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I had this issue with my Smart a few months ago. Every time I would turn on the AC it made this really loud rattling noise and it was quite embarrassing! I took mines to my dealership (Carmaxx) and they told me a part had came undone and that's why it was rattling and making that noise so I got it replaced and it has been working well ever since. I don't remember the name of the part (sorry) but definitely get it checked out!
 
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