Engine Cooling System (Coupe): Removal & Installation Smart Fortwo II

Replace coolant - AP20.00-P-2080MCU

ENGINE 132.910 in MODEL 451.3/4

Scheme 16

Drain Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. AS20.00-Z-0001-01A Notes on coolant AH20.00-N-2080-01A 1 Remove maintenance flap 2 Turn cooling system cap (1) on the engine radiator (2) a half turn counterclockwise, relieve the pressure and then unscrew the cooling system cap (1) Risk of death caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A 3 Raise the vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver 4 Loosen hose clamp (4) for coolant hose (3), detach coolant hose (3) at radiator (5) and coolant Catch coolant in a suitable vessel. 5 Disconnect electrical connector on knock sensor and on crankshaft position sensor, lay electrical wiring harness to one side and cover crankshaft position sensor This prevents coolant finding its way into the crankshaft position sensor. 6 Remove coolant drain screw (8) at engine and drain off coolant Catch coolant in a suitable vessel. Filling 7 Position coolant hose (3) on radiator (5) and fasten hose clamp (4) of coolant hose (3) Replace hose clamp (4). 8 Tighten coolant drain plug (8) on engine Replace seal ring of coolant drain plug (8). 9 Remove cover on crankshaft position sensor, lay electrical wiring harness and contact electrical connector on knock sensor and on crankshaft position sensor 10 Lower vehicle with lifting platform 11 Remove engine compartment cover Remove/install interior compartment flap above engine AR88.40-P-1100-03MCC 12 Fill cooling system via the expansion reservoir (2) The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking. Coolant specifications Sheet 310.1 BB00.40-P-0310-01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325-00A 13 Loosen clamp (7) and pull coolant hose (6) off connection fitting on cylinder head, wait until the coolant escapes from the coolant hose (6) and from the connection fitting on the cylinder head 14 Position coolant hose (6) on the cylinder head and fasten clamp (7) Replace hose clamp (7). 15 Correct coolant level in expansion reservoir (2) The engine coolant level in the coolant expansion reservoir (2) must be positioned at the max. marking. Coolant specifications Sheet 310.1 BB00.40-P-0310-01A Anticorrosion/antifreeze agents (Sheet 325.0) Sheet 325.0 BB00.40-P-0325-00A 16 Seal expansion reservoir (2) with cap (1) Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A 17 Run engine until warm Until the coolant fan motor cuts in. 18 Check coolant level in the expansion reservoir (2) and correct if necessary AP20.00-P-2010MCU 19 Inspecting cooling system for leaks Inspecting cooling system for leaks AR20.00-P-1010MCU 20 Raise vehicle with vehicle lift 21 Install underfloor paneling 22 Lower vehicle with lifting platform 23 Install engine compartment cover Remove/install interior compartment flap above engine AR88.40-P-1100-03MCC 24 Install maintenance flap

Remove/install coolant pump - AR20.10-P-1271MCU

ENGINE 132.910 in MODEL 451.3 /4

Scheme 17

Remove/install 1 Drain coolant AR20.00-P-1142MCU 2 Remove belt pulley (2) for coolant pump (1) AR20.10-P-1275MCU 3 Remove poly-V belt tensioning device (3) AR13.25-P-3200MCU 4 Remove poly-V belt for supercharger On vehicles with code (I01) Air conditioning Plus AR13.21-P-1202MCU 5 Remove bolt (4) on timing case cover (5) and lay ground line (6) for engine mass to one side 6 Remove bolts (7, 8) Catch coolant in a suitable vessel. *BA20.10-P-1007-01J 7 Remove coolant pump (1) from timing case cover (5) Installation: Replace profiled rubber seal of coolant pump (1). 8 Install in the reverse order

Scheme 18

COOLANT PUMP, COOLANT THERMOSTAT

Remove/install belt pulley for the coolant pump - AR20.10-P-1275MCU

ENGINES 132.910 in MODEL 451.3 /4

Scheme 19

Remove/install 1 Remove poly-V belt (2) AR13.22-P-1202MCU 2 Counterhold belt pulley (1) and remove bolts (3) see scheme 9 *BA20.10-P-1001-01J 3 Remove belt pulley (1) from the coolant pump 4 Install in the reverse order

COOLANT PUMP, COOLANT THERMOSTAT

Scheme 20

Remove/install coolant thermostat - AR20.10-P-2460MCU

ENGINE 132.910 in MODEL 451.3 /4

Scheme 21

Remove/install 1 Drain coolant AR20.00-P-1142MCU 2 Release rear drive module AR01.00-P-3050MCU 3 Remove fender liner in right rear fender AR88.10-P-1400MCU 4 Remove poly-V belt AR13.22-P-1202MCU 5 Remove intake manifold (2) AR09.20-P-1310MCU 6 Unscrew nut (3) on alternator (G2) and remove charge current line (4) *BA15.40-P-1002-01G 7 Remove bolt (5) on alternator (G2) on timing case cover *BA15.40-P-1008-01G 8 Loosen bolt (6) and swivel alternator (G2) upwards *BA15.40-P-1008-01G 9 Remove bolts (7) and lay coolant line (8) with attached coolant hoses to one side *BA20.10-P-1011-01J *BA20.10-P-1012-01J 10 Remove bolt (9) on holder (10) on the oil pan 11 Remove bolts (11) and pass coolant thermostat (1) under the coolant line (8) Catch coolant in a suitable vessel. *BA20.10-P-1008-01J 12 Loosen clamps (12) and detach coolant hoses (13) from coolant thermostat (1) Note installation locations for coolant hoses (13). Installation: Replace clamps (12). 13 Remove holder (10) on coolant thermostat (1) When replacing coolant thermostat (1). 14 Install in the reverse order

ALTERNATOR

COOLANT PUMP, COOLANT THERMOSTAT

Remove/install radiator - AR20.20-P-3865MCU

ENGINE 132.910 in MODEL 451.3 /4

Scheme 22

Remove/install 1 Remove front module AR62.30-P-1575MCU 2 Remove condenser On vehicles with code (I01) Air conditioning Plus AR83.30-P-6540MCU 3 Drain coolant at radiator (1) AR20.00-P-1142MCU 4 Detach hose clamp (4) on expansion reservoir (3) Replace hose clamp (4). 5 Loosen expansion reservoir (3) from bracket (arrow A) on radiator support, detach from radiator (1) coolant hose (2) and lay to one side with attached coolant hoses Secure expansion reservoir (3) against falling down using a suitable cable tie. 6 Carefully lead radiator (1) on the left side on the brackets (arrows B) and take off 7 Install in the reverse order

Remove, install coolant line - AR20.20-P-7441MCU

ENGINE 132.910 in MODEL 451.3/4

Scheme 23

Remove/install 1 Drain coolant AR20.00-P-1142MCU 2 Remove intake manifold (2) AR09.20-P-1310MCU 3 Loosen clamp (3) and detach coolant hose (4) from coolant line (1) Installation: Replace clamp (4). 4 Loosen clamp (5) and detach coolant hose (6) from coolant line (1) Installation: Replace clamp (6). 5 Remove bolts (7) and coolant line (1) *BA20.10-P-1011-01J *BA20.10-P-1012-01J 6 Install in the reverse order

COOLANT PUMP, COOLANT THERMOSTAT

Remove/install coolant pipe - AR20.20-P-7450MCU

ENGINE 132.910 in MODEL 451.3 /4

Scheme 24

Remove/install 1 Drain coolant AR20.00-P-1142MCU 2 Remove intake manifold (2) AR09.20-P-1310MCU 3 Mark installation position of the coolant hose (3) to coolant pipe (1) (arrow) 4 Release clamp (4) and detach coolant hose (5) from coolant pipe (1) Installation: Replace clamp (4). 5 Remove bolt (6) for coolant pipe (1) on cylinder crankcase *BA20.10-P-1009-01J 6 Remove bolt (7) for coolant pipe (1) on oil pan *BA20.10-P-1010-01J 7 Pull coolant pipe (1) out of timing case cover (8) Installation: Replace seal ring on coolant pipe (1). 8 Release clamp (9) and detach coolant hose (3) from coolant pipe (1) Installation: Replace clamp (9). 9 Remove coolant pipe (1) 10 Install in the reverse order

COOLANT PUMP, COOLANT THERMOSTAT

Remove/install expansion reservoir - AR20.30-P-4950MCU

ENGINES 132.910 in MODEL 451.3 /4

ENGINES 780.009 in MODEL 451.391 /491

Shown on vehicle with engine 132

Scheme 25

Vehicles with engine 780

Scheme 26

Remove/install Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant. Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers. Wear protective gloves, protective clothing and safety glasses. AS20.00-Z-0001-01A Notes on coolant AH20.00-N-2080-01A 1 Remove front module AR62.30-P-1575MCU 2 Turn cooling system cap (2) on engine radiator (1) a half turn counterclockwise, relieve pressure and then unscrew the cooling system cap (2) 3 Suction off coolant in expansion reservoir (1) 4 Clamp off coolant hoses (5, 6) using suitable hose clamps 5 Loosen clamps (3) on coolant hoses (4, 5, 6 and 8) On engine 780.009 only the clamps (3) of coolant hoses (5, 6 and 8) should be loosened Installation: Replace snap clamps (3). 6 Detach coolant hose (4) on expansion reservoir (1) and lay to one side in such a way that so no coolant can run out For engine 132.9 Collect coolant which flows out in a suitable vessel. 7 Detach coolant hoses (5, 6) on expansion reservoir (1) Collect coolant which flows out in a suitable vessel. 8 Detach expansion reservoir (1) from holder (7), detach from coolant hose (8) and take off Collect coolant which flows out in a suitable vessel. 9 Loosen clamp (10) and detach blind plug (11) For engine 780.009 Only when replacing the expansion reservoir (1). Installation: Replace snap clamp (10). 10 Install in the reverse order 11 Pour in coolant For engine 132.9 AR20.00-P-1142MCU For engine 780.009 Coolant circuit high-voltage battery AR20.00-P-1142MEV

Remove/install electric fan - AR20.40-P-5000MCU

ENGINE 132.910 in MODEL 451.3 /4

Scheme 27

Remove/install 1 Remove radiator (2) AR20.20-P-3865MCU 2 Disconnect electrical connector (3) at coolant fan motor (M4/2) 3 Unclip retaining clip (4, 5) for electrical line (6) to fan shroud (1) and lay electrical line (6) to one side 4 Remove mounts (7) from fan shroud (1) see scheme 17 5 Take off fan shroud (1) 6 Install in the reverse order

Scheme 28