch is enabled; and when the vehicle is locked, it is disabled. If the rear end door handle switch is actuated when the central locking has been globally unlocked, the SAM control unit directly actuates the trunk lid CL [ZV] motor to unlock the rotary tumbler. Selective unlocking If the Unlock button on the transmitter key is pressed once, only the driver door and fuel filler flap are unlocked. The anti theft alarm system is deactivated and all turn signal indicators flash once. Global unlocking If the Unlock button on the transmitter key is pressed again, the passenger door is unlocked and the rear end door handle switch is enabled. The turn signal indicators flash again once. Door opening from the inside The vehicle doors can always be opened from the inside with the door handle regardless of the status of the central locking. In this case, only the respective vehicle door and the fuel filler flap are unlocked.
P80.35-2332-00
A 1 2 3 4
Transmitter key Locking button Unlocking button Open folding top button (cabrio) Open rear end door button (coup) PANIC button
96
Central locking
PANIC alarm Pressing the PANIC button for at least 1 s triggers an acoustic alarm. The turn signal indicators also flash. The alarm is deactivated when Circuit 15 is switched ON or The PANIC button is pressed Unlocking and locking from the inside via the switches in the cockpit switch group When the side doors and the rear end door are closed, pressing the "Lock or unlock" switch in the cockpit switch group causes a signal to be sent straight to the SAM control unit. This actuates the central locking motors. The vehicle doors and the fuel filler flap are either locked or unlocked accordingly and the rear end door handle switch is either enabled or disabled. Special function: If the vehicle cannot be locked using the transmitter key due to a flat battery in the key, proceed as follows: Open driver door Switch circuit 15 ON Actuate inside CL [ZV] switch Within 5 s, switch circuit 15 OFF and remove transmitter key Close driver door, vehicle is locked. Manual unlocking of the driver door with the trans mitter key at the door lock When the door lock on the driver door is operated with the transmitter key, the driver door and (if the on board power supply voltage is sufficient) the fuel filler flap are unlocked. If the antitheft alarm system on the vehicle is armed, an alarm is triggered. Speed dependent locking The vehicle is automatically locked if circuit 15 is ON and the vehicle speed exceeds 8 mph (14 km/h). Speed dependent locking can be activated or deacti vated as required. Relocking This function relocks the vehicle automatically if none of the doors is opened 60 s after unlocking. Emergency opening after crash recognition This functions unlocks the doors after an accident that triggers a crash signal. Remote rear end door opening (smart fortwo coup only) When the "Open rear end door" button on the trans mitter key is pressed, it sends a radio signal to the SAM control unit. This checks the access authorization of the transmitter key. If the access authorization is valid, the SAM control unit actuates the trunk lid CL [ZV] motor directly. Remote folding top opening (smart fortwo cabrio only) When the "Open folding top" button on the transmitter key is pressed, it sends a radio signal to the SAM control unit. This checks the access authorization of the transmitter key. If the access authorization is valid, the SAM control unit actuates the electric soft top motor directly.
i Note The radio signal for unlocking the door is picked up by an antenna integrated in the SAM control unit. There is no external antenna for the central locking.
97
Body
Body
Central locking
P80.20-3177-00
1 2 3 4 5 6 7 8 9 10 11 12 13 14 A1 E1e5 E2e5 E3e11 E4e11
Unlocking/locking request Doors status Rear end door status Unlocking/locking actuation Rear end door unlocking request Visual feedback actuation Rear end door unlocking actuation Unlocking via inside door opener request Inside unlocking/locking request Emergency opening request Rear end door opening request (coup) Open soft top actuation (cabrio) Open soft top request (cabrio) Vehicle speed Instrument cluster Left turn signal light Right turn signal light Left brake/turn signal light Right brake/turn signal light
E22/1 E22/2 M12/6 M14/5 M14/5s1 M14/6 M14/6s1 M14/7 M14/10 N2/7 N10/10 S6/1 S6/1s1 S6/1s11 S6/1s12 S15 S17/8 S88/9 A CAN
Left additional turn signal lamp Right additional turn signal lamp Electric soft top motor (cabrio) Right door CL [ZV] motor Right door CL [ZV] microswitch Left door CL [ZV] motor Left door CL [ZV] microswitch Rear end door CL [ZV] motor Fuel filler flap CL [ZV] motor Restraint systems control unit SAM control unit Cockpit switch group Hazard warning flasher switch Inside unlock CL [ZV] switch Inside lock CL [ZV] switch Remote trunk opening switch (coup) Trunk lid rotary tumbler microswitch (cabrio) Rear end door handle switch Transmitter key Controller Area Network (data bus/CAN bus)
98
Anti theft alarm system (ATA [EDW])

ATA [EDW] system
The anti theft alarm system (ATA [EDW]) monitors all relevant inputs for their non actuated state. If a change of status is detected at one of the monitored inputs, an acoustic and visual alarm is issued. The acoustic signals are output by the alarm signal siren with inclination sensor. The visual signals are output via the turn signal indicators. The SAM control unit is the master control unit for the anti theft alarm system (ATA [EDW]). When armed, the anti theft alarm system (ATA [EDW]) monitors: The doors The rear end door The alarm siren with inclination sensor The position change of the vehicle Movements in the interior compartment Alarm triggering An alarm is triggered when the SAM control unit receives a status change from the following compo nents: ATA [EDW] microwave sensor Inclination sensor in alarm siren Trunk lid rotary tumbler microswitch Right door rotary tumbler microswitch Left door rotary tumbler microswitch
Alarm output The alarm is output via the turn signal indicators and the alarm siren with inclination sensor. Interior protection/tow away protection The ATA [EDW] microwave sensor is activated approx. 30 s after the vehicle is locked. Interior protection can be deactivated using the tow away protec tion/interior protection switch. The inclination sensor in the alarm siren with inclina tion sensor registers a positional change of the vehicle. The inclination sensor, and thus the tow away protection, can be deactivated using the tow away protection/interior protection switch. The interior protection or tow away protection is reactivated automatically the next time the vehicle is locked.
Activation and deactivation The anti theft alarm system (ATA [EDW]) is activated when the vehicle is locked with the transmitter key. The anti theft alarm system (ATA [EDW]) is deacti vated by unlocking the vehicle with the transmitter key or by inserting an authorized transmitter key in the ignition lock and turning circuit 15 ON.
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Body
Body
Anti theft alarm system (ATA [EDW])
P80.50-2648-00
Data flow chart of anti theft alarm system (ATA [EDW])
1 2 3 4 5 6 7 8 9 10 11
Activate ATA [EDW] with transmitter key Deactivate ATA [EDW] with transmitter key Rear end door status Doors status Deactivate ATA [EDW] via ignition/starter switch Movement in interior signal Alarm siren actuation Turn signal lights actuation Inclination sensor status change Turn signal indicator actuation Tow away protection/interior protection shutoff Instrument cluster Left turn signal indicator lamp Right turn signal indicator lamp ATA [EDW] microwave sensor Left turn signal light Right turn signal light Left brake/turn signal light
E4e11 E22/1 E22/2 H3/2 L11 N10/10 S2/1 S6/1 S6/1s10 S15 S17/8 S87/6 S87/7 A CAN LIN C
A1 A1e1 A1e2 B32 E1e5 E2e5 E3e11
Right brake/turn signal light Left additional turn signal lamp Right additional turn signal lamp Alarm siren with inclination sensor Transponder coil SAM control unit Ignition/starter switch Cockpit switch group Tow away protection/interior protection switch Remote trunk opening switch (coup) Trunk lid rotary tumbler microswitch (cabrio) Right door rotary tumbler microswitch Left door rotary tumbler microswitch Transmitter key Controller Area Network (data bus/CAN bus) Interior Local Interconnect Network 2
100
Exterior lights
Auto on/off headlamps (Autolight function)
The basic equipment can be expanded with the conve nient Autolight function as special equipment. A rain sensor/light sensor is additionally installed for the Autolight function. The rain sensor/light sensor is located on the inside of the windshield near the inside rearview mirror. The rain/light sensor distinguishes between light and dark by measuring the intensity of the light and thereby enables the exterior lights to be switched on and off automatically according to the ambient light conditions. The activated light corre sponds to the "usual" driving lights with low beam. Special feature
P54.21-2893-00
The Autolight function is activated by moving the combination switch to the AUTO position. The AUTO position of the combination switch is only available in vehicles with Autolight function installed as special equipment. Signal flow When the Autolight function is activated and darkness is detected, the rain sensor/light sensor sends a corresponding signal via the LIN B to the SAM control unit. This evaluates the signal and actuates the appropriate lamps over direct lines.
B38 Rain sensor/light sensor
P54.25-5577-00
1 S4
AUTO position Combination switch
Coming Home function The function is a component of the Autolight function. When the vehicle is locked or unlocked, the driving lights are switched on for 12 s. The function is also activated by the rain sensor/light sensor; the position of the combination switch is immaterial. The Coming Home function can only be deactivated by coding in the workshop.
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Body
Body
Audio system
Radio and sound systems
Two radio variants are available as special equipment and accessories for model series 451. Variant 1: smart radio 9 with radio and CD player
P82.60-5801-00
smart radio 9
Variant 2: smart radio 10 with radio, integral 6 disk CD changer, MP3 compatible
P82.60-5802-00
smart radio 10
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Audio system
Speaker sound variants Basic package
A basic package with one broadband speaker in each door is available as special equipment.
Sound system
The sound system (special equipment) includes two tweeters/midrange speakers and a subwoofer. Due to the modular design, these components can also be retrofitted individually as accessories. The smart MP3 interface (AUX jack) is installed as standard. smart accessory sound system (two tweeters, two midrange speakers): The tweeters are simply clipped in place under the instrument panel; the wiring harness is already installed. The door panels must be removed in order to install the midrange speakers. Subwoofer: The driver seat is removed and the subwoofer is bolted on together with the driver seat; the wiring harness is already there under the floor carpeting.
P82.62-3243-00
P82.62-3242-00
Speaker diagram basic package
Speaker diagram sound systems
A2/1 A2/2 H4/9 H4/10
smart radio 9 smart radio 10 Left front speaker Right front speaker
1 A2/1 A2/2 H4/9 H4/10 H4/29 H4/33 H4/34
smart MP3 interface (AUX jack) smart radio 9 smart radio 10 Left front speaker Right front speaker Subwoofer Left tweeter Right tweeter
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Body
Body
Climate control
Heating
Model series 451 is equipped with a heating system as standard. The temperature and blower speed are each set by means of a slide control. The temperature blend flap in the air distribution box is operated mechani cally via a Bowden cable. The air distribution is adjusted with a 360 rotating button switch. The air distribution flap is actuated mechanically via a cable shaft. The blower can be adjusted in four power stages. The rpm is regulated by means of an external series resistor: Stage 0: Blower off Stage 1: Blower on Weak, low speed Stage 2: Blower on Strong, higher speed Stage 3: Blower on Stronger, higher speed Stage 4: Blower on Maximum strength The rear window heater button in the heater/AC oper ating unit switches on the heated rear window and the function LED in the button lights up. The heated rear window is switched off either auto matically via a timer control or by pressing the rear window heater button again. The function LED goes out. If the on board power supply voltage is too low, the rear window heater is switched off automatically.
Temperature regulated air conditioning

The control functions of air distribution, blower output, temperature setting and heated rear window are as described for the heater. Activation of the air conditioning: Press A/C button. The function LED lights up. Deactivation of the air conditioning: Press A/C button. The function LED goes out.
P83.10-2640-00
Air outlets for heater and temperature regulated air conditioning
104
Climate control
For safety reasons, if the air distribution lever is moved precisely to "Windshield Defrost", the air conditioning switches itself on automatically with no action by the occupants in order to ensure that the windshield is defrosted and dried as quickly as possible. In this case the function LED does not light up to indi cate that the air conditioning has been activated automatically. When the air distribution lever is moved away from the Defrost position, this function is canceled. This happens regardless of the programmed temperature or blower stage. In addition, air recirculation mode is deactivated if it is on. The air recirculation flap and the temperature blend flap are actuated via electric actuator motors. The cooling output of the refrigerant compressor is controlled by means of an appropriate CAN signal from the SAM control unit. The interior temperature is measured by an integral interior temperature sensor located on the bottom of the heater/air conditioning operating unit.
Air recirculation mode

When the air recirculation mode button is pressed, the fresh air flap is closed. This causes the air to circu late in the interior compartment only. The function LED in the button lights up during air recirculation mode.
i Note The temperature regulated air conditioning switches off temporarily: If the engine speed is too low When starting up At a coolant temperature greater than 239 F (115 C), At outside temperatures below 37 F (3 C).
i Note The air conditioning cannot be operated in temperatures below 37 F (3 C).
P83.40-3926-00
Heater/AC operating unit
105
Body
Body
Customized Bodypanel System (CBS)

CBS concept
The CBS concept is composed of "bodypanels" that are installed as detachable parts around the vehicle and form a large proportion of the vehicle's external skin. Front end module The statics of the CBS in the area of the front end are based on a one piece, bolt on front end module with integral pedestrian protection. The front end module is injection molded polypropy lene plastic stiffened with partial reinforcement panels on the longitudinal frame member. The front end module also holds the engine radiator module, including the AC condenser, the headlamps, the front fog lamp and the CBS bodypanels. Bodypanels Depending on the color variant, the bodypanels are supplied either as colored plastic or with 2 coat metallic paintwork. The bodypanels are overcoated with a clearcoat to protect against UV radiation. The bodypanel concept has proven to be robust and easy to repair in practice. If damaged, they can be replaced with little effort and at low cost. Rear end door The inside of the rear end door in the new smart fortwo coup contains an integral compartment for accommodating the hazard warning triangle, the first aid kit or similar. In the smart fortwo cabrio the stowage space is intended for crash proof storage of the roof side supports.
Surfaces and paintwork

General features Galvanized body Cathodic immersion painting Seam sealing Powder paint tridion safety cell in two colors: Black as standard equipment or silver as special equipment Painted CBS (Customized Bodypanel System) components
Paint of the Customized Bodypanel System

The plastic parts of the Customized Bodypanel System (CBS) are dyed through and/or painted. A two coat system of base coat and clearcoat is applied. Paintwork repairs are possible only if the paint coat has not been worn down to the polypropylene (PP) base material. A new paintwork structure can then be built up. Otherwise proper adhesion of the paint on the component cannot be guaranteed.
106
Customized Bodypanel System (CBS)
P88.00-2375-00
CBS components with front end module and crash management system (CMS)
1 2 3 4 5 6 7 8 9
Front end module Front CMS Left fender Right fender Front spoiler Front center part Maintenance flap Fresh air intake cover Left door paneling
10 11 12 13 14 15 16 17 18
Right door paneling Left side part Fresh air intake Right side part Fuel filler flap Rear CMS Exhaust system covering Rear center part Rear end door paneling
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Body
Body
Seats
Seats, general
The safety integral seats on both sides of model series 451 can be adjusted in terms of seat length and backrest angle. The backrest of the passenger seat can be folded forwards to allow through loading of long loads. A TopTether anchor is bolted to the load compartment floor behind the passenger seat as standard. The guide for the TopTether belt is located on the back rest cover of the passenger seat level with the head restraint. Seat heaters in the seat bolster and backrest cushion are available as special equipment.
Seat heaters
The seat heater special equipment in model 451 consists of two heating elements which are installed in the seat bolster and backrest cushion of each seat. The seat heaters are activated separately for each side via the switch panel in the center console. Pressing the seat heater switch for the driver or passenger side switches on the seat heater at stage 2. Another press of the switch switches the seat heater to stage 1. If the switch is pressed a third time, the seat heater is switched off. The different stages are indicated in the relevant switch by the lighting of one LED for stage 1 and two LEDs for stage 2. The heated seats control unit incorporates a temper ature sensor that measures the ambient temperature. The heating elements in the driver and passenger seats follow a temperature profile based on this temperature. The heater output is constantly moni tored to check the seat temperature.
Function
Function requirements: Switch circuit 15 ON When the seat heater switch for the driver or passenger seat is pressed, a request signal is sent directly to the heated seats control unit. In the heated seats control unit the request for activation of the seat heater is processed with the function require ment. The function requirement is transmitted by the igni tion/starter switch straight to the SAM control unit, from where it is forwarded to the heated seats control unit. If all the criteria for activation are satisfied, the appropriate seat heater is switched on by the heated seats control unit over a direct line.
P91.10-3254-00-
Integral seats
108
Supplemental restraint system

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

Weight sensing system (WSS)
To determine the situation in the interior compart ment, the system detects whether the passenger seat is occupied. The seat occupied recognition pressure sensor determines the weight on the passenger seat by means of a pressure measure ment from a seat mat filled with silicone oil. The force applied to the seat belt is measured via the belt tension sensor. These two measured values are used by the Weight Sensing System (WSS) control unit to classify the weight on the seat. The values are transferred to the instrument cluster via CAN B, which acts as a gateway to transfer the data to the restraint systems control unit via CAN. The following conditions are defined depending on the occupant classification: Passenger seat not occupied: Passenger airbag unit, passenger head/thoraxbag and passenger emergency tensioning retractor unit are disabled; the airbag OFF indicator lamp is switched ON. Passenger seat occupied light weight (e.g. hand luggage): Passenger airbag unit, passenger head/thoraxbag and passenger emergency tensioning retractor unit are disabled; the airbag OFF indicator lamp is switched ON. Passenger seat occupied person detected: The required restraint equipment is enabled; the airbag OFF indicator lamp is switched OFF.
P91.60-3635-00
1 2 B48/4 N110
Seat cushion frame Seat mat filled with silicone oil Seat occupied recognition pressure sensor Weight Sensing System (WSS) control unit
110
P91.60.3634-00
Data flow chart of supplemental restraint system
See next page for legend
111
Body
Body
1 2 3 4 5 6 7 8 9 10 A1 A1e9 A1e15 A53 A54 E16 B48/1 B48/2 B48/3 B48/4
Occupant classification Crash signal Warning and fault message output Squib and sensor monitoring Trigger restraint equipment Passenger airbag cutout display Impact detection Seat occupied status 'Belt tension sensor status Seat belt buckle status Instrument cluster Seat belt warning lamp Airbag indicator and warning lamp Driver head/thoraxbag sensor Passenger head/thoraxbag sensor Automatic child seat recognition airbag OFF indicator lamp Driver side frontal acceleration sensor Passenger side frontal acceleration sensor Belt tension sensor Seat occupied recognition pressure sensor
N2/7 N3/10 N10/10 N110 R12/1 R12/2 R12/4 R12/5 R12/13 R13/14 R12/20 R12/21 S68/3 S68/4
Restraint systems control unit ME SFI [ME] control unit SAM control unit Weight Sensing System (WSS) control unit Left emergency tensioning retractor squib Right emergency tensioning retractor squib Passenger airbag ignition squib 1 Passenger airbag ignition squib 2 Driver airbag ignition squib 1 Driver airbag ignition squib 2 Driver head/thoraxbag squib Passenger head/thoraxbag squib Driver seat belt buckle restraint systems switch Passenger seat belt buckle restraint sys tems switch Controller Area Network (data bus/CAN bus) Controller Area Network bus class B (interior compartment)
CAN CAN B
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Body
Bodyshell structure
The bodyshell structure of model series 451 exhibits the following features: tridion safety cell with high strength steels and low weight: smart fortwo coup: 352 lb (160 kg) smart fortwo cabrio: 379 lb (172 kg) Light alloy detachable parts Front CMS Rear CMS tridion safety cell The tridion safety cell which forms the bodyshell ensures that the vehicle is robust, absorbs energy by deformation in the event of a crash and provides optimum protection of the survival space to keep the occupants safe. Design based benefits of tridion safety cell: Its longitudinal members and crossmembers absorb impact energy at front and rear The most important major assemblies are safely accommodated in its underfloor area. Crash boxes attached at the front and rear absorb the impact energy at speeds of up to approx. 10 mph (16 km/h). It supports the extendable steering column via the cockpit crossmember. The tridion safety cell consists of more than 50 percent high strength steel sheet. These steels are alloyed to be more rigid and stronger than standard steel sheet. The high strength sheet metal parts can be worked in the same way as standard sheet metal and provide the following benefits: Improved torsional stiffness Optimized crash behavior Reduced metal sheet thickness Weight saving Bodyshell material diagram of the steels used (coup and cabrio) Silver areas The silver areas are soft deep drawing steels of regular strength. In these areas all the usual welding methods can be used. Red areas The red areas consist of micro alloyed high strength steels. Resistance spot welding can easily be carried out in these areas. However, metal active gas (MAG) welding is only permissible on approved areas. See the Workshop Information System (WIS) for further instructions and information. Green area (cabrio only) The green area consists of a particularly high strength and torsionally stiff martensite phase steel. This steel is only used in the cabrio for the window pillars of the A pillars because particularly stringent demands are made on the strength of the vehicle at these points.
113
Body
Body
Body
P60.20-2063-00
Overview of bodyshell materials smart fortwo coup
P60.20-2064-00
Overview of bodyshell materials smart fortwo cabrio
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Body
Crash management system (CMS)
CMS concept Model series 451 features a bolt on crash manage ment system at the front and rear in the smart fortwo coup and smart fortwo cabrio. To prevent damage, the front CMS is mounted on the longitudinal frame member and the rear CMS on the frame type integral support. The CMS is a specially shaped steel profile that absorbs impact energy at a defined rate in the low vehicle speed range up to approx. 10 mph (16 km/h).
P62.30-2944-00
P64.20-4995-00
Front CMS
Rear CMS
1 Front steel profile
3 Rear steel profile
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Body
Accessories
smart accessories
i A complete overview of all accessory packages can be found: On the Internet at http://pit.smart.com Accessory designation Brief description WIS no. ASRA no.
Interior All weather floor mats Velour floor mats To protect the standard carpeting. Optimum fit for the footwell on the driver and passenger side. Luggage net with integral luggage compartment cover to allow the full volume of the luggage compartment to be used safely. Plastic platform for MP3 player etc. G 68 9210 0 G 68 9210 0
Divider plus (including luggage compartment cover)
AZ68.50 P 0005MCC AZ68.50 P 0005MCO
G 68 9240 0
Telephone console
AZ82.70 P 0010MCU
G 82 8872 0
Rubber mats for the stowage compartments (set of 3)
For reducing the noise and preventing the slippage of small arti cles on the dashboard. Package consisting of ashtray and cigarette lighter for the standard 12 V socket, clips easily in and out of the vertical strut.
Smoking set
G 68 5194 0
CD box (for 6 CDs)
Storage slots for up to 6 CDs, clips easily in and out of the vertical strut.
G68 4852 0
Luggage anchoring
For versatile anchoring of objects in the trunk. Package consisting of one net pocket for the left trunk side panel and one trunk floor net.
Trunk net package
AZ68.50 P 0003MCC
G 68 7476 0
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smart accessories
Accessory designation Eyeglass compartment Brief description Flip top plastic spectacle case with magnetic catch. WIS no. AZ68.10 P 0010MCC ASRA no. G 68 4846 0
Luggage compartment cover (retractable cover with net pocket) Cargo management system
Retractable luggage compartment cover box with integral net pocket in the passenger compartment. Complete solution for clearly dividing the trunk with three different solu tions: divider, fastening strap and shopping bag.
Exterior smart design sticker Decorative film with one or more digits in black or silver. The self adhesive decorative film is car wash proof, lightfast and can be applied horizontally or vertically with or without digits. AZ72.10 P 0003MCC G 72 7178 0
Bodypanel Fresh Up
Contains all CBS detachable parts installed on a smart fortwo in stan dard or metallic colors.
AR88.00 P 1200MCC
G 88 9991 0
Attaching parts for Body panel Fresh Up
Contains all attaching parts for all CBS detachable parts installed on the vehicle. Radiator grille, outside mirror caps and rear trim strip plated in high gloss chrome. The ideal supplement to the chrome package.
Chrome package
Front fog lamps (chrome style)
117
Accessories
Accessories
smart accessories
Accessory designation Exterior Car cover The portable garage for the smart fortwo made of hard wearing, breathable and water repellent material. Brief description WIS no. ASRA no.
Function and electrical components Additional instruments (cockpit clock and tachom eter) Tachometer and cockpit clock, both with analog display and night illumi nation. Accent trim rings are avail able to match the interior color scheme. AZ54.30 P 0001MCC G 54 5073 0
Audio and telematics smart radio 9 Radio and CD player. AZ82.60 P 0003MCC G 82 7660 0
smart radio 10
Radio with integral 6 disk CD changer, MP3 compatible. The design differs from the smart radio 9 by its silver trim.
AZ82.60 P 0003MCC
G 82 7660 0
smart sound system
Consists of two tweeters and two midrange speakers. Active subwoofer, optimally tuned to suit the smart interior. It is mounted under the driver seat.
AZ82.62 P 0002MCC
G 82 7970 0
Subwoofer
AZ82.62 P 0004MCU
G 82 7970 0 G 82 7814 0
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smart accessories
Accessory designation Wheels and tires Light alloy wheel Alurad Design 5 Front 155/60 R15 Rear 175/55 R15 AR40.10 P 1030MCU G 40 1450 0 V40 2740 0 Brief description WIS no. ASRA no.
Safety First aid pouch Packed in a waterproof nylon pouch, with velcro fastener for attaching to the carpet. 2 piece foam insert for the stowage compartment in the liftgate with useful accessories such as a first aid pouch, smart umbrella, flashlight and smart ice scraper.
Safety Plus package
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Accessories
Index
Numerics
5 speed automated manual transmission . . . . . . . . . . . . . . . . . . . 47
D
Data link connector . . Diagnostic tester . . . Dimensions smart fortwo cabrio . smart fortwo coup . Door structure . . . . . . . . . . . . . . . . . . 26 . . . . . . . . . . . . . 26 . . . . . . . . . . . . . 11 . . . . . . . . . . . . . 10 . . . . . . . . . . . . . 86
A
Acceleration skid control Accessories . . . . . . . . . Active safety . . . . . . . . Air conditioning . . . . . . Alternator . . . . . . . . . . Antilock brake system . . . ATA . . . . . . . . . . . . . . Auto on/off headlamps . . Autolight function . . . . . Automated manual transmission control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 116 . 17 104 . 21 . 73 . 99 101 101
E
Electric power steering . . . . . . . . Electronic brake force distribution Electronic selector lever module control unit . . . . . . . . . . . Electronic Stability Program . . . . . Emergency unlocking of rear end door . . . . . . . . . . . . . . Engine braking regulation . . . . . . . Engine mount . . . . . . . . . . . . . . . Evaporative emission control system Exhaust aftertreatment . . . . . . . . . . . . 75 . . . . 73 . . . . 58 . . 73, 74 . . . . . . . . . . . . . . . . . . . . 89 73 41 42 45
. . . . . . . . . . . 57
B
Battery . . . . . . . . . . . . . . . Belt drive . . . . . . . . . . . . . Bleed cooling system . . . . . . Body . . . . . . . . . . . . . . . . . Bodypanels . . . . . . . . . . . . Bodyshell . . . . . . . . . . . . . . Borg Warner synchronization Brake assist system . . . . . . . Brake pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . 38 . 40 114 106 113 . 54 . 73 . 71
F
Front axle . . . . . . . . . . . . . . . . . . . . . 64 Fuel tank . . . . . . . . . . . . . . . . . . . . . . 42 Full roof . . . . . . . . . . . . . . . . . . . . . . 91
H
Heated seats . . . . . . . . . . . . . . . . . . .108 Heating . . . . . . . . . . . . . . . . . . . . . . .104
C
CBS . . . . . . . . . . . . . . . . . . . . . Central locking . . . . . . . . . . . . . Clutch motor . . . . . . . . . . . . . . . Coming Home function . . . . . . . . control unit . . . . . . . . . . . . . . . Coolant circuit . . . . . . . . . . . . . Crash management system . . . . . . Customized Bodypanel System (CBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 . 96 . 63 101 . 68 . 39 115 106
I
Injection control . . . Instrument cluster . Instrument panel . . Interior design . . . . Interior protection/ tow away protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 21, 84, 85 . . . . 83 . . . . 82
. . . . . . . . . . . . . . 99
120
Index
L
Leak test . . . . . . . . . . . . . . . . . . . . . . 42
S
Safety concept . . . . . . . . . . . . . SAM control unit . . . . . . . . . . . . SCN (Software Calibration Number) coding . . . . . . . . . . . . . . . . . . Seats . . . . . . . . . . . . . . . . . . . Service brake . . . . . . . . . . . . . Service flap . . . . . . . . . . . . . . Shift mechanism . . . . . . . . . . . . Side door emergency opening . . . Side doors . . . . . . . . . . . . . . . Single plate dry clutch . . . . . . . Soft top control . . . . . . . . . . . . Soft top operation . . . . . . . . . . Speakers . . . . . . . . . . . . . . . . Starter . . . . . . . . . . . . . . . . . . Start off assist . . . . . . . . . . . . Stretch belt . . . . . . . . . . . . . . . System . . . . . . . . . . . . . . . . . . . . . 17, 18 . . . . . .28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 . . 108 . . .69 . . .15 . . .49 . . .86 . . .86 . . .62 94, 95 . . .93 . . 103 . . .20 . . .73 . . .38 . . .99
M
Maintenance concept . . . . . Maintenance interval display Maintenance intervals . . . . Maintenance points Engine compartment . . . . . Front end . . . . . . . . . . . Mechanical park pawl . . . . . Muffler system . . . . . . . . . Multifunction display . . . . . . . . . . . . . . 13 . . . . . . . . . 14 . . . . . . . . . 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 15 61 45 84
O
Occupant restraint systems . . . . . . . . . 18 Oil Service Plus . . . . . . . . . . . . . . . . . 13 Overall network CAN bus/LIN bus . . . . . 23
P
Paddle shifts on steering wheel Paintwork . . . . . . . . . . . . . . PANIC alarm . . . . . . . . . . . . . Panoramic sunroof . . . . . . . . Parking brake . . . . . . . . . . . Passive safety . . . . . . . . . . . Power and torque graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 . 106 . 97 . 91 . 69 . 18 . 31
T
TAN generator . . . . . . . Tire pressure sensing . . Torque support . . . . . . Transmission motors . . . Transmission mount . . . Transmission rpm sensor tridion safety cell . . . . . Tritop fabric soft top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 . .67 . .41 . .56 . .41 . .55 . 113 . .92
R
Radio 10 . . . . . . . . . . Radio 9 . . . . . . . . . . . TPM . . . . . . . . . . . . . Rear axle . . . . . . . . . Rear end door . . . . . . Recirculated air mode . Remote soft top opening Remote trunk opening . Restraint system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 . 102 . 68 . 65 . 88 . 105 . 97 . 97 . 109
V
Valve assembly . . . . . . . . . . . . . . . . . . .33 Vehicle characteristics . . . . . . . . . . . . . 9 Vehicle concept . . . . . . . . . . . . . . . . . . 9
W
Weight sensing system (WSS) . . . . . . . . . 110 Wiring harness repair capability . . . . . . .25 Wiring harness repair kit . . . . . . . . . . . .25
121

2008 Smart Fortwo Tech Manual

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What are the main components and systems described in the manual?

What are the main components and systems described in the manual?

What maintenance procedures are outlined in the manual?

What maintenance procedures are outlined in the manual?

,

Introduction of the smart fortwo Model series 451

Introduction of the smart fortwo Model series 451

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

Introduction of the smart fortwo Model Series 451

SN_Typ 451_us.book Seite 2 Freitag, 30. November 2007 1:56 13

Published by smart USA, 2007 Printed in U.S.A. www.smartusa.com

SN_Typ 451_us.book Seite 3 Freitag, 30. November 2007 1:56 13

Complete vehicle Overview Technical data Maintenance Safety concept

SN_Typ 451_us.book Seite 4 Freitag, 30. November 2007 1:56 13

Exhaust system Overview Secondary air injection

Introduction of the smart fortwo, Model Series 451

SN_Typ 451_us.book Seite 5 Freitag, 30. November 2007 1:56 13

Accessories smart accessories

Introduction of the smart fortwo, Model Series 451

SN_Typ 451_us.book Seite 6 Freitag, 30. November 2007 1:56 13

Introduction of the smart fortwo, Model Series 451

SN_Typ 451_us.book Seite 7 Freitag, 30. November 2007 1:56 13

smart USA aftersales

Introduction of the smart fortwo, Model Series 451

SN_Typ 451_us.book Seite 8 Freitag, 30. November 2007 1:56 13

smart fortwo coup

smart fortwo cabrio

Introduction of the smart fortwo, Model Series 451

SN_Typ 451_us.book Seite 9 Freitag, 30. November 2007 1:56 13

Introduction of the smart fortwo, Model Series 451

SN_Typ 451_us.book Seite 10 Freitag, 30. November 2007 1:56 13

Dimensions smart fortwo coup

Unit in (mm) in (mm) in (mm) in (mm) in (mm) in (mm)

Introduction of the smart fortwo, Model Series 451

SN_Typ 451_us.book Seite 11 Freitag, 30. November 2007 1:56 13

Dimensions smart fortwo cabrio

Unit in (mm) in (mm) in (mm) in (mm) in (mm) in (mm)

Introduction of the smart fortwo, Model Series 451

SN_Typ 451_us.book Seite 12 Freitag, 30. November 2007 1:56 13

Loads, weights and other data

Permissible rear axle load

Curb weight as per DIN

Permissible gross vehicle weight

of which max. in luggage compart ment

7.8 (220) 12 (340) 9.57 (8.75) 8.72/1.32 33/5

Tank capacity/including reserve

Introduction of the smart fortwo, Model Series 451

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

* depending on first occurrence

Oil Service Plus

Introduction of the smart fortwo, Model Series 451

SN_Typ 451_us.book Seite 14 Freitag, 30. November 2007 1:56 13

Instrument cluster A1 A1p13 Instrument cluster Multifunction display

Multifunction display with maintenance interval display

Introduction of the smart fortwo, Model Series 451

SN_Typ 451_us.book Seite 15 Freitag, 30. November 2007 1:56 13

Maintenance points at front end

Introduction of the smart fortwo, Model Series 451

SN_Typ 451_us.book Seite 16 Freitag, 30. November 2007 1:56 13

Introduction of the smart fortwo, Model Series 451