Complete Engine (Coupe): Removal & Installation Smart Fortwo II

Remove/install engine with transmission - AR01.10-P-2401MCU

ENGINES 132.910 in MODEL 451.3 /4

Scheme 23

Scheme 24

Remove/install Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel No fire, sparks, open flames or smoking. Pour fuels only into suitable and appropriately marked containers. Wear protective clothing when handling fuel. AS47.00-Z-0001-01A 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 cap on engine coolant expansion reservoir a half turn counterclockwise, relieve pressure and then unscrew the cap 3 Remove right side paneling in trunk AR68.30-P-4800MCU 4 Remove interior flap above engine AR88.40-P-1100-03MCC 5 Disconnect ground line of battery AR54.10-P-0003MCC 6 Disconnect engine wiring harness on vehicle side AR15.18-P-1000-02MCU 7 Detach tank vent valve (Y58/1) from holder (1) on right engine mount (2) and unlock tank vent line (3) on tank vent valve (Y58/1) and detach 8 Detach molded hose (4) on valve for secondary air injection (5) 9 Detach bolts (6) for engine mount on the right (2) on timing case cover *BA22.10-P-1007-01M 10 Remove air filter housing AR09.10-P-1150MCU 11 Detach vacuum line for brake booster (7) at intake manifold (8) 12 Unhook thrust bearing (9) for park pawl cable (10) on transmission and unclip park pawl cable (10) on lever (11) 13 Detach bolts (12) for transmission mounting bearing (13) on transmission *BA26.00-P-1002-01D 14 Detach clamp (14), disconnect fuel line (15) on fuel distributor (16) and expose Seal fuel line (15) and fuel distributor (16) using suitable stop plugs. Installation: Replace clamp (14). 15 Remove fender liner in the left and right rear fender AR88.10-P-1400MCU 16 Remove complete exhaust system AR49.10-P-7000MCU 17 Remove rear axle crossmember together with bar links AR35.15-P-0250MCC 18 Drain coolant AR20.00-P-1142MCU 19 Detach electric wiring harness at transmission AR26.19-P-0001-05MCU 20 Remove bulkhead wall On model 451.4 AR61.25-P-6600MCU 21 Detach clamps (17) and disconnect coolant return flow line (18), coolant line feed line (19) as well as heater coolant line (20) from the respective coolant pipe Installation: Replace clamps (17). 22 Remove expansion clips (21) and remove cover (22) 23 Detach left and right rear axle shaft outboard and fix at a suitable location with a cable ties AR35.30-P-0620MCU 24 Remove coolant compressor poly-V belt On vehicles with code (I01) Air conditioning Plus AR13.21-P-1202MCU 25 Position major assembly lifting table with universal main assembly mount and fix in place with the mount on the engine AR01.10-P-2400-06MCU Support Major assembly lifting platform and universal lifting platform see scheme 22 26 Remove bolt (23) to torque support (24) *BA22.10-P-1010-01M 27 Remove bolts (12) for transmission mounting bearing (13) on transmission The bolts (12) are accessible over the left wheel well. 28 Remove bolts (6) for engine mount on the right (2) on timing case cover The bolts (6) are accessible over the right wheel well. 29 Lower engine with transmission carefully until the charge current line is accessible During lowering and positioning, ensure that no electrical lines and hoses are pinched to prevent damage. 30 Remove refrigerant compressor and fix at a suitable location using a cable tie On vehicles with code (I01) Air conditioning Plus AR83.55-P-5300-04MCU *BA83.55-P-1001-01V *BA83.55-P-1002-01V 31 Detach charging current line on the engine side AR15.18-P-2000-01MCU *BA15.30-P-1002-01E *BA15.40-P-1002-01G 32 Carefully lower combustion engine with transmission During lowering and positioning ensure that no electrical lines and hoses get pinched. Aid of helper required. 33 Lift vehicle using the vehicle lift until the engine with transmission can be pulled forward under the vehicle 34 Install in the reverse order

STARTER

ALTERNATOR

ENGINE MOUNTS, ENGINE SUPPORTS

COMPLETE MANUAL TRANSMISSION

REFRIGERANT COMPRESSOR

Scheme 25

Remove/install crankcase ventilation valve (partial load) - AR01.20-P-0010MCU

ENGINE 132.910 in MODEL 451.3 /4

Scheme 26

Remove/install 1 Remove intake manifold (2) AR09.20-P-1310MCU 2 Remove crankcase ventilation valve (1) from grommet (3) on partial load vent plate (4) Installation: Check hose (5) on crankcase ventilation valve (1); replace if necessary. 3 Remove grommet (3) from partial load vent plate (4) Installation: Check grommet (3) and replace if necessary. 4 Detach clamp (6) and detach crankcase ventilation valve (1) from hose (5) When replacing crankcase ventilation valve (1). 5 Install in the reverse order

Remove/install cover on crankcase - AR01.20-P-0100MCU

ENGINE 132.910 in MODEL 451.3 /4

Scheme 27

Remove/install 1 Remove intake manifold (2) AR09.20-P-1310MCU 2 Remove crankcase ventilation valve (3) from grommet (4) on partial load vent plate (1) 3 Remove bolts (5) *BA01.20-P-1003-01I 4 Detach partial load venting plate (1) from the crankcase using the knife and take off Installation: Clean sealing surfaces to partial load venting plate (1) and on crankcase. Apply sealant to cylinder crankcase. see scheme 32 Sealant *BR00.45-Z-1053-01A 5 Install in the reverse order

CRANKCASE VENTILATION, CYLINDER HEAD COVER

Scheme 28

REPAIR MATERIALS

Remove/install cylinder head cover - AR01.20-P-5014MCU

ENGINE 132.910 in MODEL 451.3 /4

Scheme 29

Scheme 30

MODIFICATION NOTES

Remove/install 1 Remove ignition coils AR15.12-P-2003MCU 2 Remove clamp (11) of crankcase vent hose (2) on cylinder head cover (1) For vehicles, on which the clamp (11) is not yet installed, it must then be retrofitted during installation. Installation: Replace clip (11). The clamp (11) must be fitted as close as possible to the cylinder head cover (1). Clamp pliers with side cutter 3 Detach crankcase vent hose (2) to the cylinder head cover (1) 4 Remove oil dipstick (3) from cylinder head cover (1) 5 Disconnect engine wiring harness (4) on engine AR01.00-P-2420-01MCU 6 Detach vacuum hose (5) and supply line (7) on secondary air injection valve (6) 7 Remove complete exhaust system AR49.10-P-7000MCU 8 Remove bolts for secondary air injection pipe (8) on cylinder head The secondary air injection pipe (8) is attached to cylinder head by three bolts. *BA14.30-P-1002-03C 9 Remove bolts (9) for secondary air injection valve (6) on cylinder head and remove together with secondary air injection pipe (8) 10 Remove bolts on cylinder head cover (1) The cylinder head cover (1) is fastened with ten bolts. Loosen bolts for cylinder head cover (1) in reverse order of the tightening procedure. Installation: Observe prescribed tightening sequence of bolts for the cylinder head cover (1). AR01.20-P-5014-03MCC *BA01.20-P-1002-01I 11 Detach and remove cylinder head cover (1) from cylinder head Check seal on cylinder head cover (1) for damage; replace cylinder head cover (1) if necessary. Remove sealant residue in the area of the joint edge of the cylinder head and timing case cover. Installation: Check seals for spark plug shafts for damage, replace if necessary. Apply sealant in the area of the joint edge of the cylinder head and timing case cover. Sealing compound *BR00.45-Z-1053-01A 12 Remove bracket (10) for engine wiring harness (4) on cylinder head cover (1) When replacing the cylinder head cover (1). 13 Install in the reverse order 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 14 Conduct engine test run and check engine for leaks in the area of the cylinder head cover (1)

CRANKCASE VENTILATION, CYLINDER HEAD COVER

COMBINATION VALVE

REPAIR MATERIALS

Remove/install cylinder head - AR01.30-P-5800MCU

ENGINE 132.910 in MODEL 451.3 /4

Scheme 31

Illustrated on removed engine

Scheme 32

Scheme 33

Remove/install 1 Check basic position of camshafts AR05.20-P-6010MCU 2 Remove timing case cover AR01.40-P-8000MCU 3 Support rear axle crossmember (2) in the middle with a transmission jack, remove bolts (3) and lower rear axle crossmember (2) Use a suitable base. Transmission jack *BA35.10-P-1003-01F 4 Disconnect electrical connector (4) on coolant temperature sensor (B11/4) and unclip retaining clip (5) from electrical wiring harness on holder (6) 5 Turn back ratchet (7) on chain tensioner (8) using a suitable screwdriver and lock chain tensioner (8) via the bore (arrow A) In order to lock the chain tensioner (8), place a pin with a diameter of 1.5 mm into the bore (arrow A) in the chain tensioner (8). Installation: Attach adapter to crankshaft, remove retaining lock on starter ring gear and turn engine in direction of engine rotation through about two revolutions until the markings on the crankshaft sprocket and on the cylinder crankcase stand opposite each other. Then check whether the marking (arrow B) on the camshaft sprocket (14) and the marking (arrow C) on the camshaft adjuster (15) stand opposite each other; remove timing chain (13) if necessary and mount again anew. Attach/disassemble retaining lock for engine AR03.30-P-1600-06MCE see scheme 40 If the cylinder head (1) was replaced the valve clearance must be checked and adjusted if necessary. Refer to: ↓ see scheme 41 Set valve clearance AP05.30-P-0560MCU 6 Unscrew bolts (9) and remove slide rail (10) *BA05.10-P-1002-01P *BA05.10-P-1003-01P 7 Unscrew bolt (11) and remove tensioning rail (12) *BA05.10-P-1001-01P 8 Take off timing chain (13) Installation: Before mounting the timing chain (13) check whether the marking (arrow B) on the camshaft sprocket (14) and the marking (arrow C) on the camshaft adjuster (15) are standing opposite each other. If this is not the case, the intake camshaft and the exhaust camshaft must be turned appropriately. 9 Lower vehicle with lifting platform 10 Remove bolt (16) and pull adjustable camshaft timing solenoid (Y49) out of cylinder head (1) Cover oil holes on adjustable camshaft timing solenoid (Y49) to protect against ingress of foreign objects. Ingress of foreign objects can cause engine damage. *BA05.20-P-1006-01M 11 Remove intake camshaft and exhaust camshaft The camshaft sprocket (14) remains on the exhaust camshaft. AR05.20-P-6992MCU 12 Loosen clamp (17) and detach coolant hose (18) from connection fitting on cylinder head (1) Installation: Replace clamp (17). 13 Remove bolt (19) and pull camshaft Hall sensor (B6/1) out of cylinder head (1) *BA15.12-P-1004-01G 14 Remove bolt (20) for coolant pipe (21) on cylinder head (1) *BA20.10-P-1011-01J 15 Detach holder (22) for electrical wiring harness (23) on intake manifold (24) 16 Remove bolts (25) and detach air intake manifold (24) from intake manifold (1) Installation: Replace seals on intake manifold (24). *BA09.20-P-1001-01J 17 Loosen cylinder head bolts (26) in stages Loosen cylinder head bolts (26) in reverse order of tightening procedure. Installation: Replace cylinder head bolts (26) and wet on thread and on bolt head contact surfaces with engine oil. AR01.30-P-5800-01MCC *BA01.30-P-1001-01K 18 Support engine on carrier for front engine mount using a hand-operated hydraulic floor jack Use a suitable base. Hand-operated hydraulic floor jack 19 Unhook chain for engine-lifting device on retaining plate (30) see scheme 42 20 Remove cylinder head bolts (26) and cylinder head (1) from cylinder crankcase 21 Take cylinder head gasket (27) off crankcase Installation: Replace cylinder head gasket (27). 22 Remove valve tappet (28) from basic bores in cylinder head (1) Do not use magnets. Gathering of the smallest metal shavings can occur due to magnetization of the valve tappets (28) which can lead to damage of valve tappets (28) and intake camshaft or exhaust camshaft. Installation: The valve tappet (28) must be installed again at the same location. 23 Clean separating surfaces on cylinder head (1) and crankcase then check for visible damage and flatness Replace cylinder head (1) if necessary. Straightedge 24 Clean threaded hole for cylinder head bolts (26) in crankcase 25 Unscrew bolt (29) and remove retaining plate (30) from cylinder head (1) When replacing the cylinder head (1). see scheme 42 26 Remove coolant temperature sensor (B11/4) from cylinder head (1) When replacing the cylinder head (1). *BA15.60-P-1002-01B 27 Install in the reverse order 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 28 Conduct engine test run and check engine for leaks in area of the cylinder head (1)

CYLINDER HEAD

TIMING CHAIN DRIVE

CAMSHAFT

INTAKE MANIFOLD, INTAKE MANIFOLD PREHEATER

ECI IGNITION SYSTEM

TEMPERATURE SENSOR

COOLANT PUMP, COOLANT THERMOSTAT

REAR AXLE CARRIER

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Remove/install timing case cover - AR01.40-P-8000MCU

ENGINE 132.910 in MODEL 451.3 /4

Scheme 38

Scheme 39

Scheme 40

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 service flap 2 Turn cap for coolant expansion reservoir half a revolution counterclockwise, release excess pressure, and take off the cooling system cap 3 Remove interior flap above engine AR88.40-P-1100-03MCC 4 Disconnect ground line of battery AR54.10-P-0003MCC 5 Remove fender liner in right rear fender AR88.10-P-1400MCU 6 Release rear drive module AR01.00-P-3050MCU 7 Drain coolant AR20.00-P-1142MCU 8 Remove poly-V-belt tensioning device AR13.25-P-3200MCU 9 Remove belt pulley for crankshaft AR03.30-P-1700MCU 10 Remove oil pan Remove front engine mount carrier (2) together with torque support (3). For this, unscrew the bolt of the torque support (3) on the frame-type integral support (4). AR01.45-P-7500MCU *BA22.10-P-1010-01M 11 Reinstall front engine mount carrier (2) together with the torque support (3). On order to support the engine during the work procedure. 12 Remove cylinder head cover AR01.20-P-5014MCU 13 Lower vehicle with lifting platform 14 Undo bolts (5) and remove bracket (6) 15 Fix retaining plate in place on cylinder head (7) using a bolt (5), attach support braces to engine using an engine lifting device and support engine using an engine lifting device and appropriate chain via the retaining plate on the cylinder head (7) see scheme 47 Engine lifting device see scheme 42 16 Remove bolts (8, 9) and right engine mount (10) *BA22.10-P-1006-01M *BA22.10-P-1007-01M 17 Remove bolts (11) and loosen alternator (G2) from timing case cover (1) and fix in place at a suitable location using a cable tie *BA15.40-P-1008-01G 18 Raise vehicle with vehicle lift 19 Disconnect electrical connector (12) at oil pressure switch (S41/1) 20 Remove bolt (13) as well as ground (14) line for engine ground 21 Unscrew bolt (15) 22 Remove bolts (16) and lay electrical wiring harness (17) to the side *BA01.40-P-1007-01M 23 Remove refrigerant compressor and fix at a suitable location using a cable tie On vehicles with code (I01) Air conditioning Plus Installation: Only attach refrigerant compressor after installing the oil pan. AR83.55-P-5300-04MCU *BA83.55-P-1001-01V *BA83.55-P-1002-01V 24 Remove bolts (18, 19), detach timing case cover (1) using a tool from cylinder crankcase and remove downwards Installation: Clean sealing surface on timing case cover (1) and on cylinder crankcase, replace seal ring (20) on timing case cover (1) and seal ring on coolant feed line. Before installing the timing case cover (1), screw guide for crankshaft radial sealing ring (21) into the threaded hole for crankshaft and align the drive for oil pump in timing case cover (1) according the position of the crankshaft. Pay attention to different bolt lengths (18, 19). AR01.40-P-8000-01MCC *BA01.40-P-1007-01M see scheme 49 Sealing compound *BR00.45-Z-1053-01A Notes on sealant path for timing case cover AH01.40-P-1000-01MCC 25 Lever crankshaft radial sealant ring (21) out of timing case cover (1) using a suitable tool Ensure that timing case cover (1) is not damage otherwise it must be replaced. Installation: The crankshaft radial sealing ring (21) must be installed dry and lock flush with the timing case cover (1). see scheme 50 26 Remove cooling pump (22) from timing case cover (1) When replacing timing case cover (1). Installation: Replace gasket of coolant pump (22). *BA20.10-P-1007-01J 27 Remove oil pressure switch (S41/1) from timing case cover (1) When replacing timing case cover (1). *BA18.40-P-1002-01G 28 Install in the reverse order

CRANKCASE, TIMING CASE COVER, END COVER

BELT TENSIONING DEVICE

ALTERNATOR

OIL LEVEL/OIL PRESSURE SENSOR

COOLANT PUMP, COOLANT THERMOSTAT

ENGINE MOUNTS, ENGINE SUPPORTS

REFRIGERANT COMPRESSOR

Scheme 41

Scheme 42

Scheme 43

Scheme 44

REPAIR MATERIALS

Remove/install end cover together with shaft seal - AR01.40-P-8920MCU

ENGINE 132.910 in MODEL 451.3 /4

Scheme 45

Remove/install 1 Remove oil pan Remove front engine mount carrier (2) together with torque support (3). To do this remove bolt for torque support (3) on frame-type integral support (4). AR01.45-P-7500MCU 2 Reinstall front engine mount carrier (2) together with the torque support (3). On order to support the engine during the work procedure. 3 Remove flywheel AR03.30-P-8002MCU 4 Remove bolts (5) *BA01.40-P-1006-01M 5 Detach and remove end cover together with radial shaft seal (1) on crankcase (6) Make sure that surfaces are completely clean to prevent leaks around the end cover with radial shaft sealing ring (1). Installation: Clean sealing surface on crankcase (6) (e.g. with acetone), clean contact surface to crankshaft with a clean rag without using cleaning agent. Apply sealant to cylinder crankcase (6). Sealant *BR00.45-Z-1053-01A Notes on application of sealant to end cover with radial shaft seal AH01.40-P-1000-06MCC 6 Install in the reverse order

CRANKCASE, TIMING CASE COVER, END COVER

REPAIR MATERIALS

Remove/install oil pan - AR01.45-P-7500MCU

ENGINE 132.910 in MODEL 451.3 /4

Shown on vehicle with Code (I01) AC Plus

Scheme 46

Remove/install 1 Drain engine oil Engine oil and filter change AP18.00-P-0101MCU 2 Remove fender liner in right rear fender On vehicles with code (I01) Air conditioning Plus AR88.10-P-1400MCU 3 Remove poly-V belt for refrigerant compressor On vehicles with code (I01) Air conditioning Plus AR13.21-P-1202MCU 4 Detach refrigerant compressor to oil pan (1) AR83.55-P-5300-04MCU *BA83.55-P-1001-01V *BA83.55-P-1002-01V 5 Remove carrier for front engine mount (2) AR22.10-P-1001MCU 6 Remove bolt (3) for coolant pipe (4) to oil pan (1) *BA20.10-P-1010-01J 7 Remove bolt (5) for bracket (6) to oil pan (1) 8 Remove oil pan bolts (1) on cylinder crankcase and on timing case cover The oil pan (1) is fixed using eight bolts on the cylinder crankcase and with four bolts on the timing case cover. *BA01.45-P-1001-01J 9 Detach and remove oil pan (1) using a blade on the cylinder crankcase as well as on the timing case cover Installation: Clean sealing surfaces. Coat sealing surface to oil pan (1) with sealant. Replace seal ring on timing case cover. see scheme 32 Sealant *BR00.45-Z-1053-01A Information on application of sealant to oil pan AH01.45-P-0001-01MCC 10 Install in the reverse order

OIL PAN

COOLANT PUMP, COOLANT THERMOSTAT

REFRIGERANT COMPRESSOR

Scheme 47

REPAIR MATERIALS