2008 Smart
FORTWOProblems & recalls

Complaint Clanking noise from the area of the speakers in the doors. Cause Under analysis. Remedy To narrow down the cause, first of all remove the door trim. • If the noise continues to occur even with the door trim removed, then continue the diagnosis working towards the speaker and if necessary, create a TIPS case with an informative video as an attachment. Information: Please refer to this document in the warranty claim and, after completing diagnosis, select the damage code corresponding to the component part that caused the problem. • If the noise stops when the door trim is removed, please proceed in accordance with LI72.10-P-067691. Information: In this case, do not use a damage code for the speakers in the warranty claim!

Components: STRUCTURE:BODY. Confirm detailed applicability in the original document.

Single throttle lift-off clunking noise from the side shaft when moving off (audible at the outboard end). The noise is heard once in each instance when changing direction of travel. Note: Sound file in attachment Cause If the complaint is eliminated by experimentally loosening the outboard collar nut (by 1 turn), the problem is due to cracking of the microweld between the wheel bearing inner race and the joint housing of the side shaft. Note: The collar nut must always be replaced after being loosened. See also LI33.20-P-078406 Remedy Coat contact surface of side shaft with wheel bearing with Molykote paint. To do this, proceed as follows: 1. Remove side shafts 2. Clean contact surface A (see image file in attachment "Outer joint housing before") before coating with Molykote, using "spirit" (free of dust and grease) 3. Coat contact surface A (see image file in attachment "Outer joint housing after") with Molykote and leave to dry for "one hour" in removed condition 4. Reinstall side shafts Note: Before using the antifriction coating (Molykote), stir it or shake it thoroughly for (at least 1 minute).

Components: POWER TRAIN. Confirm detailed applicability in the original document.

Complaint There are several types of complaint about noises or poor windshield wiper wiping performance: A: Wiper blades squeaking, chattering, shuddering B: The windshield is not wiped completely (streaking) C: During the downward movement water is pulled back onto the windshield from the A-pillar (Figure 1) D: After windshield cleaning, water keeps spraying onto the windshield for several wipe cycles (Figure 2) A1: The windshield and wiper blades are contaminated with residues from car washing facilities, identifiable by the water beading. The resulting differences in the friction values between the wiper blades and the windshield can excite the wiper blades to vibrate. Note: It is mostly wax residue from the washer system, but also water-repellent nano-particle coating for paint and/or silicone-based washer fluid, that could cause this problem. A partially dry windshield also has different friction values, which can likewise result in squeaking of the wiper blades A2: The wiper blades are worn by mechanical damage (wiper lip damaged by ice or insect debris, or deformed by long periods of disuse). A3: Incorrect angle of incidence of the wiper arms to the windshield. Because of this, the rubber lip of the wiper blade may not flip over at the reversal point. Cause B: B1: Wax/ dirt residues on the windshield B2: Wiper blades deformed or worn B3: Downforce of wiper arm not OK (Figure 3) Cause C: Water is pulled back onto the windshield by the differential pressure created as the wiper arm moves downwards. Cause D: Washer water collects in the fastening of the wiper blade and is blown onto the windshield by the airstream over several wipe cycles. Note and supporting information: Wiper blades are wear parts which, even when "not used" for long periods (kept in park position), may become permanently deformed and damaged. Further stresses on the rubber wiper blade arise due to various environmental influences which progressively change the effectiveness of the rubber wiper blade and accelerate the aging process. Due to the natural aging process and wear, the wiper blades should be replaced twice a year, preferably in Spring and Fall (see operator's manual). Remedy Remedy A: A1: Cleaning entire windshield with A 000 986 40 71. A2: Checking water's flow behavior after windshield has been cleaned (see Video 1). If, after cleaning, there are still areas with water beading, then the cleaning process must be carried out again until a rejection reaction is no longer present. • Note: On the vehicle in the video (Video 1), water still beads on the bottom left of the windshield. The windshield is still not properly clean, even though it appears to be clean. The windshield is only properly clean when there are no more areas on the windshield where water beads. A3: Replace wiper blades with genuine wiper blades. Important: Only exchange wiper blades if windshield no longer has water-repellent areas Note: Replacement of wiper blades is not covered under warranty and can be replaced at the expense of the customer. Remedy B: B1: Clean windshield with intensive cleaner A 000 986 40 71. Important: Do not clean the wiper blades otherwise the graphite coating will be damaged. B2: Replace wiper blades with genuine wiper blades • Note: Replacement of wiper blades is not covered under warranty and can be replaced at the expense of the customer. B3: Check the wiper arm for excessive resistance in the bearing. Restore mobility or replace wiper arm if necessary. Remedy C: Problem inherent in design for which there is no technical remedy. Exception: X204 up to 02/2014. In these vehicles, it is possible to install the design configuration of vehicles as of 02/2014. This includes wiper arms (styled arms) with improved behavior in this respect. It is also necessary to replace the wiper blades because the styled arms feature a Top Lock connection (previously Side Lock).

Components: VISIBILITY/WIPER. Confirm detailed applicability in the original document.

Complaint Headlamp, front fog lamp leaky or fogged. Cause Fogging of the headlamps is a natural phenomenon, which can occur under certain climatic conditions. It does not lead to any technical impairment of the headlamp. If a pressure compensation diaphragm is fitted in the housing cover, then the lamp unit is a "closed system". Remedy Headlamp: Remedy 1 Clearing fogged/condensed LED headlamps: 1. Drive vehicle into workshop (temperature higher than +18 °C/+64.4 °F) and connect the exhaust extraction. Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine and connect battery support via a charger. 3. Open the hood. 4. Switch on the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Clearing of fogged/condensed LED headlamps and LED rear lamps on electric vehicles: 1. Drive the vehicle into the workshop (temperature higher than +18 °C/+64.4°F). 2. Connect battery backup via a charger. 3. Open the front-end flap and ensure sufficient ventilation. 4. Switch on the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Clearing fogged/condensed halogen/xenon headlamps: 1. Drive the vehicle into the workshop (temperature higher than +18 °C/+64.4°F). Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine. 3. Open the hood. 4. Switch off the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Note: If there is no visible reduction in condensation, check the headlamp for malfunctions. (see Remedy 2) It is not physically possible to defog the headlamps completely. Fogging does not impair the operation or the service life of the headlamp. Note: Only implement Remedy 1 for model series 463 (from model year 2018) and model series 465. Remedy 2 A defective headlamp can be identified as follows: 1. Check the headlamp for external damage and that the cover caps and the diaphragm are correctly seated. 2. Check the electrical connectors of the plugs and pins. 3. Check for leak tightness according to LI82.10-P-078307. The test can only be conducted on headlamps. 4. If the headlamp or the rear lamp has any external damage, replace the component part in accordance with the WIS instructions. Note: External damage to the headlamp/rear lamp or faulty seating of the cover caps does not present a warranty or goodwill case. Note: With headlamps, it is possible to install desiccant packs if the problem occurs repeatedly. • Open ventilation system LI82.10-P-078302 • Closed ventilation system LI82.10-P-078304

Components: EXTERIOR LIGHTING. Confirm detailed applicability in the original document.

Complaint Single throttle lift-off clunking noise from the side shaft when moving off (audible at the outboard end). The clunk is heard once when changing from forward to reverse (and vice versa). Note: Sound file in attachment Cause If the complaint is eliminated by experimentally loosening the outboard collar nut (by 1 turn), the problem is due to micromovement in the connection between the wheel bearing inner race and the joint housing of the side shaft. Note: The collar nut must always be replaced after being loosened and must be tightened to the specified torque. Remedy Coat contact surface of side shaft with wheel bearing with Molykote paint. To do this, proceed as follows: 1. Remove outboard side shafts (extract outer joint gearing from wheel hub) 2. Clean contact surface A (see image file in attachment "Outer joint housing before") before coating with Molykote, using "spirit" (free of dust and grease) 3. Coat contact surface A (see image file in attachment "Outer joint housing after") using Molykote and leave to dry for one hour in removed condition 4. Reinstall side shafts

Components: POWER TRAIN. Confirm detailed applicability in the original document.

Complaint Headlamps leaking or fogged Cause The fogging of the headlamp is a natural phenomenon which can occur under certain climatic conditions. In contrast to a leaky headlamp, physical fogging does not result in a technical impairment of the headlamp. A leak test must be performed to determine if physical fogging exists or if the headlamp is leaky. Remedy Check for external damage: You can identify a damaged headlamp in the following way: For headlamps with a closed system 1. Check the headlamps for any external damage and check also for correct seating of the Gore-diaphragm/correct latching of the cover caps. 2. If the headlamp exhibits any external damage, replace the headlamp. For headlamps with an open system 1. Check the headlamps for any external damage and seal off the vent, then make sure the cover caps are latched correctly into place. 2. If the headlamp exhibits any external damage, replace the headlamp. Note: External damage to the headlamp does not present a warranty or goodwill case. 1. Clear fogged/condensed LED headlamps and LED rear lamps: 1. Drive the vehicle into the workshop (temperature higher than +18 °C/+64.4°F). Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine and connect battery support via a charger. 3. Open the hood or trunk. 4. Switch on the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). 7. If the condensation has disappeared, nothing else has to be done. Note: If defrosting has been performed, you can skip the first step. 2. Leak test of headlamp with overpressure: • Connect test adapter to pressure tester. (Figure 1) • Check test adapter for leak tightness. To do so, connect plug and coupling (picture 2) and apply a maximum overpressure of 30 mbar. The pressure must remain constant. If the pressure does not remain constant, use a new adapter. • All vents have to be sealed with sealing compound and the existing diaphragm with the stamp (picture 3 [3]). (Picture 4) Make allowance for the different headlamp variants here (there are different outlet openings). • Check if the headlamp needs to be removed to gain access to the diagnostic socket on the headlamp housing. • Plug the adapter onto the diagnostic socket on the headlamp housing. (Picture 5). • Apply a maximum of 30 mbar overpressure to the headlamp housing. Note: If the maximum overpressure of 50 mbar is exceeded the headlamp seal will be damaged (picture 6). • If a pressure drop of less than 10 mbar is measured within 30 seconds, the headlamp is tight and there is natural physical condensation. • If a higher pressure drop than 10 mbar is measured within 30 seconds, the headlamp is leaky. Note: The leaky position can be localized with the aid of soap suds. If the pressure test is not passed, the headlamp is leaky. If the cause cannot be rectified, the headlamp must be replaced. Note: If the headlamp is replaced, no dry packs may be installed on the new replacement headlamp. AR82.10-P-5455WT was created for the pressure test. This AR can be used as a reference manual for all closed headlamps. In the event of an open headlamp system, the vent ducts must be sealed before the pressure test.

Components: EXTERIOR LIGHTING. Confirm detailed applicability in the original document.

Complaint Headlamp, front fog lamp leaky or fogged Cause Fogging of the headlamps is a natural phenomenon, which can occur under certain climatic conditions. It does not lead to any technical impairment of the headlamp. Remedy NOTE: If a pressure compensation diaphragm is fitted in the housing cover, then the lamp unit is a "closed system". Headlamp: Remedy 1 Clearing fogged/condensed LED headlamps and LED rear lamps: 1. Drive vehicle into workshop (temperature higher than +18 °C/+64.4 °F) and connect the exhaust extraction. Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine and connect battery support via a charger. 3. Open the hood or trunk. 4. Switch on the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Clearing fogged/condensed halogen/xenon headlamps: 1. Drive the vehicle into the workshop (temperature higher than +18 °C/+64.4°F). Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine. 3. Open the hood. 4. Switch off the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Note: If there is no visible reduction in the formation of condensation, check the headlamp for damage. (See Remedy 2) It is not physically possible to defog the headlamps completely. Fogging does not impair the operation or the service life of the headlamp. Remedy 2 A damaged headlamp can be identified as follows: 1. Check the headlamp for external damage and that the cover caps and the diaphragm are correctly seated. 2. Check the electrical connectors of the plugs and pins. 3. Check for leak tightness in accordance with LI82.10-P-078896 The test can only be conducted on headlamps. 4. If the headlamp or the rear lamp has any external damage, replace the component part in accordance with the WIS instructions.

Components: EXTERIOR LIGHTING. Confirm detailed applicability in the original document.

Complaint During a phone call, the called party has difficulty understanding/cannot understand the driver, or interference/background noises are audible to the called party during a call. It becomes increasingly difficult to understand as the speed rises. Cause A. Seating of the microphones in the headliner. Side edges are covered by the textile cover (see picture "1") B. Assembly of microphones (B25/20 or B25/21) in the headliner. C. Dirt inside the microphone housing Remedy 1. Press finger on rear of microphone (on adhesive tape) 2. Remove microphone cap from the front 3. Eliminate protruding material residues of the microphone cutout at the headliner, e.g. with a soldering iron. The microphone must be seated in the headliner as shown in picture "2". 4. Push microphone from behind until it is firmly pressed into the headliner 5. Maintain pressure and press/clip cap into microphone from the front. Note: The cover cap must be clearly heard and felt to engage. 6. This procedure must be carried out on both microphones (B25/20 and B25/21) Note: • It is recommended to replace the cover caps. • The non-woven cloth in the cover cap protects the microphone from soiling and must not be removed. NOTE: The information contained in this document is intended for use by trained, professional technicians with the knowledge to properly and safely perform diagnosis and repairs on Mercedes-Benz vehicles, using Mercedes-Benz approved tools and equipment. It informs service technicians about conditions that could occur in certain vehicles and provides information that could assist in proper vehicle diagnosis, service, or repair. It does not indicate that a defect is present in any vehicle referenced in this document nor does it imply warranty coverage. DO NOT assume that a symptom or condition, or a described cause of a symptom or condition, affects any particular vehicle or groups of vehicles, or that a described repair applies to any particular vehicle or groups of vehicles. There can be multiple causes resulting in the same or similar symptoms or conditions described in this document, and trained professional service technicians must use their diagnostic skills to make evaluations on a case-by-case basis. The information contained in this document does not guarantee warranty coverage nor does it extend the vehicle’s warranty in any way.

Components: ELECTRICAL SYSTEM. Confirm detailed applicability in the original document.

Complaint Washer fluid system leaks Cause Various possible causes: 1. Washer fluid reservoir itself. 2. Seal on washer fluid pump/washer fluid reservoir. 3. Washer fluid pump. 3.1. Distributor housing leaks. 3.2. Pump fitting leaks. 3.3. Washer fluid hose cannot be snapped into place on pump fitting. 3.4. Washer fluid hose will not stay on pump fitting, although connector OK. 4. Washer fluid line. 4.1 Connector will not stay on pump fitting because it is broken. 4.2 Sealing ring in connector missing. 4.3 Sealing ring in connector fitted, but deformed and therefore leaks. 4.4 Damage to washer line by animal. 5. Seal on heating washer fluid reservoir/washer fluid reservoir. Remedy Replace defective component parts only. Do not replace any adjacent component parts that are intact. Note: Repair kits for washer line hoses do exist to allow patches for line damage.

Components: STRUCTURE:BODY · VISIBILITY/WIPER. Confirm detailed applicability in the original document.

Complaint During a phone call, the called party has difficulty understanding/cannot understand the driver, or interference/background noises are audible to the called party during a call. It becomes increasingly difficult to understand as the speed rises. Cause A. Seating of the microphones in the headliner. Side edges are covered by the textile cover (see picture "1") B. Assembly of microphones (B25/20 or B25/21) in the headliner. C. Dirt inside the microphone housing Remedy 1. Press finger on rear of microphone (on adhesive tape) 2. Remove microphone cap from the front 3. Eliminate protruding material residues of the microphone cutout at the headliner, e.g. with a soldering iron. The microphone must be seated in the headliner as shown in picture "2". 4. Push microphone from behind until it is firmly pressed into the headliner 5. Maintain pressure and press/clip cap into microphone from the front. Note: The cover cap must be clearly heard and felt to engage. 6. This procedure must be carried out on both microphones (B25/20 and B25/21) Note: • It is recommended to replace the cover caps. • The non-woven cloth in the cover cap protects the microphone from soiling and must not be removed. NOTE: The information contained in this document is intended for use by trained, professional technicians with the knowledge to properly and safely perform diagnosis and repairs on Mercedes-Benz vehicles, using Mercedes-Benz approved tools and equipment. It informs service technicians about conditions that could occur in certain vehicles and provides information that could assist in proper vehicle diagnosis, service, or repair. It does not indicate that a defect is present in any vehicle referenced in this document nor does it imply warranty coverage. DO NOT assume that a symptom or condition, or a described cause of a symptom or condition, affects any particular vehicle or groups of vehicles, or that a described repair applies to any particular vehicle or groups of vehicles. There can be multiple causes resulting in the same or similar symptoms or conditions described in this document, and trained professional service technicians must use their diagnostic skills to make evaluations on a case-by-case basis. The information contained in this document does not guarantee warranty coverage nor does it extend the vehicle’s warranty in any way.

Components: ELECTRICAL SYSTEM. Confirm detailed applicability in the original document.

Complaint Headlamps leaking or fogged Cause The fogging of the headlamp is a natural phenomenon which can occur under certain climatic conditions. In contrast to a leaky headlamp, physical fogging does not result in a technical impairment of the headlamp. A leak test must be performed to determine if physical fogging exists or if the headlamp is leaky. Remedy In advance, observe LI82.10-P-078301 "Headlamps or Front Fog Lamps Leaking or Fogged". 1. Prepare headlamp/check for external damage: For headlamps with a closed system 1. Check the headlamps for any external damage and check also for correct seating of the Gore-diaphragm/correct latching of the cover caps. 2. If the headlamp exhibits any external damage, replace the headlamp. For headlamps with an open system 1. Check the headlamps for any external damage and seal off the vent then make sure the cover caps are latched correctly into place. 2. If the headlamp exhibits any external damage, replace the headlamp. Note: A headlamp with external damage is not a warranty or goodwill case. 2. Leak test of headlamp with overpressure: • Connect test adapter to pressure tester. (Figure 1) • Check test adapter for leak tightness. To do so, connect plug and coupling (picture 2) and apply a maximum overpressure of 30 mbar. The pressure must remain constant. If the pressure does not remain constant, use a new adapter. • Seal all the outlet openings using sealing compound and the given diaphragm with the plunger (picture 3). (Picture 4) Make allowance for the different headlamp variants here (there are different outlet openings). • Check if the headlamp needs to be removed to gain access to the diagnostic socket on the headlamp housing. • Plug the adapter onto the diagnostic socket on the headlamp housing. (Picture 5). • Apply a maximum of 30 mbar overpressure to the headlamp housing. Note: If the maximum overpressure of 50 mbar is exceeded the headlamp seal will be damaged. • If a pressure drop of less than 10 mbar is measured within 30 seconds, the headlamp is not leaky and the problem is down to natural physical fogging. • If a pressure drop of more than 10 mbar is measured within 30 seconds, the headlamp is leaky. Note: The leaky position can be localized with the aid of soap suds. Replace any leaky headlamps. Note: Desiccant packs can be installed for headlamps that are not leaky. See: • LI82.10-P-064766 Fogged headlamp, desiccant pack installed - open ventilation system • LI82.10-P-078304 Fogged headlamp, desiccant pack installed - closed ventilation system

Components: EXTERIOR LIGHTING. Confirm detailed applicability in the original document.

Complaint Headlamp or front fog lamp leaky or fogged Cause Fogging of the headlamps is a natural phenomenon, which can occur under certain climatic conditions. It does not lead to any technical impairment of the headlamp. Headlamps comply with all applicable standards. If a pressure compensation diaphragm is fitted in the housing cover, then the lamp unit is a "closed system". Remedy Headlamp: Remedy 1 Clearing fogged/condensed LED headlamps and LED rear lamps: 1. Drive vehicle into workshop (temperature higher than +18 °C/+64.4 °F) and connect the exhaust extraction. Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine and connect battery support via a charger. 3. Open the hood or trunk. 4. Switch on the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Clearing fogged/condensed halogen/xenon headlamps: 1. Drive the vehicle into the workshop (temperature higher than +18 °C/+64.4°F). Note: Do not perform an engine wash before the defogging test. 2. Switch off the engine. 3. Open the hood. 4. Switch off the lights. 5. Leave the vehicle in this state for 60 minutes. 6. Check for formation of condensation, a significant reduction in the formation of condensation must be clearly recognizable (thawing progress). Note: If there is no visible reduction in the formation of condensation, check the headlamp for a defect. (See Remedy 2) It is not physically possible to defog the headlamps completely. Fogging does not impair the operation or the service life of the headlamp. Remedy 2 A Damaged headlamp can be identified as follows: 1. Check the headlamp for external damage and that the cover caps and the diaphragm are correctly seated. 2. Check the electrical connectors of the plugs and pins. 3. Check for leak tightness in accordance with LI82.10-P-078307. The test can only be conducted on headlamps. 4. If the headlamp or the rear lamp has any external damage, replace the component part in accordance with the WIS instructions. Note: External damage to the headlamp/rear lamp or faulty seating of the cover caps does not present a warranty or goodwill case. With headlamps, it is possible to install desiccant packs if the problem occurs repeatedly. Open ventilation system: LI82.10-P-064766. Closed ventilation system LI82.10-P-078304

Components: EXTERIOR LIGHTING. Confirm detailed applicability in the original document.