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Info guides and mods

Torque settings for fortwo, forfour and roadster

Acknowledgements to BBE - Binman - The AIM - Blackdog - Tolsen

Modification Details





ForTwo Engine 450 ForTwo Chassis 450 ForTwo/
Roadster Transmission
Roadster Engine Roadster Chassis ForFour Engine ForFour Transmission Odds & Sods

Smart ForTwo Engine

Cylinder head at crankcase (new bolts only):

Petrol M160 EU2 & EU3 21.0Nm + 3x90degree + 10degree
Petrol M160/1 EU4 21.0Nm +2x90degree + 10 degree
Diesel OM660 EU3 30.0Nm + 3x90degree + 10degree
 

Cylinder head cover at cylinder head:

Petrol M160 EU2 & EU3 (New only) 12.0Nm
Petrol M160/1 EU4 (New) 12.0Nm, (Used) 9.5Nm
Diesel OM660 EU3 (New only) 12.0Nm
 

Oil pan at crankcase:

Petrol M160 EU2 & EU3 (New only) 12.0Nm
Petrol M160/1 EU4 (New) 12.0Nm, (Used) 8.4Nm
Diesel OM660 EU3 (New only) 12.0Nm
 

Water Pump at major assembly carrier (new only):

Petrol M160 EU2 & EU3 9.5Nm
Petrol M160/1 EU4 14.0Nm
Diesel OM660 EU3 9.5Nm
 

Oil intake tube at crankcase:

Petrol M160 EU2 & EU3 (New only) 14.0Nm
Petrol M160/1 EU4 (New) 14.0Nm, (Used) 9.5Nm
Diesel OM660 EU3 (New only) 14.0Nm
 

Exhaust to turbo manifold:

Petrol M160 EU2 & EU3 (New only) 30.0Nm
Petrol M160/1 EU4 (New only) 30.0Nm
Diesel OM660 EU3 (New only) 30.0Nm
 

Exhaust Manifold at cylinder head (new & used):

Petrol M160 EU2 & EU3 16.0Nm
Petrol M160/1 EU4 16.0Nm
Diesel OM660 EU3 23.0Nm
 

Water Drain Plug:

All Engines 12.0Nm
 

Glow Plug:

Diesel OM660 EU3  (new & used) 15.0Nm

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Smart ForTwo Chassis (all engines)
ForTwo road wheels 110Nm

Lower ball joint nut

46Nm +/-4.6Nm
Brake caliper at pivot bearing (new & used) 115Nm +/-5Nm
Wheel bearing stretch bolt 120Nm +/-12Nm
Front axle shock absorber at support bearing (transverse leaf spring) 60Nm +/-6Nm
Shock absorber strap (transverse leaf spring) 46Nm +/-6Nm
Shock absorber top nut (MacPherson strut) 45Nm +/-4.5Nm
Shock absorber strap (MacPherson strut) 46Nm +/-4.6Nm
Lower ball joint bolts 40Nm +/-4Nm
Steering ball joint bolts 40Nm +/- 4Nm
Front axle wishbone control arm at front sub frame 120Nm +/-12Nm
Drop link to wishbone nut 46Nm
Sway bar bush housing 85Nm
Steering gear at front sub frame 46Nm +/-4.6Nm
Front sub frame to body 85Nm +/-10Nm
Rear central wheel bearing bolt into driveshaft 30Nm + 90 Degrees
Rear axle shock absorber at frame-type integral support bearing bracket 65Nm +/-6.5Nm
Rear axle shock absorber at axle tube 65Nm +/-6.5Nm
X-frame bar end to axle tube 100Nm
 

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Smart ForTwo and Roadster Transmission
Filler plug, transmission oil 43.0Nm
Drain plug, transmission oil 43.0Nm
Transmission at engine 23.0Nm
Engine mount at transmission 28.0Nm
Engine mount at frame-type integral support 58.0Nm
Starter at transmission housing 23.0Nm
Clutch release at transmission 10.0Nm
Modular clutch at flexible plate 20.0Nm +90degree +/- 5degree

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Smart Roadster Engine

Cylinder head at crankcase (new bolts only):

Petrol M160/1 EU4 21.0Nm +2x90degree + 10 degree
 
Cylinder head cover at cylinder head:
Petrol M160/1 EU4 (New) 12.0Nm, (Used) 12.0Nm
 
Oil pan at crankcase:
Petrol M160/1 EU4 (New) 12.0Nm, (Used) 8.4Nm
 
Water Pump at major assembly carrier (new only):
Petrol M160/1 EU4 14.0Nm
 
Oil intake tube at crankcase (new only):
Petrol M160/1 EU4 14.0Nm
 
Exhaust Manifold at cylinder head (new & used):
Petrol M160/1 EU4 16.0Nm
 
Water Drain Plug:

All engines

12.0Nm
 
Spark Plug (new & used):
Petrol M160/1 EU4 (New) 27.5 Nm, (Used) 22.5 Nm


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Smart Roadster Chassis (all engines)
Roadster road wheels 120Nm
Lower ball joint nut 46Nm +/-4.6Nm
Brake caliper at pivot bearing (new & used) 115Nm +/-5Nm
Wheel bearing stretch bolt 120Nm +/-12Nm
Shock absorber top nut (MacPherson light) 45Nm +/-4.5Nm
Shock absorber strap (MacPherson light) 46Nm +/-4.6Nm
Lower ball joint bolts 40Nm +/-4Nm
Steering ball joint bolts 40Nm +/- 4Nm
Front axle wishbone control arm at front sub frame 120Nm +/-12Nm
Drop link to wishbone nut 46Nm
Sway bar bush housing 85Nm
Steering gear at front sub frame 46Nm +/-4.6Nm
Front sub frame to body 85Nm +/-10Nm
Rear central wheel bearing bolt into driveshaft 30Nm + 90 Degrees
Rear axle shock absorber at frame-type integral support bearing bracket 65Nm +/-6.5Nm
Rear axle shock absorber at axle tube 65Nm +/-6.5Nm

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Smart ForFour Petrol M135 Engine
Cylinder head 24.5Nm +2x90degree
Cylinder head cover 8.0Nm
Oil pan 7.5Nm
Oil filter 14.0Nm
Oil filter connection 27.0Nm
Oil intake bell 8.5Nm
Water pump 8.5Nm
Timing case cover M6 8.5Nm
Timing case cover M10 39.0Nm
Intake manifold/bracket for intake manifold in engine block 18.5Nm
Exhaust manifold 34.0Nm
Spark plugs 25.0Nm

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Smart ForFour Transmission
Filler plug, transmission oil 43.0Nm
Drain plug, transmission oil 43.0Nm
Transmission at engine  25.0Nm
Engine mount at transmission 40.0Nm
Starter at transmission housing 20.0Nm
Clutch release at transmission 20.0Nm
Pressure plate at flywheel 19.0Nm
Clutch actuator 12.0Nm

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Odds & sods
Camshaft 10Nm
Inlet manifold to head 10Nm
Front hub 120Nm
Rear hub 30Nm + 90 degrees
Track rod end 40Nm
ForTwo road wheels 110Nm
Roadster road wheels 120Nm
Oil filter housing Smart recommend 25Nm
I do mine to about 15Nm.
Sump drain plug 30Nm
Spark plug EU2 & EU3 M160 engine (New) 27.5 Nm, (Used) 20.0 Nm
Spark plug EU4 (New) 27.5 Nm, (Used) 22.5 Nm
Exhaust to manifold nut 30Nm
Exhaust bolts on upper & lower of exhaust bracket 25Nm
Exhaust bracket rear bolt onto transmission box 23Nm


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