T0503F <> Issue date 01/2012 smart Training

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T0503F <> Issue date 01/2012 smart Training
Engine variants 2007 09/2010
Engine M132(45kW) M132(52kW) M132(62kW) M132(72kW) OM660/1(33kW) OM660/2(33kW) OM660/3(40kW)
Vehicle 451mhd 451mhd 451 turbo 451 turbo 451(DPF open) 451(DPF closed) 451(DPF closed)
Model designation 132.910 132.910 132.930 132.930 660.950 660.950 660.950
Emissions standard EU4 EU4 EU4 EU4 EU4 EU4 EU5
Engine model
3 cylinder in-line
engine
3 cylinder in-line
engine
3 cylinder in-line
engine
3 cylinder in-line
engine
3 cylinder in-line engine 3 cylinder in-line engine 3 cylinder in-line engine
Installation position Rear/transverse Rear/transverse Rear/transverse Rear/transverse Rear/transverse Rear/transverse Rear/transverse
Rated output kW (HP) 45 (61) 52 (71) 62 (84) 72 (98) 33 (45) 33 (45) 40 (54)
At speed 5800 5800 5250 5500 3800 3800 3800
Torque (Nm) 89 92 120 140 110 110 130
Valves per cylinder 4 (VVT) 4 (VVT) 4 (VVT) 4 (VVT) 2 2 2
Valve assembly
Bucket tappet direct
drive
Bucket tappet direct
drive
Bucket tappet direct
drive
Bucket tappet direct
drive
Hydraulic tappet Hydraulic tappet Hydraulic tappet
Variable valve timing Manual at 100,000 Km Manual at 100,000 Km Manual at 90,000 Km Manual at 90,000 Km
Automatic
hydraulic
Automatic
Hydraulic
Automatic
hydraulic
Spark plugs per cylinder 1 1 1 1
Common-rail
direct injection
Common-rail
direct injection
Common-rail
direct injection
Displacement (cm) 999 999 999 999 799 799 799
Compression ratio 11.4:1 11.4:1 10.0:1 10.0:1 18.5:1 18.5:1 16.3:1
Camshaft DOHC/chain DOHC/chain DOHC/chain DOHC/chain OHC/chain OHC/chain OHC/chain
Stroke (mm) 81.8 81.8 81.8 81.8 79 79 79
Bore (mm) 72 72 72 72 65.5 65.5 65.5
T0503F <> Issue date 01/2012 smart Training
Engine variants as of 10/2010
Engine M132(45kW) M132(52kW) M132(62kW) M132(74kW) OM660/3(40kW)
Vehicle 451mhd 451mhd 451 turbo 451 turbo 451(DPF closed)
Model designation 132.910 132.910 132.930 132.930 660.950
Emissions standard EU5 EU5 EU5 EU5 EU5
Engine model 3 cylinder in-line engine 3 cylinder in-line engine 3 cylinder in-line engine 3 cylinder in-line engine 3 cylinder in-line engine
Installation position Rear/transverse Rear/transverse Rear/transverse Rear/transverse Rear/transverse
Rated output kW (HP) 45 (61) 52 (71) 62 (84) 75 (102) 40 (54)
At speed 5800 5800 5250 6000 3800
Torque (Nm) 89 92 120 147 130
Valves per cylinder 4 (VVT) 4 (VVT) 4 (VVT) 4 (VVT) 2
Valve assembly Bucket tappet direct drive Bucket tappet direct drive Bucket tappet direct drive Bucket tappet direct drive Hydraulic tappet
Variable valve timing Manual at 100,000 Km Manual at 100,000 Km Manual at 90,000 Km Manual at 90,000 Km
Automatic hydraulic
Spark plugs per cylinder 1 1 1 1 Common-rail direct inj.
Displacement (cm) 999 999 999 999 799
Compression ratio 11.4:1 11.4:1 10.0:1 9.9:1 16.4:1
Camshaft DOHC/chain DOHC/chain DOHC/chain DOHC/chain OHC/chain
Stroke (mm) 81.8 81.8 81.8 81.8 79
Bore (mm) 72 72 72 72 65.5
Maximum speed (km/h) 145 145 145 155 135
ECE series veh. efficiency class C C E E B
T0503F <> Issue date 01/2012 smart Training
Diesel engine generation
Engine OM660/1 OM660/2 OM660/3
Model designation OM660.950 w/o code 474 OM660.950 with code 474 OM660.951
Build period 01/2007 01/2009 02/2009 09/2009 As of 10/2009
Engin output in KW 33 33 40
Emissions standard EURO 4 EURO 4 EURO 5
Open particle filter system Yes No No
Closed particle filter system No Yes Yes
Injection pressure in bar 1600 1600 1600
Element shutoff No No No
EGR valve (actuation)
Pneumatic Pneumatic Pneumatic
EGR cooler Yes Yes Yes
Classifiied injectors Yes Yes Yes
Hot-film air mass sensor Yes Yes Yes
T0503F <> Issue date 01/2012 smart Training
open your mind.
T0503F <> Issue date 01/2012 smart Training
OM660/1
System overview:

CDI 3
Injector quantity compensation (IMA) injectors
1600 bar
33 kW
110 Nm
Euro 4
Particulate filter


Changes in comparison to OM660:

B2/ 5 Hot film mass air flow sensor
B50 Fuel temperature sensor
G3/ 2 O2 sensor upstream of CAT (wideband sensor)
Y27 Exhaust gas recirculation switchover valve (pneumatic)
Y94 Quantity control valve
Y76/ 1 Cylinder 1 injection nozzle (injector quantity compensation)
Y76/ 2 Cylinder 2 injection nozzle (injector quantity compensation)
Y76/ 3 Cylinder 3 injection nozzle (injector quantity compensation)

T0503F <> Issue date 01/2012 smart Training
Coolant circuit OM660/1
R
A
D
I
A
T
O
R


AGB
H
E
A
T
E
R

Small coolant circuit

Large coolant circuit



KP

T
H
E
N
G
I
N
E
AGB Expansion reservoir
TH Thermostat
KP Coolant pump
Pipe set
Pipe 1
Pipe 3
Pipe 2
EGR cooler

T0503F <> Issue date 01/2012 smart Training
OM660/2
Changes in comparison to OM660/ 1:

Modified exhaust system with DPF and connections for
differential pressure sensor and temp. sensor
Modified mixing chamber with integrated pressure sensor (1)
Additional throttle valve (intake air throttle) (2)
Electronically regulated vacuum control of wastegate flap
(turbocharger)
Modified engine oil pan
(oil volume +0.9 liters), refill quantity 3.6 liters
Piston with cooling gallery
Modified vacuum hoses through additional
electropneumatic pressure converter * turbocharger
Differential pressure sensor incl. lines and hoses
Oil filter module with enlarged heat exchanger

* Electropneumatic pressure converter

T0503F <> Issue date 01/2012 smart Training
Piston with cooling gallery
OM 660/2

The modified piston is equipped with a cooling gallery,
which is supplied at the bottom with engine oil through
an oil injection nozzle in the crankshaft housing and
which is used to cool the piston crown.

Cooling gallery
T0503F <> Issue date 01/2012 smart Training
Enlarged engine oil pan
OM 660/2
The engine oil pan has been enlarged and the oil volume
increased by 0.9 liters
Refill quantity 3.6 liters
Use of low ash engine oil (Low Spash,
low-sulfur engien oil) as per Sheet 229.51
T0503F <> Issue date 01/2012 smart Training
Oil filter module
OM 660/2
The oil filter module has been given a larger heat
exchanger with greater cooling output
Heat exchanger equipped with extra heat sink
T0503F <> Issue date 01/2012 smart Training
OM 660/2
The exhaust system is differentiated externally to the open system by the two
connections of the differential pressure sensor and the temperature sensor.
Exhaust system with DPF
1. Exhaust system
2. CAT assembly
3. Monolith
4. Particulate filter
5. Suspension
6. Oxygens sensor
7. Temperature sensor
8. Short pressure line
9. Long pressure line
Differential pressure sensor
T0503F <> Issue date 01/2012 smart Training
OM 660/2
The vacuum supply for the turbochargers aneroid capsule is
electronically controlled.
This means that an additional EPT2* is required.


Vacuum supply
*Electropneumatic pressure transducer
T0503F <> Issue date 01/2012 smart Training
OM660/3
Component Change description
EGR cooler
Piston
Glow plugs + control unit
Thermostat
Control unit

Enlarged and switchable with bypass
-reduction 16.3 (piston combustion cavity) (old: 18.5:1)
Ceramics + software
Heated
Software for EU5 and OBD
Cylinder head
Crankcase

Cylinder-head bolts
Crankshaft
Connecting rod
Piston
Oil filter module
Reinforcement measures adapted to ceramic glow plugs
Screw-ion depth for cylinder head bolts to 3.2D, optimization
with regard to residual spoiling, new tool (KS company)
New length, strength restricted to upper tolerance
Metasco material
Trapezoidal conrod, actual dimension 130 128mm,
Wieland bushing
New piston recess, ring package, trapezoidal support
Oil temperature sensor


Power boost by 21 percent to 40 kW
Torque increase of 18 percent to 130 Nm
Consumption values identical with current smart fortwo cdi
Fulfills EU5 emissions standard
Offer solely with closed diesel particulate filter


T0503F <> Issue date 01/2012 smart Training
OM660/3 performance map thermostat
Advantages:

Extension of functional range through variable opening
temperature
Fast response time through possible current supply
Improved engine management for benefit of environment
Optimized compatibility for conventional thermostat


This further development offers, on the one hand, as before the option
to heat up the wax through the coolant, while on the other hand it also
offers additional electrical heating.
This combination means that the temperature difference range can be
configured to be much larger. In other words, the working element' s
electrical heating feature is actuated under certain engine load
conditions. These are defined by parameters and filed in a
characteristics map in the electronic engine management.

1 Coolant thermostat
6 Click clamps
7 Coolant return flow line
8 Coolant feed line
9 Clamp
10 Coolant line feed line
11 Bolts
B11/ 4 Coolanmt temperature sensor
Y88 Thermostatic valve
T0503F <> Issue date 01/2012 smart Training
Diagnosis of sensors/actuators OM660/3
Exercise:
Measure the internal resistance of the injector for cylinder 1 (Adapter 220589009935).
Specified value: 0.3 0.5 Actual value:

Exercise:
With the aid of current clamp KR015 connect the oscilloscope to the positive line of the cylinder 1 injector.
Record the signal of the injector with the oscilloscope and transfer the signal path and all settings to your
document.

Which circuit diagram do you need for this?
PE07.16-p-2000-97mcd
Wiring diagram for common rail diesel
injection (CDI)




T0503F <> Issue date 01/2012 smart Training
Diagnosis of sensors/actuators OM660/3
Exercise:
Measure the power supply for the rail pressure sensor B4/ 6.
Specified value: 5V Actual value:

Exercise:
Using adapter cable (166589016300) connect the oscilloscope in parallel to the rail pressure sensor.
Record the signal of the sensor with the oscilloscope and transfer the signal path and all settings to your document.

Which circuit diagram do you need for this?
pe07.16-p-2000-97mcd
Wiring diagram for common-rail diesel
injection (CDI)




T0503F <> Issue date 01/2012
Exercise:
How can you evaluate the mechanical function of the pressure regulator valve (Y74) without actually removing it?

Detach connector from pressure regulating valve Start Actual values approx. 90 bar (spring force)
with intact component or seal

Exercise:
Connect the oscilloscope in parallel to the pressure regulating valve or quantity control valve.
Record the signal of the pressure regulating valve with the oscilloscope and transfer the signal path and all settings to your
document.

Which circuit diagram do you need for this?
pe07.16-p-2000-97mcd
Wiring diagram for common-rail diesel
injection (CDI)




smart Training
Diagnosis for sensors/actuators OM660/3
T0503F <> Issue date 01/2012 smart Training
Diagnosis of sensors/actuators OM660/3
Checking the compression

Test requirement:
Battery is charged
Apply hand brake
Ignition ON
Engine not running
Note:
As from a difference in speed of more than 7 rpm
between the smallest and the largest value, it is
to perform a manual compression test and a
cylinder leak test on all cylinders to enable
the fault to be localized.

Test result: Evaluation
Cylinder 1: 299 rpm OK
Cylinder 2: 299 rpm OK
Cylinder 3: 299 rpm OK

T0503F <> Issue date 01/2012 smart Training
Diagnosis of sensors/actuators OM660/3
Check if engine runs smoothly
Test requirement:
Engine at idle
Test of compression OK

Note:
In the event of a complaint after a cold start or during
the warm-up phase, do not condition the engine for

the operating temperature, but proceed in a complaint-

specific basis.


Test result: Actual value Actual value min. Actual value max. Evaluation
Cylinder 1: -4.77mm
3
/ stroke -4.77mm
3
/ stroke -0.23mm
3
/ stroke OK
Cylinder 2: 2.43mm
3
/ stroke 0.30mm
3
/ stroke 2.64mm
3
/ stroke OK
Cylinder 3: 2.35mm
3
/ stroke -0.41mm
3
/ stroke 2.35mm
3
/ stroke OK

T0503F <> Issue date 01/2012 smart Training
6. Overall network C/A451
EPS ESP ASG
ME CDI LWS KI SAM Yaw/Rot.
KLA OBD SRS
EFH
SIH
KGZS
Alt
RLS
DZM
Horn +
inclination sensor
DWA
-C
N129
mhd
B95
LIN D
BS
T0503F <> Issue date 01/2012 smart Training
smart open your mind
open your mind.