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

Replace spark plugs - AP15.10-P-1580MCU

ENGINE 132.910 in MODEL 451.3 /4

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Remove/install 1 Remove ignition coils Remove/install ignition coils AR15.12-P-2003MCU 2 Unscrew spark plugs (R4) *BA15.10-P-1001-01B 3 Install in the reverse order

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SPARK PLUGS

Remove/install ignition coils - AR15.12-P-2003MCU

ENGINE 132.910 in MODEL 451.3 /4

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Remove/install Risk of death caused by contact with parts conducting high voltages. Do not come into contact with parts that are under high voltage. Persons who have electronic implants (e.g. pacemakers) must not perform any work on the ignition system. AS15.10-Z-0001-01A 1 Withdraw ignition key 2 Remove interior flap above engine AR88.40-P-1100-03MCC 3 Unlock electrical connector (1) at respective ignition coil (T1/1, T1/2, T1/3) and disconnect 4 Remove bolt (2) respective ignition coil (T1/1, T1/2, T1/3) *BA15.12-P-1003-01G 5 Remove ignition coils (T1/1, T1/2, T1/3) 6 Install in the reverse order 7 Read out fault memory Connect STAR DIAGNOSIS and read out fault memory AD00.00-P-2000-04MCC

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ECI IGNITION SYSTEM

Remove/install crankshaft position sensor - AR15.12-P-2133MCU

ENGINE 132.910 in MODEL 451.3 /4

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Remove/install Risk of death caused by vehicle slipping or toppling off the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A 1 Raise vehicle with vehicle lift 2 Disconnect electrical connector (1) on crankshaft position sensor (L5) 3 Remove bolt (2) and pull crankshaft position sensor (L5) off the crankcase Installation: Check seal ring on crankshaft position sensor (L5); replace if necessary. *BA15.12-P-1002-01G 4 Install in the reverse order 5 Read out fault memory, erase if necessary When replacing the crankshaft position sensor (L5). Connect STAR DIAGNOSIS and read out fault memory AD00.00-P-2000-04MCC Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A 6 Conduct engine test run and check engine around crankshaft position sensor (L5) for leaks

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ECI IGNITION SYSTEM

Remove/install camshaft position sensor - AR15.12-P-2140MCU

ENGINE 132.910 in MODEL 451.3 /4

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Remove/install 1 Remove interior flap above engine AR88.40-P-1100-03MCC 2 Disconnect electrical connector (1) at camshaft Hall sensor (B6/1) 3 Remove bolt (2) and pull camshaft Hall sensor (B6/1) out of cylinder head Installation: Check seal ring on camshaft Hall sensor B6/1); replace if necessary. *BA15.12-P-1004-01G 4 Install in the reverse order 5 Read out fault memory, erase if necessary When replacing the camshaft Hall sensor (B6/1). Connect STAR DIAGNOSIS and read out fault memory AD00.00-P-2000-04MCC Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A 6 Conduct engine test run and check engine around the camshaft Hall sensor (B6/1) for leaks

ECI IGNITION SYSTEM

Remove/install knock sensor - AR15.12-P-2185MCU

ENGINE 132.910 in MODEL 451.3 /4

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Remove/install Risk of death caused by vehicle slipping or toppling off the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A 1 Raise vehicle with vehicle lift 2 Disconnect electrical connector (1) at knock sensor (A16) 3 Unscrew screw (2) and remove knock sensor (A16) Observe installation position of knock sensor (A16). Installation: The contact surface for the knock sensor (A16) on the cylinder crankcase must be clean and flat. *BA15.12-P-1001-01G 4 Install in the reverse order 5 Read out fault memory, erase if necessary When installing new a knock sensor (A16). Connect STAR DIAGNOSIS and read out fault memory AD00.00-P-2000-04MCC

ECI IGNITION SYSTEM

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1. Unclip and disconnect separation point (arrow) for line (2) on tank vent valve from mount on intake manifold (4).
2. Detach holder (3) from intake manifold (4).
3. Disconnect electrical connector on alternator (G2), on throttle valve actuator (M16/6) and on intake manifold pressure sensor (B28).
4. Disconnect electrical connector (5) for refrigerant compressor (A9) On vehicles with CODE (I01) Air conditioning Plus.
5. Unlock retaining clamps (6) for engine wiring harness (1) on intake manifold (4) and remove engine wiring harness (1) from retaining clamps (6).
6. Unlock retaining clamps (7, 8) for engine wiring harness (1) on intake manifold (4) and remove engine wiring harness (1) from retaining clamps (7, 8).
7. Unclip retaining clip (9) for engine wiring harness (1) on intake manifold (4).
8. Lead and place engine wiring harness (1) to the side over the throttle valve actuator (M16/6).
9. Connect in reverse order.

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1. Unlock and disconnect electrical connector (2) on ME-SFI [ME] control unit (N3/10)
2. Cut through cable tie (3) on engine wiring harness (1). Connecting: Replace cable tie (3).
3. Disconnect electrical connector (4) and secondary air injection pump connector (X15).
4. Push grommet (5) for engine wiring harness (1) through the vehicle body opening into the engine compartment.
5. Lift vehicle with lifting platform.
6. Unscrew nuts (6) and remove electrical lines (7) for engine mass.
7. Unclip retaining clip for engine wiring harness (1) on secondary air injection pump holder (M33).
8. Lead engine wiring harness (1) downwards into the engine compartment and to the side between the body and secondary air injection pump (M33). Attaching: Route engine wiring harness (1) in such a way that it is not damaged by crushing.
9. Connect in reverse order.

Remove/install starter - AR15.30-P-7100MCU

ENGINE 132.910 in MODEL 451.3 /4

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Remove/install 1 Disconnect ground line of battery AR54.10-P-0003MCC Risk of death caused by vehicle slipping or toppling off the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z-0010-01A 2 Raise vehicle with vehicle lift 3 Unscrew nut (1) and remove charge current line (2) from starter (M1) *BA15.30-P-1002-01E 4 Pull out plug (3) on starter (M1) 5 Remove bolts (4) and remove starter (M1) from transmission *BA15.30-P-1001-01E 6 Install in the reverse order

STARTER

Remove/install alternator - AR15.40-P-5032MCU

ENGINE 132.910 in MODEL 451.3 /4

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Remove/install 1 Remove interior flap above engine AR88.40-P-1100-03MCC 2 Disconnect ground line for battery AR54.10-P-0003MCC 3 Remove fender liner in right rear fender AR88.10-P-1400MCU 4 Release rear drive module AR01.00-P-3050MCU 5 Remove poly-V belt AR13.22-P-1202MCU 6 Lower vehicle with lifting platform 7 Unplug electrical connector (1) at the alternator (G2) 8 Remove nut (2) on alternator (G2) and remove charge current line (3) *BA15.40-P-1002-01G 9 Remove right engine mount (4) AR22.10-P-1102MCU 10 Remove bolts (5) *BA15.40-P-1008-01G 11 Remove alternator (G2) from timing case cover 12 Install in the reverse order

ALTERNATOR

Remove/install coolant temperature sensor - AR15.60-P-2711MCU

ENGINE 132.910 in MODEL 451.3 /4

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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 maintenance flap 2 Turn cooling system cap on engine radiator a half turn counterclockwise, relieve the pressure and then unscrew the cooling system cap 3 Remove interior flap above engine Installation: Only install Interior flap above engine after the leak test. AR88.40-P-1100-03MCC 4 Remove secondary air injection pump switchover valve (Y32) on holder(1) (arrow), and lay to the side 5 Disconnect electrical connector (2) at coolant temperature sensor (B11/4) 6 Remove coolant temperature sensor (B11/4) from cylinder head (3) Catch coolant in a suitable vessel. Installation: Screw in coolant temperature sensor (B11/4) with sealant. *BA15.60-P-1002-01B Sealant *BR00.45-Z-1053-01A 7 Install in the reverse order 8 Pour in coolant AR20.00-P-1142MCU 9 Read out fault memory, erase if necessary When replacing the coolant temperature sensor (B11/4). Connect STAR DIAGNOSIS and read out fault memory AD00.00-P-2000-04MCC Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running Secure vehicle to prevent it from moving by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts. AS00.00-Z-0005-01A 10 Conduct engine test run and check engine in the area of the coolant temperature sensor (B11/4) for leaks

TEMPERATURE SENSOR

REPAIR MATERIALS