engine SMART FORTWO COUPE 2011 Service Manual

The first 1000 miles (1500 km)
In the Operation section you will find
detailed information on operating,
maintaining and caring for your vehicle.
The more cautiously you treat your vehicle
during the break-in period, the more
satisfied you will be with its performance
later on.
R Drive your vehicle during the first
1 000 miles (1 500 km) at varying but
moderate vehicle and engine speeds.
R During this period, avoid heavy loads
(full throttle driving) and excessive
engine speeds (no more than 2
/ 3 of
maximum rpm in each gear).
R Shift gears in a timely manner.
R Do not attempt to slow the vehicle down
by shifting to a lower gear.
R Avoid accelerating by kickdown.
After 1 000 miles (1 500 km), you may
gradually increase vehicle and engine
speeds to the permissible maximum.
All of the above instructions also apply
when driving the first 1 000 miles (1 500 km)
after the engine has been replaced.
i Always obey applicable speed limits.
At the gas station
Refueling
GWarning!
Gasoline is highly flammable and
poisonous. It burns violently and can cause
serious personal injury.
Never allow sparks, flame or smoking
materials near gasoline!
Turn off the engine before refueling.
Whenever you are around gasoline, avoid
inhaling fumes and skin or clothing
contact. Extinguish all smoking materials.
Direct skin contact with fuels and the
inhalation of fuel vapors are damaging to
your health.
! Do not put diesel fuel in vehicles with
gasoline engines. Do not mix gasoline
with diesel fuel. Even small quantities
of diesel fuel will damage the injection
system. Damage caused by adding diesel
fuel will not be covered by the smart
Limited Warranty.
If diesel fuel has mixed with gasoline,
do not start the engine. Otherwise the
catalytic converter will be irreparably
damaged.
Contact an authorized smart center or
Roadside Assistance immediately and
have the vehicle towed.
! Damage resulting from mixing gasoline
with diesel fuel is not covered by the
smart Limited Warranty.
The fuel filler flap is located on the
passenger side towards the rear. Locking/
unlocking the vehicle with the key
automatically locks/unlocks the fuel filler
flap.
i In case the central locking system does
not release the fuel filler flap, or the
opening mechanisms is clamping,
contact Roadside Assistance or an
authorized smart center.0046 Opening the fuel filler flap0047 Inserting the fuel filler cap008A Fuel filler cap118At the gas station>> Operation.
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0088 Fuel type label0086 HolderXTurn off the engine.XRemove the key from the starter switch.XOpen the fuel filler flap by pulling at the
point indicated by arrow 0046.XTurn fuel filler cap 008A counterclockwise
and hold on to it until possible pressure
is released.XTake off fuel filler cap 008A.
!
The fuel filler cap is tethered to the
fuel filler flap. Do not drop the fuel
filler cap. It could damage the vehicle
paint finish.
XInsert fuel filler cap 008A in direction of
arrow 0047 into holder 0086 on the inside of
the fuel filler flap.XFully insert filler nozzle unit and
refuel.XOnly fill your tank until the filler nozzle
unit cuts out — do not top off or overfill .GWarning!
Overfilling of the fuel tank may create
pressure in the system which could cause a
gas discharge. This could cause the gas to
spray back out when removing the fuel pump
nozzle, which could cause personal injury.
XReplace fuel filler cap 008A.XTurn fuel filler cap 008A clockwise until
the handle grip overturns.
i Make sure to close the fuel filler flap
before locking the vehicle as the fuel
filler flap locking pin prevents closing
after you have locked the vehicle.
XClose the fuel filler flap.
You should hear the latch close shut.
i Only use premium unleaded gasoline
with a minimum Posted Octane Rating of
91 (average of 96 RON/86 MON).
Information on gasoline quality can
normally be found on the fuel pump.
Please contact gas station personnel in
case labels on the pump cannot be found.
For more information on gasoline, see
“Premium unleaded gasoline”
( Y page 221) and “Fuel requirements”
( Y page 222), or contact an authorized
smart center.
Check regularly and before a long trip
For information on quantities and
requirements of operating agents, see
“Service fluids and capacities”
( Y page 218).
Check the following:
R Engine oil level ( Y page 120)
R Tire inflation pressure ( Y page 128)
R Coolant level ( Y page 124)
R Vehicle lighting ( Y page 180)
R Windshield washer system ( Y page 124)
R Brake fluid ( Y page 125)
Engine compartment
Engine compartment cover
Open the engine compartment cover to
check the engine oil level and if necessary,
to add engine oil.
GWarning!
High outside temperature, stop-and-go
traffic, driving on long uphill grades or
driving at high engine speed may increase
the temperature in the engine
compartment. Therefore, the engine
compartment cover and parts in the area
around the engine compartment cover may
be hot. Parts of the engine can become very
hot. To prevent burns, let the engine cool
off completely before touching the engine
compartment cover, parts in the area
around the engine compartment cover, and
parts of the engine.
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XTurn off the engine.XEngage the parking brake.XOpen the tailgate.GWarning!
Exercise extreme caution if you see flames
or smoke coming from the engine
compartment. Move away from the vehicle
and call the fire department.
If the coolant temperature warning lamp
indicates that the engine is overheated, do
not attempt to open the engine compartment
cover. Move away from the vehicle and wait
until the engine has cooled before opening
the engine compartment.
GWarning!
To help prevent personal injury, stay clear
of moving parts when the engine
compartment cover is open and the engine
is running.
GWarning!
The engine is equipped with a
transistorized ignition system that
utilizes high voltage. Do not touch any
components (ignition coils, spark plug
sockets, diagnostic socket) of the ignition
system
Rwhile the engine is running
Rwhile starting the engine
Rif ignition is “on” and the engine is
turned manually
XOpening: Grasp the strap on cargo
compartment floor \000G.
XLift cargo compartment floor \000G with the
strap.
XEngage hook \000

When checking the engine oil level
Rthe vehicle must be parked on level
ground
Rthe vehicle must have been stationary for
at least five minutes with the engine
turned off
XTurn off the engine.XEngage the parking brake.XOpen the tailgate.XOpen the engine compartment cover
(Y page 119).
The oil dipstick is located in the engine
compartment on the passenger side.
XPull out oil dipstick \000F.XWipe oil dipstick \000F clean with a clean
cloth.
XFully insert oil dipstick \000F into the
dipstick guide tube.
XPull out oil dipstick \000F again after
approximately one minute to obtain
accurate reading.
The oil level is correct when it is
between lower mark \000

XCheck the engine oil level once more.XAdd engine oil once more if necessary.
Be careful not to spill any oil when adding
to avoid environmental damage caused by
oil entering the ground and water.
! Excess engine oil must be siphoned or
drained off. It could cause damage to the
engine or emission control system not
covered by the smart Limited Warranty.
XScrew filler cap \000F back on the filler
neck.
XClose the engine compartment cover
(Y page 119).
Front compartment
Service flap
Remove the service flap to check the
coolant level, windshield washer reservoir
level, and brake fluid level.
Insert the service flap on the front of the
vehicle so that it does not get damaged or
dirty.
iThe service flap has a strap on the rear
side that ties it to the vehicle body.
GWarning!
Always turn the key to starter switch
position 0 and remove the key from the
starter switch before opening the service
flap.
If the windshield wipers should
inadvertently be switched on, you could be
seriously injured by the wiper washer
drive, which is located just below the
service flap.
GWarning!
Make sure the service flap is locked while
driving. Otherwise, the service flap could
become detached and pose a hazard to you
or others.
GWarning!
To help prevent personal injury, stay clear
of moving parts when the service flap is
open.
The radiator fan may continue to run for
approximately 30 seconds or may even
restart after the engine has been turned
off. Stay clear of fan blades.
! Check the fill levels at regular
intervals.
! Carefully remove ice, snow, and any
other deposits from the air intake
grilles above the service flap to ensure
air intake at all times.
XPark the vehicle on level ground.XTurn off the engine.XEngage the parking brake.
Removing
XFold both levers \000G outward in direction
of the arrows \000

Vehicle maximum load on the tire
Load on an individual tire that is
determined by distributing to each axle
its share of the maximum loaded vehicle
weight and dividing it by two.
Winter driving
Before the onset of winter, have your
vehicle winterized at an authorized smart
center. This service includes:
R Check of anticorrosion and antifreeze
concentration.
R Addition of washer concentrate to the
water of the windshield/rear window.
Use a windshield washer concentrate
labeled for winter which is formulated
for temperatures below freezing point
( Y page 222).
R Battery test. Battery capacity drops with
decreasing ambient temperature. A well
charged battery helps to make sure the
engine can be started, even at low
ambient temperatures.
R Tire change.
Winter tires
GWarning!
Winter tires with a tread depth of less
than 1
/ 6 in (4 mm) must be replaced. They
are no longer suitable for winter
operation.
Always use winter tires at temperatures
below 45 ¦ (7¥ ) and whenever wintry road
conditions prevail. Not all M+S rated tires
provide special winter performance. Make
sure the tires you use show the mountain/
snowflake marking 004D on the tire
sidewall. These tires meet specific snow
traction performance requirements of the
Rubber Manufacturers Association (RMA)
and the Rubber Association of Canada (RAC)
and have been designed specifically for
use in snow conditions. Use of winter tires
is the only way to achieve the maximum
effectiveness of the ABS and ESP ®
in winter
operation.
For safe handling, make sure all mounted
winter tires are of the same make and have
the same tread design.
For information on winter tires for your
vehicle model, see the "Technical data"
section ( Y page 217).
Always observe the speed rating of the
winter tires installed on your vehicle. If
the maximum speed for which your tires are
rated is below the speed rating of your
vehicle, you must place a notice to this
effect where it will be seen by the driver.
Such notices are available at your tire
dealer or any authorized smart center.
Snow chains*
! Remember that snow chains must always
be compatible with the tire sizes of a
vehicle. Snow chains that are approved
by smart are only permitted for the
following tire size:
175/55 R15 on the rear axle.
For safety reasons, smart recommends
that you only use snow chains that have
been approved by smart.
Information on this is available from any
smart center.
Please refer to the separate operating
instructions for detailed information on
mounting the snow chains.
Snow chains should only be driven on
snow-covered roads at speeds not to
exceed 30 mph (50 km/h). Remove chains
as soon as possible when driving on roads
without snow.
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Please observe the following guidelines
when using snow chains:
R Using snow chains is not permissible
with all wheel/tire combinations
( Y page 217).
R Use snow chains in pairs and on rear
wheels only. Follow the manufacturer’s
mounting instructions.
R Use of snow chains may be prohibited
depending on location. Always check
local and state laws before mounting
snow chains.GWarning!
When mounting or removing snow chains,
always park your vehicle on level ground,
engage the parking brake, and turn off the
engine. The vehicle could otherwise move
and injure yourself or other road users.
GWarning!
When mounting and removing snow chains,
ensure that you and your vehicle are at a
safe distance from moving traffic. Not
doing so could endanger other road users or
even lead to you being injured by the
vehicles behind you.
GWarning!
The vehicle’s handling changes when
driving with snow chains on any kind of
road surface. This means that you should
always adapt your driving style to suit the
current road and weather conditions.
! If snow chains that do not meet
requirements are mounted, they may
scrape against the body or axle
components when the vehicle is in
motion. This could result in damage to
the rim/tire or vehicle.
Driving instructions
Drinking and driving
GWarning!
Do not drink alcohol or take drugs and drive
or allow anyone to drive who has been
drinking alcohol or taking drugs. Even a
small amount of alcohol or drugs can affect
your reflexes, perceptions and judgment.
The possibility of a serious or even fatal
accident are greatly increased when you
drink or take drugs and drive.
Pedals
GWarning!
Make sure absolutely no objects are
obstructing the pedals’ range of motion.
Keep the driver’s footwell clear of all
obstacles. If there are any floormats* or
carpets in the footwell, make sure the
pedals still have sufficient clearance.
During sudden acceleration or braking
maneuvers, the objects could get caught
between or beneath the pedals and restrict
your ability to brake or accelerate. This
could lead to accidents and/or injury.
Power assistance
GWarning!
With the engine not running, there is no
power assistance for the brake and
steering* systems. In this case, it is
important to keep in mind that a
considerably higher degree of effort is
necessary to brake and steer the vehicle.
Adapt your driving accordingly.
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BrakesGWarning!
Make sure not to endanger any other road
users when carrying out braking
maneuvers.
Refer to the description of the hydraulic
brake assistant ( Y page 48).
! Because the ESP ®
operates
automatically, the engine must be turned
off (ignition switched off) when the
parking brake is being tested on a brake
test dynamometer. Active braking action
through the ESP ®
may otherwise seriously
damage the brake system which is not
covered by the smart Limited Warranty.
Brake pad wear or a leak in the brake system
may be the reason for low brake fluid level
in the brake fluid reservoir.
The brake fluid level in the brake fluid
reservoir may be too low if the brake
warning lamp in the instrument cluster
comes on ( Y page 22) although the parking
brake is released.
Have the brake system inspected
immediately. Contact an authorized smart
center.
All checks and service work on the brake
system should be carried out by qualified
technicians only. Contact an authorized
smart center.
Only install brake pads and use brake fluid
recommended by smart.
Inclines
! When driving down long and steep
grades, relieve the load on the brakes by
shifting into a lower gear to use the
engine’s braking power. This helps
prevent overheating of the brakes and
reduces brake pad wear.
When using the engine’s braking power, a
drive wheel may not spin for an extended
period of time, e.g. on slippery road
surfaces. This may cause serious damage
to the drive- train which is not covered
by the smart Limited Warranty.
High and low stressesGWarning!
Resting your foot on the brake pedal will
cause excessive and premature wear of the
brake pads.
It can also result in the brakes
overheating, thereby significantly
reducing their effectiveness and your
ability to stop the vehicle in sufficient
time to avoid an accident.
After hard braking, it is advisable to drive
on for some time, rather than immediately
park, so that the air stream will cool down
the brakes faster.
If your brake system is normally only
subjected to moderate loads, you should
occasionally test the effectiveness of the
brakes by applying above-normal braking
pressure at higher speeds. This will also
enhance the grip of the brake pads.
GWarning!
Make sure not to endanger any other road
users when carrying out these braking
maneuvers.
Wet road surface
GWarning!
After driving in heavy rain for some time
without applying the brakes or through
water deep enough to wet brake components,
the first braking action may be somewhat
reduced and increased pedal pressure may
be necessary to obtain expected braking
effect. Maintain a safe distance from
vehicles in front.
To help prevent brake disc corrosion after
driving on wet road surfaces (particularly
salted roads), it is advisable to brake the
vehicle with considerable force prior to
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parking. The heat generated serves to dry
the brakes.GWarning!
Make sure not to endanger any other road
users when carrying out these braking
maneuvers.
Limited braking effect on salted roads
Remember that the effect of the brakes can
be limited on salted road surfaces. A layer
of salt can form on brake discs and brake
pads, considerably reducing the friction
between the brake disc and the brake pad.
The effect is most noticeable after long
trips without braking, e.g. on the highway,
and after the vehicle has been parked for
several hours.
GWarning!
The accumulation of salt on brake discs and
brake pads reduces braking effectiveness
and increases the distance necessary to
come to a complete standstill. This could
potentially cause an accident and/or
personal injury.
To avoid this risk, you should
R brake carefully every now and then on
salted roads in order to remove any layer
of salt on the brake disc and brake pad,
but do so without endangering any other
road users
R keep a good safe distance from the
vehicle in front and drive carefully
R press the brake carefully at the end of the
trip and again when beginning the next
trip in order to remove any salt residues
from the brake disc
New brake pads
Only install brake pads recommended by
smart.
GWarning!
If other than recommended brake pads are
installed, or other than recommended brake
fluid is used, the braking properties of the
vehicle can be degraded to an extent that
safe braking is substantially impaired.
This could result in an accident.GWarning!
New brake pads will not achieve their
optimal braking effect until after several
hundred miles (kilometers). This means
that you must compensate for the reduced
braking effect by pressing harder on the
brake pedal and adapt your driving style
accordingly. The same applies after brake
pads or brake discs have been changed.
Drive sensibly - save fuel
Fuel consumption, to a great extent,
depends on driving habits and operating
conditions.
To save fuel you should:
R Shift gears in a timely manner.
R Avoid frequent acceleration and
deceleration.
R Keep tires at the recommended inflation
pressures.
R Remove carriers* when not in use.
R Remove unnecessary loads.
R Allow engine to warm up under low load
use.
R Have all maintenance work performed at
the intervals specified in the
Maintenance Booklet and as required by
the Maintenance System. Contact an
authorized smart center.
Fuel consumption is also increased by
driving in cold weather, in stop-and-go
traffic, on short trips, and in hilly areas.
Catalytic converter
Your smart is equipped with monolithic-
type catalytic converter, an important
element in conjunction with the oxygen
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sensors to achieve substantial control of
the pollutants in the exhaust emissions.
Keep your vehicle in proper operating
condition by following our recommended
maintenance instructions as outlined in
your Maintenance Booklet.GWarning!
The catalytic converter can become very
hot. Coming into contact with the catalytic
converter could result in burns.
Note the following:
R Do not remove the protective heat guards.
R Do not apply any underseal.
R As with any vehicle, do not idle, park, or
operate this vehicle in areas where
combustible materials such as grass,
hay, or leaves can come into contact with
the hot exhaust system, as these
materials could be ignited and cause a
vehicle fire.
! To prevent damage to the catalytic
converter, only use premium unleaded
gasoline in this vehicle.
Any noticeable irregularities in engine
operation should be repaired promptly.
Otherwise, excessive unburned fuel may
reach the catalytic converter, causing it
to overheat and potentially start a fire.
It is essential to observe the following
points, as there is otherwise a danger of
overheating and the catalytic converter
may be damaged.
R Fill up only with premium unleaded
gasoline. Even small quantities of
leaded gasoline can damage the catalytic
converter.
R Make sure you adhere to the prescribed
service intervals.
R Never run the fuel tank empty.
R If the engine starts to misfire, bring the
vehicle to an immediate standstill
without endangering traffic.
R If the engine fails to start the first time,
you should not try to start it any more
than three times in succession.
R Do not try to start for more than four
seconds at a time.
Tires
GWarning!
If you feel a sudden significant vibration
or ride disturbance, or you suspect that
possible damage to your vehicle has
occurred, you should turn on the hazard
warning flashers, carefully slow down, and
drive with caution to an area which is a safe
distance from the road.
Inspect the tires and the vehicle underbody
for possible damage. If the vehicle or tires
appear unsafe, have the vehicle towed to the
nearest smart center or tire dealer for
repairs.
Treadwear indicators (TWI) are required by
law. These indicators are located in six
places on the tread circumference and
become visible at a tread depth of
approximately 1
/ 16 in (1.6 mm), at which
point the tire is considered worn and
should be replaced.
The treadwear indicator appears as a solid
band across the tread.
GWarning!
Although the applicable federal motor
vehicle safety laws consider a tire to be
worn when the treadwear indicators (TWI)
become visible at approximately 1
/ 16 in
(1.6 mm), we recommend that you do not allow
your tires to wear down to that level. As
tread depth approaches 1
/ 8 in (3 mm), the
adhesion properties on a wet road are
sharply reduced.
Depending upon the weather and/or road
surface (conditions), the tire traction
varies widely.
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