450 — fortwo (1998-2007) — Seats & Restraints

Workshop and reference excerpts for 450 — fortwo (1998-2007) in the Seats & Restraints system.

128 excerpts from 2 sources.

Sources on this page

• 1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf — 1 excerpts
• 2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf — 127 excerpts

1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf

Check seat rail and backrest for correct engagement

1998-2015 smart fortwo (450_451) - Technical & Service Reference.pdf · p. 178 · Applies to: 450, 451 · AR: AR91.10-P-1060SM

13.4.06 Top rail 2 Bottomra/1 P91 .10-2833·06 l~I Checking 1 Sling the seat to thfl center position via seat fore/aft adjustment until an audible engaging noise Is heard 2 Move the seat back and forth transverse to LiJ If 1 to 2 mm of movement can be the direction of travel at the front end of the detected between the top rail (1) and the seat cushioo bottom rail (2), the seat rail is not OK and must be replaced: ,l Remove, install seat console. AR91 10-P-3000SM 3 Fold down backrest of front passenger seat, W Ensure that you hear an engaging noise then fold backrest of front passenger seat at the backrest unlock (arrows} on the left back into the upright position and right sides. [TI If the backrest does not correctly engage, it must be replaced: t Remove, install front seat backrest. AR91.10-P-1060SM

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf

is output. The status of the left door rotary tumbler microswitch (S87/7) is read in by the SAM

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1615 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4048MCU, GF07.61-P-6000MCU, GF42.45-P-5118MCU, GF46.35-P-7100MCU, GF40.15-P-5124MCU (+1 more)

control unit which requests acoustic feedback. Door warning (warning tone) Daytime running lights activated or deactivated (signal tone) (with code (K06) Daytime running lights) Seat belt reminder warning Instrument cluster, component description A1 GF54.30-P- 6000MCU Restraint systems control unit, component description N2/7 GF91.60-P-4048MCU ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MCU SAM control unit, component description N10/10 GF54.21-P- 4157MCU ESP control unit, component description N47-5 GF42.45-P-5118MCU Electric steering control unit, component description N68For vehicles with code (V26) Power steering, EPS (FFO) GF46.35-P-7100MCU Tire pressure monitor control unit, component description N88 GF40.15-P-5124MCU BASIC KNOWLEDGE > DISPLAY SPEED, FUNCTION - GF54.30-P-3025MCU > MODEL 451.3/4 Shown on code (K07) Speedometer (miles)

component description

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1922 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4048MCU, GF07.61-P-6000MCU, GF54.21-P-4157MCU, GF26.19-P-1010MCU, GF83.40-P-3001MCU (+5 more)

Restraint systems control unit, component description N2/7 GF91.60-P-4048MCU ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MCU SAM control unit, component description N10/10 GF54.21-P-4157MCU Component description for the automated manual transmission control unit N15/6 GF26.19-P-1010MCU Component description for the heater/air conditioning operating unit N23For code (I01) Air conditioning Plus GF83.40-P-3001MCU ESP control unit, component description N47-5 GF42.45-P-5118MCU Component description for the oil pressure switch S41/1 GF18.40-P-4000MCC Ignition coils, component description T1/1, T1/2, T1/3 GF15.10-P-2100MCC Secondary air injection pump switchover valve, component description Y32 GF14.30-P-2055MCU Adjustable camshaft timing solenoid, component description Y49 GF05.20-P-2100MCC Activated charcoal filter shutoff valve, component description Y50 GF47.31-P-2100MCU Component description for the tank vent valve Y58 GF47.30-P-4037MCC Fuel injection valves, component description Y62/1, Y62/2, Y62/3 GF07.03-P-6010MCC BASIC KNOWLEDGE > COMPONENT DESCRIPTION FOR THE ME-SFI [ME] CONTROL UNIT - GF07.61-P-6000MCU > ENGINE 132.9 in MODEL 451.3 /4

Restraint systems control unit,

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1926 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4048MCU, GF07.61-P-6000MCU, GF54.21-P-4157MCU, GF26.19-P-1010MCU, GF83.40-P-3001MCU (+5 more)

component description N2/7 GF91.60-P-4048MCU ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MCU SAM control unit, component description N10/10 GF54.21-P-4157MCU Component description for the automated manual transmission control unit N15/6 GF26.19-P-1010MCU Component description for the heater/air conditioning operating unit N23For code (I01) Air conditioning Plus GF83.40-P-3001MCU ESP control unit, component description N47-5 GF42.45-P-5118MCU Component description for the oil pressure switch S41/1 GF18.40-P-4000MCC Ignition coils, component description T1/1, T1/2, T1/3 GF15.10-P-2100MCC Data link connector component description X11/4 GF54.22-P-2200MCC Secondary air injection pump switchover valve, component description Y32 GF14.30-P-2055MCU Adjustable camshaft timing solenoid, component description Y49 GF05.20-P-2100MCC Activated charcoal filter shutoff valve, component description Y50 GF47.31-P-2100MCU Component description for the tank vent valve Y58 GF47.30-P-4037MCC Fuel injection valves, component description Y62/1, Y62/2, Y62/3 GF07.03-P-6010MCC Table of contents for function description of motor electronics (ME-SFI) fuel injection and ignition system

GF07.61-P-0999MCU WIRING DIAGRAMS > OVERVIEW OF WIRING DIAGRAMS FOR MIXTURE FORMATION - PE07.00-P-1100MCU > ENGINE 132 in MODEL 451 PE07.61-P-2000MCU Wiring diagram, fuel injection and ignition system ME-SFI ENGINE 132 in MODEL 451 PE07.61-P-2000MCU

Always perform repair cavity preservation twice in succession after a flash-off time of 5 min. After drying,

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2611 · Applies to: 450, 451, 452, 454 · AR: AP97.20-P-0640MCC

ensure that drain holes are not plugged. It is important that the wax preservation agent is applied following sealing and paintwork, however, before assembly. Otherwise paint flaws result or installation parts are contaminated with wax. Replacement bodyshells must also be preserved twice in succession after painting. Replacement bodyshells top-coated in the factory have already been treated with the standard cavity preservation. Processing instructions The cavities should be dry for preservation. Before commencing preservation work, check the spray pattern from the spraying hose or spray can. The wax must spray uniformly from the openings in a circular pattern. Particularly advantageous are nozzles which spray toward the front as well as at an angle toward the rear. The spraying hose of the hand-held lance must be "stiff". Hoses that tend to roll up are not suitable. When preserving, insert spraying hose as far as possible to all sides in the hollow cavities. Spray while slowly inserting and retracting the hose (processing temperature not below +15°C). Clean spray nozzle and spray hose together with spray equipment. MAINTENANCE > PRESERVATION - AP97.20-P-0640MCC > MODEL 451

Application

1 Apply seam seal

Seam sealing following repair

AR97.10-P- 4000MCC 2 Apply hollow cavity preservation Thoroughly shake and stir cavity sealant before use.

Cavity preservation following repair work

AR97.20-P- 1500FF 3 Apply underbody preservation agent During subsequent preservation work on the underbody, cover brake parts such as brake discs and brake hoses in a suitable manner to prevent them from being sprayed resulting in subsequent extensive cleaning

Processing permanent underfloor protection agent for painting

AR97.20-P-0500- 03FF

Electroplastic hot air blower, Flat nozzle with scraper, Compressed air gun, http://gotis.aftersales.mercedes- benz.com

Underfloor preservation

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2612 · Applies to: 450, 451, 452, 454 · AR: AR97.00-Z-9451CA, AR97.20-P-1500FF, AR97.20-P-0500FF, AR97.10-P-4000MCC

AH97.20-P-2000- 01FF Instructions for processing permanent underbody protection

AH97.20-P-9409- 01FF 4 Remove wax fog residues on outer surface with silicon remover

5 Treat outer surface with polish and gloss preservation agent Polish BR00.45-Z-1013- 04A Gloss preserver BR00.45-Z-1014- 04A AUXILIARY REPAIR MATERIALS Number Designation Order number BR00.45-Z-1013-04A Polish, silicone free 5 l, DB supply specification 7545.00 A 000 986 45 74 BR00.45-Z-1014-04A Gloss preservation, 500 ml, DB supply specification 7551.10 A 000 986 44 74 TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: BODY SEALING, CORROSION PROTECTION - AR97.00-Z-9451CA > MODEL 451 Cavity preservation following repair work MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0 AR97.20-P-1500FF Processing corrosion protection materials before painting MODEL 450, 451, 452, 454 AR97.20-P-0500FF Seam sealing following repair MODEL 451.3/4 AR97.10-P-4000MCC TESTING & REPAIR > PROCESSING OF BODY SEALANT (PAINTABLE) BEFORE PAINTING - AR97.10-P-0500-02FF > When replacing sheet metal detachable body components (trunk lid, etc.) and also sheet metal parts welded in place, carefully seal the folds and openings with body sealant in order to avoid corrosion and leaks. Seal spot weld seams on both sides. Observe following procedure: 1. Carefully clean affected body parts. 2. Apply sealant uniformly. 3. Spread body sealant evenly. 4. Maintain drying time before painting.

The brushes, wooden spatulas, etc. used to spread the body sealant should generally be

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2613 · Applies to: 450, 451, 452, 454 · AR: AR97.10-P-4000MCC, AR97.20-P-1500FF

cleaned only with naphtha. If these objects are cleaned with paint thinner or other alcoholic liquids before applying the body sealant, the sealant does not cure. TESTING & REPAIR > SEAM SEALING FOLLOWING REPAIR, DETACHABLE BODY COMPONENTS - AR97.10-P-4000-04FF > 1. Seal spot welds of area to be repaired with seam sealing material Insert plastic plugs and grommets with sealing compound. Keep sealant out of threads on weld nuts and threaded bolts by masking or covering with cardboard sleeves. Also keep sealant out of drain openings and contact surfaces for axle mounts, washers and attachment parts. It is necessary to seal accessible spot weld flanges on both sides. If accessible from one side only seal corresponding surface. Observe standard sealing! TESTING & REPAIR > SEAM SEALING FOLLOWING REPAIR - AR97.10-P-4000MCC > MODEL 451.3/4 Figure item, etc. Work instructions

Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. AS97.00-Z-0001-01A Underfloor preservation

AH97.20-P-2000- 01FF Notes on sprayable seam sealing

AH97.10-P-0002- 01FF Cavity preservation following repair work

AR97.20-P-1500FF Processing of body sealant (paintable) before painting

AR97.10-P-0500- 02FF Seam sealing following repair, detachable body components

AR97.10-P-4000- 04FF TESTING & REPAIR > PROCESSING ZINC DUST PAINT BEFORE PAINTING - AR97.20-P- 0500-01FF >

Always perform repair cavity preservation twice in succession after a flash-off time of 5 min. After drying,

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2620 · Applies to: 450, 451, 452, 454 · AR: AP97.20-P-0640MCC, AR97.10-P-4000MCC, AR97.20-P-1500FF

ensure that drain holes are not plugged. It is important that the wax preservation agent is applied following sealing and paintwork, however, before assembly. Otherwise paint flaws result or installation parts are contaminated with wax. Replacement bodyshells must also be preserved twice in succession after painting. Replacement bodyshells top-coated in the factory have already been treated with the standard cavity preservation. Processing instructions The cavities should be dry for preservation. Before commencing preservation work, check the spray pattern from the spraying hose or spray can. The wax must spray uniformly from the openings in a circular pattern. Particularly advantageous are nozzles which spray toward the front as well as at an angle toward the rear. The spraying hose of the hand-held lance must be "stiff". Hoses that tend to roll up are not suitable. When preserving, insert spraying hose as far as possible to all sides in the hollow cavities. Spray while slowly inserting and retracting the hose (processing temperature not below +15°C). Clean spray nozzle and spray hose together with spray equipment. MAINTENANCE > PRESERVATION - AP97.20-P-0640MCC > MODEL 451

Application

1 Apply seam seal

Seam sealing following repair

AR97.10-P-4000MCC 2 Apply hollow cavity preservation Thoroughly shake and stir cavity sealant before use.

Cavity preservation following repair work

AR97.20-P-1500FF 3 Apply underbody preservation agent During subsequent preservation work on the underbody, cover brake parts such as brake discs and brake hoses in a suitable manner to prevent them from being sprayed resulting in subsequent extensive cleaning

Processing permanent underfloor protection agent for painting

AR97.20-P-0500- 03FF

Electroplastic hot air

blower, Flat nozzle with

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2621 · Applies to: 450, 451, 452, 454 · AR: AR97.00-Z-9451CA, AR97.20-P-1500FF, AR97.20-P-0500FF, AR97.10-P-4000MCC

scraper, Compressed air gun, Underfloor preservation

AH97.20-P-2000- 01FF Instructions for processing permanent underbody protection

AH97.20-P-9409- 01FF 4 Remove wax fog residues on outer surface with silicon remover

5 Treat outer surface with polish and gloss preservation agent Polish BR00.45-Z-1013- 04A Gloss preserver BR00.45-Z-1014- 04A AUXILIARY REPAIR MATERIALS Number Designation Order number BR00.45-Z-1013- 04A Polish, silicone free 5 l, DB supply specification 7545.00 A 000 986 45 74 BR00.45-Z-1014- 04A Gloss preservation, 500 ml, DB supply specification 7551.10 A 000 986 44 74 TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: BODY SEALING, CORROSION PROTECTION INDEX - AR97.00-Z-9451CA > MODEL 451 Cavity preservation following repair work MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0 AR97.20-P-1500FF Processing corrosion protection materials before painting MODEL 450, 451, 452, 454 AR97.20-P-0500FF Seam sealing following repair MODEL 451.3 /4 AR97.10-P-4000MCC TESTING & REPAIR > PROCESSING OF BODY SEALANT (PAINTABLE) BEFORE PAINTING - AR97.10-P-0500-02FF > When replacing sheet metal detachable body components (trunk lid, etc.) and also sheet metal parts welded in place, carefully seal the folds and openings with body sealant in order to avoid corrosion and leaks. Seal spot weld seams on both sides. Observe following procedure: 1. Carefully clean affected body parts.

2. Apply sealant uniformly.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2622 · Applies to: 450, 451, 452, 454 · AR: AR97.10-P-4000MCC

1. Spread body sealant evenly.
2. Maintain drying time before painting. The brushes, wooden spatulas, etc. used to spread the body sealant should generally be cleaned only with naphtha. If these objects are cleaned with paint thinner or other alcoholic liquids before applying the body sealant, the sealant does not cure. TESTING & REPAIR > SEAM SEALING FOLLOWING REPAIR, DETACHABLE BODY COMPONENTS - AR97.10-P-4000-04FF >
3. Seal spot welds of area to be repaired with seam sealing material Insert plastic plugs and grommets with sealing compound. Keep sealant out of threads on weld nuts and threaded bolts by masking or covering with cardboard sleeves. Also keep sealant out of drain openings and contact surfaces for axle mounts, washers and attachment parts. It is necessary to seal accessible spot weld flanges on both sides. If accessible from one side only seal corresponding surface. Observe standard sealing! TESTING & REPAIR > SEAM SEALING FOLLOWING REPAIR - AR97.10-P-4000MCC > MODEL 451.3 /4 Figure item, etc. Work instructions

Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. AS97.00- Z-0001- 01A Underfloor preservation

AH97.20- P-2000- 01FF Notes on sprayable seam sealing

AH97.10- P-0002- 01FF Cavity preservation following repair work

AR97.20- P- 1500FF Processing of body sealant (paintable) before painting

AR97.10- P-0500- 02FF Seam sealing following repair, AR97.10-

http://gotis.aftersales.mercedes-benz.com

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2624 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-0500FF

Do not spray underfloor protection on major assemblies, otherwise functions may be impaired. Maintain drying time before painting. TESTING & REPAIR > PROCESSING CORROSION PROTECTION MATERIALS BEFORE PAINTING - AR97.20-P-0500FF > MODEL 450, 451, 452, 454

Application

1 Apply corrosion protection materials in repair areas Processing zinc dust paint before paintingPrimer gun and brush AR97.20-P-0500- 01FF

Processing of body sealant (paintable) before painting AR97.10-P-0500- 02FF

Processing permanent underfloor protection agent for paintingElectric plastic hot air blower, flat nozzle with scraper and compressed air gun AR97.20-P-0500- 03FF Instructions for processing permanent underbody protection

AH97.20-P-9409- 01FF TESTING & REPAIR > CAVITY PRESERVATION FOLLOWING REPAIR WORK - AR97.20-P- 1500FF > MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0 Risk of explosion and poisoning caused by solvent vapors and gasses. Risk of injury to skin and eyes when working with anticorrosion agents Never spray anticorrosion agents on flames or glowing hot objects and keep them well away from all potential sources of ignition. Use them only in well-ventilated rooms; wear respiratory protection. AS97.00-Z-0001-01A Notes on cavity preservation

AH97.20-P-0001- 01FF 1 Perform repair preservation Apply cavity preservation agent in marked areas only

WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR AIRBAG (AB),

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2769 · Applies to: 450, 451, 452, 454 · AR: PE91.00-P-2050MCU

EMERGENCY TENSIONING RETRACTOR (ETR) - PE91.00-P-2050MCU > MODEL 451 PE91.00-P- 2050-99MCU Electrical function diagram for airbag (AB), emergency tensioning retractor (ETR)

PE91.00-P- 2050-99MCU Fig 2: Outside Mirror - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Supply standard seam

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2927 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

30 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC

Sealant BR00.45-Z-1003- 01A 31 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 32 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 33 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 34 Reinstall all detachable parts removed

AUXILIARY REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunchenGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR > REMOVE SUSPENSION STRUT TOWER - AR62.20-P-1232-01MCC >

Partially in tall

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2934 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

24 Partially in tall longitudinal member reinforcement

AR63 30 P 0818MCC 25 Partially install side wall reinforcement

AR63.20-P- 0862MCC 26 Install lower A-pillar reinforcement On model 451.3 AR63.20-P- 1114MCC On model 451.4 AR63.20-P- 1114MCO 27 Install lower outer A- pillar On model 451.4 AR63.20-P- 1102MCO 28 Partially install side wall paneling On model 451.3 AR63.10-P- 0115MCC On model 451.4 AR63.10-P- 0115MCO 29 Install front diagonal strut console on longitudinal member On model 451.4 AR61.10-P- 5140MCO 30 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

31 Prime area to be repaired using primer filler

32 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC Sealant BR00.45-Z-1003- 01A 33 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 34 Paint area repaired and adjacent surfaces

Notes on paintwork repairs AH98.00-P-9408- 02MCC 35 Apply additional cavity preservation

AR97.20-P-1500FF Teroson protective wax *BR00.45-Z-1008- 05A 36 Reinstall all detachable parts removed

AUXILIARY REPAIR MATERIALS

Remove damaged

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2942 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

4 Remove damaged console (1)

5 Grind mating surfaces on lower longitudinal member (2) down to bare metal in cross-hatched areas.

6 Remove protective paint in welding area of new console (1) and grind connecting flange down to bare metal in shaded areas

Install

7 Fit console (1) with front crossmember When fitting observe correct distances.

8 Console (1) (areas C and D)

9 Level spot welds (areas C and D)

10 Clean sheet metal flange with wire brush and clean areas to repaired

11 Prime area to be repaired using primer filler

12 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC Sealant *BR00.45-Z-1003- 01A 13 Paint area repaired and adjacent surfaces

Notes on paintwork repairs AH98.00-P-9408- 02MCC 14 Apply additional cavity preservation

AR97.20-P-1500FF Teroson protective wax *BR00.45-Z-1008- 05A 15 Reinstall all detachable parts removed

AUXILIARY REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- Sealant, white, 310 ml, DB supply A 001 989 63 20

Install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2946 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

8 Fit console (1) with crash box and front module When fitting observe correct distances.

9 Console (1) (areas D, E and F)

10 Level spot welds and clean with wire brush (areas D, E and F) and clean areas to be repaired

11 Prime area to be repaired using primer filler

12 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC

Sealant *BR00.45-Z-1003- 01A 13 Paint area repaired and adjacent surfaces Notes on paintwork repairs

AH98.00-P-9408- 02MCC 14 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective waxArt. no.: 122.73Q *BR00.45-Z-1008- 05A 15 Reinstall all detachable parts removed

AUXILIARY REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunchenGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de TESTING & REPAIR > REMOVE LONGITUDINAL MEMBER LOCKING LUG - AR62.20-P- 1267-01MCC >

Expose spot welds on

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2963 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

4 Expose spot welds on front axle carrier tapping plate (1) and cut out (area A)

5 Remove damaged front axle carrier tapping plate (1)

6 Grind mating surfaces on front axle carrier tapping plate (1) down to bare metal in cross-hatched areas.

7 Grind front axle carrier tapping plate (1) down to bare metal in shaded areas

Install

8 Fit front axle carrier tapping plate (1) and fasten with vise grip pliers When fitting observe correct distances.

9 Front axle carrier tapping plate (1) (area B)

10 Level spot welds on front axle carrier tapping plate (1) if required

11 Clean area to be repaired with wire brush and then prime

12 Supplement standard seals with body sealant Sealant *BR00.45-Z-1003- 01A 13 Paint area repaired and adjacent surfaces Notes on paintwork repairs

AH98.00-P-9408- 02MCC 14 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective waxArt. no.: 122.73Q *BR00.45-Z-1008- 05A 15 Reinstall all detachable parts removed

AUXILIARY REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- Sealant, white, 310 ml, DB supply A 001 989 63 20

Supplement standard

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2971 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF, AR62.25-P-5753MCC

32 Supplement standard underbody protection with permanent underbody sealant Underfloor protection *BR00.45-Z-1001- 05A 33 Paint area repaired and adjacent surfaces

Notes on paintwork repairs AH98.00-P-9408- 02MCC 34 Apply additional cavity preservation

AR97.20-P-1500FF Teroson protective wax *BR00.45-Z-1008- 05A 35 Reinstall all detachable parts removed

AUXILIARY REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunchenGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR > REMOVE/INSTALL FIREWALL - AR62.25-P-5753MCC > MODEL 451.3/4 Shown on model 451.3

instrument connector

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3227 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0050MCU

(A15x1) located in the installation opening of the IC (A1) 7 Remove additional instruments (A15)

8 Install in the reverse order

9 Set clock of additional instruments (A15)

TESTING & REPAIR > REMOVE/INSTALL KNEEBAG - AR91.60-P-0050MCU > MODEL 451.3 /4 with CODE (294) Kneebag

Remove/Install

Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00-Z-0001-01A Notes on avoiding damage to electronic AH54.00-P-0001-01A Fig 1: Identifyng Kneebag Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

vehicle with airbag and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3354 · Applies to: 450, 451, 452, 454 · AR: AR97.10-P-4000MCC

ETR units Pretreatment of bonding surfaces

AH60.00-P-0008- 01MCC General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027-01FF General information on repairs to body

AH60.00-P-0001-01FF The generally required conventional tools are required for body work

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Remove rear lamp insert (1)

AR64.20-P-1061- 01MCO 4 Prepare connecting points of rear lamp insert (1) on body

AR64.20-P-1061- 02MCO

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 5 Prepare rear lamp insert (1) for installation

AR64.20-P-1061- 03MCO

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

6 Install rear lamp insert (1) and weld in The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR64.20-P-1061- 04MCO

Adhesive *BR00.45-Z-1092-02A 7 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

8 Prime area to be repaired using primer filler

9 Supply standard seam seals

AR97.10-P-4000MCC

with body ealant

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3355 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

Sealant BR00.45-Z-1003-01A 10 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A 11 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 12 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 13 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1092- 02A Adhesive kit, body, 2-component adhesive A 009 989 36 71 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunichGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR > SEPARATE END CROSSMEMBER INNER SECTION - AR64.20-P- 1120-01MCC >

member inner

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3361 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

cro member inner section (1) for installation 02MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 7 Prepare connecting points on body

AR64.20-P-1120- 04MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install

8 Install end crossmember inner section (1) and weld in

AR64.20-P-1120- 03MCC 9 Install end panel

AR64.20-P- 5731MCC 10 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

11 Prime area to be repaired using primer filler

12 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC

Sealant BR00.45-Z-1003- 01A 13 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 14 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 15 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 16 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number

using primer filler

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3401 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF, BA64.00-Z-9999CZ

8 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC

Sealant BR00.45-Z-1003- 01A 9 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 10 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 11 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 12 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunchenGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: REAR WALL AND REAR END - BA64.00-Z-9999CZ > MODEL all Rear end MODEL 450.3 /4, 451.3 /4, 452.3 /4 BA64.20-P-1000-01B TORQUE SPECIFICATIONS > REAR END - BA64.20-P-1000-01B > Model 450, 451, 452 CMS REAR END

Prepare roof paneling (1) for

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3474 · Applies to: 450, 451, 452, 454 · AR: AR97.10-P-4000MCC, AR97.20-P-1500FF

5 Prepare roof paneling (1) for installation

AR65.10-P-5702- 02MCO

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

6 Install roof paneling (1) and weld in The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR65.10-P-5702- 03MCO

Adhesive *BR00.45-Z-1092-02A 7 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

8 Prime area to be repaired using primer filler

9 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003-01A 10 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A 11 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 12 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 13 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1092- 02A Adhesive kit, body, 2-component adhesive A 009 989 36 71

Prepare connecting

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3507 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

5 Prepare connecting points on upper front roof frame (1)

AR65 20 P 1006 04MCC Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install

6 Fit upper front roof frame (1) and weld in

AR65.20-P-1006- 05MCC 7 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

8 Prime area to be repaired using primer filler

9 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC Sealant BR00.45-Z-1003- 01A 10 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 11 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 12 Apply additional cavity preservation

AR97.20-P-1500FF Teroson protective wax *BR00.45-Z-1008- 05A 13 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45- Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45- Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45- Henkel Loctite Deutschland GmbHArabellastrasse 1781925

Cover all detachable

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3510 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Remove upper front roof frame

AR65.20-P- 1006MCC 4 Separate bottom front roof frame (1)

AR65.20-P-1006- 02MCD 5 Prepare connecting points on body

AR65.20-P-1006- 08MCD Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 6 Prepare connecting points on bottom front roof frame (1)

AR65.20-P-1006- 04MCD Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install

7 Fit bottom front roof frame (1) and weld in

AR65.20-P-1006- 05MCD 8 Fit upper front roof frame and weld in

AR65.20-P- 1006MCC 9 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

10 Prime area to be repaired using primer filler

11 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC Sealant BR00.45-Z-1003- 01A 12 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 13 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 14 Apply additional

AR97.20-P-1500FF

Prepare connecting

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3520 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

5 Prepare connecting points on upper rear roof frame (1)

AR65.20-P-1008- 02MCC Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install

6 Fit upper rear roof frame (1) and weld in

AR65.20-P-1008- 03MCC 7 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

8 Prime area to be repaired using primer filler

9 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC Sealant BR00.45-Z-1003- 01A 10 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 11 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 12 Apply additional cavity preservation

AR97.20-P-1500FF Teroson protective wax *BR00.45-Z-1008- 05A 13 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45- Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45- Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45- Henkel Loctite Deutschland GmbHArabellastrasse 1781925

underbody protection

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3524 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

with permanent underbody sealant 05A 17 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 18 Apply additional cavity preservation

AR97.20-P-1500FF Teroson protective wax *BR00.45-Z-1008- 05A 19 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45- Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45- Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45- Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunchenGermanyTel. +49-899268-0Fax +49- 899101978www.Loctite.de BR00.45- Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR > SEPARATING SIDE ROOF FRAME - AR65.20-P-1200-01MCD > 1. Expose spot welds on inner side roof frame (1) and cut out (areas A, B and C). Cut out area C from inside. 2. Remove damaged inner side roof frame (1)

Remove inner side

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3530 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

5 Remove inner side roof frame (1)

AR65.20-P-1200- 01MCD 6 Prepare connecting points for inner side roof frame (1) on body

AR65.20-P-1200- 04MCD Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 7 Prepare inner side roof frame (1) for installation

AR65.20-P-1200- 02MCD Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install

8 Install inner side roof frame (1) and weld in

AR65.20-P-1200- 03MCD 9 Install side roof frame reinforcement

AR65.20-P- 1210MCC 10 Install side wall paneling

AR63.10-P- 0115MCC 11 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

12 Prime area to be repaired using primer filler

13 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC Sealant BR00.45-Z-1003- 01A 14 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 15 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 16 Apply additional cavity preservation

AR97.20-P-1500FF Teroson protective wax *BR00.45-Z-1008- 05A 17 Reinstall all detachable parts

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3544 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-1000MCC, AR91.10-P-1010MCU, AR91.10-P-8656MCC, AR91.10-P-8656MCU

1 Remove driver seat (2) * not for USA AR91.10-P-1000MCC

• for USA only AR91.10-P-1010MCU 2 Carefully cut off net at backrest cover (3) with a sharp knife directly at the seam On vehicles as of 31.8.10. The net is no longer required.

3 Remove backrest cover (3) until bracket (5) can be inserted at the right in backrest frame (6) Only remove bottom five hog rings.

• not for USA AR91.10-P-8656MCC

• for USA only AR91.10-P-8656MCU 4 Loosen nut (4) for sidebag unit For code (I53) Head/ thoraxbag

5 Remove cable ties (7)

Install

6 Lift off foam part (8) from backrest frame (6) and insert bracket (5) into the planned holes

7 Screw in bolts (9)

Fig 3: Identifying Arm Rest Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Attach new cable tie (7) where

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3545 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-8656MCC, AR91.10-P-8656MCU, AR91.10-P-1000MCC, AR91.10-P-1010MCU

8 Attach new cable tie (7) where the lines are routed

9 Lay foam part (8) over the bracket (5) and cut out a passage for the bracket (5) in the foam part (8); position foam part (8) Ensure that foam part (8) is not damaged by tearing.

10 Tighten nut (4) of sidebag unit For code (I53) Head/ thoraxbag

*BA91.60-P-1007- 01C 11 Install backrest cover (3) * not for USA AR91.10-P-8656MCC

• for USA only AR91.10-P-8656MCU

Use new hog rings.For vehicles with code (I53) Head/ thoraxbag, continue to tighten the nuts (4) on the sidebag unit.

12 Mark position of the bracket (5) on the backrest cover (3) and make a cut out in the backrest cover (3) (arrows A)

13 Fold flaps so made on the backrest cover (3) inwards and pull backrest cover (3) over the bracket (5)

14 Place trim ring (10) on the bracket (5)

15 Push clamp (11) onto the bracket (5) and insert catch spring (12)

16 Insert armrest (1) into the bracket (5) in such a way that the chamfer (arrow B) points to the rear The catch spring (12) must be engaged in the armrest (1) axis.

17 Install driver seat (2) * not for USA AR91.10-P-1000MCC

• for USA only AR91.10-P-1010MCU AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1007- 01C Nut, sidebag to backrest Nm 10 10 MAINTENANCE > CHECK SEAT BELTS AND SEAT BELT BUCKLES FOR EXTERNAL

DAMAGE AND OPERATION - AP91.40-P-9150MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3546 · Applies to: 450, 451, 452, 454 · AR: AP91.40-P-9150MCU, AR91.00-Z-9451CA, AR91.10-P-3470MCC, AR91.60-P-0681MCC, AR91.60-P-0623MCC

MODEL 451.3/4 Checking

If the customer rejects replacement of a damaged seat belt, a corresponding remark should be made on the repair order

1 Pull belt out all the way and check for any signs of damage In the event of complaints about severed fibers, chafe marks or other damage, replace seat belt subject to separate repair order.

Remove/install seat belt with emergency tensioning retractor AR91.40-P- 0630MCU 2 Inspect lock function of inertia reel by pulling sharply on belt webbing In the event of complaint, replace seat belt subject to separate repair order.

Remove/install seat belt with emergency tensioning retractor AR91.40-P- 0630MCU 3 Check that seat belt buckle engages correctly In the event of complaint, replace seat belt buckle subject to separate repair order.

Remove/install seat belt buckle (front seat) AR91.40-P- 1515MCU TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: SEATS, BUNKS, RESTRAINT SYSTEMS - AR91.00-Z-9451CA > MODEL 451 Remove and install handle for seat backrest adjustment MODEL 451.3/4 AR91.10-P-3470MCC Remove/install airbag cutout switch MODEL 451.3/4 AR91.60-P-0681MCC Remove/install airbag, sidebag and emergency tensioning MODEL 451.3/4 AR91.60-P-0623MCC

retractor control unit

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3547 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0623MCU, AR91.60-P-0660MCC, AR91.60-P-0660MCU, AR91.10-P-8656MCC, AR91.10-P-8656MCU (+5 more)

Remove/install airbag, sidebag and emergency tensioning retractor control unit MODEL 451.3/4 AR91.60-P-0623MCU Remove/install airbag unit on the steering wheel MODEL 451.3/4 AR91.60-P-0660MCC Remove/install airbag unit on the steering wheel MODEL 451.3/4 AR91.60-P-0660MCU Remove/install cover for backrest at front seat MODEL 451.3/4 AR91.10-P-8656MCC Remove/install cover for backrest at front seat MODEL 451.3/4 AR91.10-P-8656MCU Remove/install driver seat MODEL 451.3/4 AR91.10-P-1010MCU Remove/install driver seat cushion MODEL 451.3/4 AR91.10-P-1070MCU Remove/install emergency tensioning retractor MODEL 451.3/4 as of 31.8.10 belt anchor fitting tensioner on driver-side AR91.40-P-1011MCU Remove/install front seat MODEL 451.3/4 AR91.10-P-1000MCC Remove/install front seat backrest foam section MODEL 451.3/4 AR91.10-P-1120MCC Remove/install front seat backrest foam section MODEL 451.3/4 AR91.10-P-1120MCU Remove/install front seat backrest frame MODEL 451.3/4 AR91.10-P-3331MCC Remove/install front seat backrest frame MODEL 451.3/4 AR91.10-P-3331MCU Remove/install front seat center armrest MODEL 451.3/4 as of 31.8.10 with CODE (I50) Armrest MODEL 451.3/4 Retrofitted center armrest AR91.27-P-1000MCC Remove/install front seat sidebag unit MODEL 451.3/4 with CODE (I53) Head/ thorax airbag AR91.60-P-0695MCC Remove/install front seat sidebag unit MODEL 451.3/4 AR91.60-P-0695MCU Remove/install frontal acceleration sensor MODEL 451.3/4 AR91.60-P-0750MCU Remove/install heated cushion at front seat backrest MODEL 451.3/4 with CODE (S17) Seat heaters (FFO) AR91.30-P-0006MCC Remove/install heated cushion at front seat backrest MODEL 451.3/4 with CODE (S17) Seat heaters (FFO) AR91.30-P-0006MCU Remove/install heated cushion on front seat cushion MODEL 451.3/4 with CODE (S17) Seat heaters (FFO) AR91.30-P-0005MCC

Remove/install heated cushion on

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3548 · Applies to: 450, 451, 452, 454 · AR: AR91.30-P-0005MCU, AR91.30-P-0005MCV, AR91.30-P-0030MCC, AR91.30-P-0030MCU, AR91.10-P-0002MCC (+5 more)

front seat cushion MODEL 451.3/4 with CODE (S17) Seat heater (FFO) driver seat AR91.30-P-0005MCU Remove/install heated cushion on front seat cushion MODEL 451.3/4 Front passenger seat AR91.30-P-0005MCV Remove/install heated seats control unit MODEL 451.3/4 with CODE (S17) Seat heaters (FFO) AR91.30-P-0030MCC Remove/install heated seats control unit MODEL 451.3/4 with CODE (S17) Seat heaters (FFO) AR91.30-P-0030MCU Remove/install ISOFIX child seat attachment MODEL 451... AR91.10-P-0002MCC Remove/install kneebag MODEL 451.3/4 with CODE (294) Kneebag AR91.60-P-0050MCU Remove/install passenger airbag unit MODEL 451.3/4 AR91.60-P-0680MCC Remove/install passenger airbag unit MODEL 451.3/4 AR91.60-P-0680MCU Remove/install passenger seat MODEL 451.3/4 AR91.10-P-1020MCU Remove/install seat belt buckle (front seat) MODEL 451.3/4 Front passenger seat without seat belt buckle detection AR91.40-P-1515MCC Remove/install seat belt buckle (front seat) MODEL 451.3/4 Driver seat AR91.40-P-1515MCE Remove/install seat belt buckle (front seat) MODEL 451.3/4 AR91.40-P-1515MCU Remove/install seat belt guide MODEL 451.3/4 AR91.45-P-0500MCC Remove/install seat belt with emergency tensioning retractor MODEL 451.3/4 AR91.40-P-0630MCC Remove/install seat belt with emergency tensioning retractor MODEL 451.3/4 AR91.40-P-0630MCU Remove/install seat cushion MODEL 451.3/4 AR91.10-P-3310MCC Remove/install seat cushion MODEL 451.3/4 Front passenger seat AR91.10-P-3310MCU Remove/install seat cushion cover MODEL 451.3/4 AR91.10-P-3312MCC Remove/install seat cushion cover MODEL 451.3/4 Driver seat AR91.10-P-3312MCU Remove/install seat cushion cover MODEL 451.3/4 Front passenger seat AR91.10-P-3312MCV Remove/install seat cushion frame MODEL 451.3/4 AR91.10-P-3334MCC Remove/install seat cushion MODEL 451.3/4 Driver seat AR91.10-P-3334MCU

frame

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3549 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-3334MCV, AR91.60-P-0715MCU, AR91.60-P-0730MCU, AR91.60-P-0710MCC, AR91.60-P-0710MCU (+2 more)

Remove/install seat cushion frame MODEL 451.3/4 Front passenger seat AR91.10-P-3334MCV Remove/install seat position sensor MODEL 451.3/4 as of 31.8.10 driver seat AR91.60-P-0715MCU Remove/install sensor for sidebag/ windowbag MODEL 451.3 with CODE (I52) Head airbag AR91.60-P-0730MCU Remove/install sidebag sensor MODEL 451.3/4 AR91.60-P-0710MCC Remove/install sidebag sensor MODEL 451.3/4 AR91.60-P-0710MCU Removing, installing windowbag MODEL 451.3 with CODE (I52) Head airbag AR91.60-P-0693MCU TESTING & REPAIR > REMOVE/INSTALL DRIVER SEAT - AR91.10-P-1010MCU > MODEL 451.3/4 Shown on vehicle up to 30.8.10 with code (S17) Seat heater (FFO) and code (C54) Sound system 2

Remove/install

Fig 1: Identifying Driver Seat Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

connector (X28/4)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3551 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-1020MCU

9 Disconnect driver head/thoraxbag connector (X28/6) and 2-pin ETR connector at driver seat (X28/8)

10 Detach sensor connector for driver seat adjustment detection (X28/10) As of 31.8.10

11 Remove driver seat (1) from vehicle Carefully remove driver seat (1) out of vehicle with a helper, as otherwise trim parts and detachable parts may be damaged.

12 Install in the reverse order

13 Check supplemental restraint system using STAR DIAGNOSIS

AD00.00- P-2000- 04MCC FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1001-01P Bolt, seat to floor panel Nm 35 SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1001-01G Screw on belt end fitting Nm 35 TESTING & REPAIR > REMOVE/INSTALL PASSENGER SEAT - AR91.10-P-1020MCU > MODEL 451.3/4

thoraxbag connector

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3554 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-1070MCU

(X28/7) and 2-pin front passenger seat ETR connector (X28/9) installed. 12 Remove front passenger seat (1) from vehicle Carefully remove front passenger seat (1) out of vehicle with a helper, as otherwise trim parts and detachable parts may be damaged.

13 Install in the reverse order

14 Program new blank value for seat occupied recognition and check supplemental restraint system using STAR DIAGNOSIS

Connect STAR DIAGNOSIS and read out fault memory

AD00.00- P-2000- 04MCC FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1001-01P Bolt, seat to floor panel Nm 35 SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1001-01G Screw on belt end fitting Nm 35 TESTING & REPAIR > REMOVE/INSTALL DRIVER SEAT CUSHION - AR91.10-P-1070MCU

MODEL 451.3/4 Shown on code (S17) Seat heaters (FFO) Fig 1: Identifying Driver Seat Cushion And Left Seat Heated Cushion Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3555 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-1120MCU

1 Remove seat cushion cover from driver seat cushion (1) Installation: If the driver seat cushion (1) is replaced in vehicles with code (S17) Seat heater (FFO), a new left heated seat cushion (R13/1) must be installed.See: ↓ AR91.10- P- 3312MCU

Remove/install heated cushion on front seat cushion AR91.30- P- 0005MCU 2 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL FRONT SEAT BACKREST FOAM SECTION - AR91.10-P-1120MCU > MODEL 451.3/4 Shown on code (S17) Seat heaters (FFO) Shown on code (S17) Seat heaters (FFO) Fig 1: Identifying Front Seat Backrest Foam Section Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Expose sidebag

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3557 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-3310MCU

7 Expose sidebag wiring harness (5) and (if necessary) seat heater wiring harness (2) at backrest frame (7) and at foam part (6) (arrow B) The seat heater wiring harness (2) is only installed in vehicles with code (S17) Seat heater (FFO).Remove cable ties for fastening sidebag wiring harness (5) and (if necessary) cable ties for fastening seat heater wiring harness (2).Pay attention to installation position of cable ties. Installation: The position of the cable ties is specified by a white marking on the sidebag wiring harness (5) and on the seat heater wiring harness (2).

8 Route lower area (arrow C) of foam section (6) forward between backrest frame (7) and seat cushion Installation: Pay attention to positioning of foam section (6) in area of sidebag.On vehicles with code (S17) Seat heater (FFO), the seat heater wiring harness (2) must be routed through the cutout (arrow A) in the foam part (6).

9 Remove foam section (6) upward Installation: If a new foam part (6) is installed in vehicles with code (S17) Seat heater (FFO), a new left heated seat cushion (R13/1) or new right heated seat cushion (R13/3) must be installed.See: ↓

Remove/install heated cushion at front seat backrest AR91.30- P- 0006MCU 10 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL SEAT CUSHION - AR91.10-P-3310MCU > MODEL 451.3/4 Front passenger seat Shown on code (S17) Seat heaters (FFO)

sensor retaining plate

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3560 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-3312MCU

10 sensor retaining plate (14) in rear area and remove

11 Fold backrest (8) forward

12 Remove bolts (9) of backrest (8) Installation: Position backrest (8) on seat console (7) and screw in bolts (9, 11) up to contact surface. Tighten bolts (11) starting from the front. Move backrest (8) to its rearmost position and lock in place.Tighten bolts (9) starting from the rear. While doing so, press the backrest (8) backwards. *BA91.10- P-1002- 01P 13 Lift backrest (8) in vicinity of seat belt buckle (12) and expose seat belt buckle wiring harness (13) from seat console (7) Installation: Ensure that grommet (10) is seated correctly.

14 Remove bolts (11) from backrest (8) and remove backrest (8) The front passenger seat console (7) must not be dismantled any further.

15 Install in the reverse order

FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002- 01P Bolt of backrest frame to seat frame Nm 45 TESTING & REPAIR > REMOVE/INSTALL SEAT CUSHION COVER - AR91.10-P-3312MCU

MODEL 451.3/4 Driver seat Shown on code (S17) Seat heaters (FFO)

TESTING & REPAIR > REMOVE/INSTALL SEAT CUSHION COVER - AR91.10-P-3312MCV >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3565 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-3312MCV

MODEL 451.3 / 4 Front passenger seat Shown on code (S17) Seat heaters (FFO) Fig 4: Identifying Padding Clip Pliers (454 589 03 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Seat Cushion Cover Components (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

eat belt buckle (1), tarting

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3573 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-3334MCU

from the rear. While doing so, press the backrest frame (2) backwards. 16 Fit retaining plate (10) to backrest frame (2)

17 Attach the clip (11) Only if the clip (11) has been installed and when the backrest frame (2) is being removed from the front passenger seat.

18 Clip the belt tension sensor connector (B48/3x1) to the retaining plate (10) When installing front passenger seat backrest frame (2).

19 Install foam part for backrest Before installing the foam part for the backrest, check the installation position (arrows) of the spring frame (7), and correct if necessary. AR91.10-P- 1120MCU 20 Insert grommet (6) into backrest frame (2), position seat belt buckle (1) with wiring harness for seat belt buckle (4) on backrest frame (2) and screw in bolt (5). *BA91.40-P-1003- 01G 21.1 Install driver seat When installing driver seat backrest frame (2). AR91.10-P- 1010MCU 21.2 Install front passenger seat When installing front passenger seat backrest frame (2). AR91.10-P- 1020MCU FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1003-01G Bolt on seat belt buckle Nm 30 TESTING & REPAIR > REMOVE/INSTALL SEAT CUSHION FRAME - AR91.10-P-3334MCU > MODEL 451.3/4 Driver seat

seat-cushion frame

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3575 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-3334MCV

2 seat-cushion frame (4) The number of connectors (1) depends on the vehicle equipment.

3 Remove cable ties (8) and detach wiring harnesses (2) from holders (3) and expose them The number of wiring harnesses (2) depends on the vehicle equipment.

4 Place driver seat on guide rails

5 Remove driver seat cushion with seat cushion cover Do not remove the seat cushion cover from driver seat cushion. AR91.10- P- 1070MCU 6 Fold backrest (6) forward

7 Remove bolts (5) of backrest (6) Installation: Position backrest (6) on seat- cushion frame (4) and turn bolts (5) all the way in. Tighten the bolts (5) opposite the seat belt buckle, starting at the front. Move backrest (6) to its rearmost position and lock in place. Tighten bolts (5) in area of seat belt buckle, starting from rear. While doing so, press the backrest (6) backwards.

*BA91.10- P-1002- 01P 8 Remove backrest (6)

9 Remove bracket (3) on seat-cushion frame (4) When replacing seat-cushion frame (4).

10 Remove edge guards (7) on seat- cushion frame (4) When replacing seat-cushion frame (4).

11 Install in the reverse order

FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 TESTING & REPAIR > REMOVE/INSTALL SEAT CUSHION FRAME - AR91.10-P-3334MCV > MODEL 451.3/4 Front passenger seat Shown on code (S17) Seat heaters (FFO)

(14) in rear area and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3578 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-3470MCC

10 (14) in rear area and remove

11 Fold backrest (8) forward

12 Remove bolts (9) of backrest (8) Installation: Position backrest (8) on seat- cushion frame (7) and turn bolts (9, 11) all the way in. Tighten bolts (11), starting from the front. Move backrest (8) to its rearmost position and lock in place. Tighten bolts (9), starting from the rear. While doing so, press the backrest (8) backwards.

*BA91.10- P-1002- 01P 13 Raise backrest (8) in area of seat belt buckle (12) and expose wiring harness for seat belt buckle (13) Installation: Ensure that grommet (10) is seated correctly.

14 Remove bolts (11) from backrest (8) and remove backrest (8) The front passenger seat-cushion frame (7) may not be dismantled any further.

15 Install in the reverse order

FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 TESTING & REPAIR > REMOVE AND INSTALL HANDLE FOR SEAT BACKREST ADJUSTMENT - AR91.10-P-3470MCC > MODEL 451.3/4

3. Draw a cut (5) 5 mm above the reference point (2) with a length of 15 mm in the upward direction.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3581 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-8656MCU

The cut (5) must be drawn directly behind the carrier (4). 4. Draw a 25 mm long cut (6) in the downward direction starting from the reference point (3). The cut (6) must be drawn directly behind the carrier (4). 5. Make cuts (5, 6) at cover (1) of backrest starting from above. The cuts (5, 6) must not be longer than the dimension specified in each case, as they will otherwise no longer be covered by the belt guide and the cover (1) must be replaced. TESTING & REPAIR > REMOVE/INSTALL COVER FOR BACKREST AT FRONT SEAT - AR91.10-P-8656MCU > MODEL 451.3/4 Shown on code (S17) Seat heaters (FFO) Fig 1: Identifying Backrest Cover, Closing Strip And Rail Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove trim ring (3) and clamp (4)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3585 · Applies to: 450, 451, 452, 454 · AR: AR91.30-P-0005MCU, AR91.10-P-1070MCU

4 Remove trim ring (3) and clamp (4)

Install

5 Place trim ring (3) on the bracket (5)

6 Push clamp (4) onto the bracket (5) and insert catch spring (2)

7 Insert armrest (1) into the bracket (5) in such a way that the chamfer (arrow B) points to the rear The catch spring (2) must be engaged in the armrest (1) axis. TESTING & REPAIR > REMOVE/INSTALL HEATED CUSHION ON FRONT SEAT CUSHION - AR91.30-P-0005MCU > MODEL 451.3/4 with CODE (S17) Seat heater (FFO) driver seat Removing

1 Remove driver seat cushion (1) The driver seat cushion (1) and the left heated seat cushion (R13/1) cannot be re-used and must be replaced. AR91.10-P-1070MCU Install

2 Align left heated seat cushion (R13/1) on driver seat cushion (1) as shown The cutouts (arrows A, B) on the left heated seat cushion (R13/1) must be above the attachment points

Fig 1: Removing/Installing Heated Cushion On Front Seat Cushion Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

(arrows C, D) for the seat

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3586 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-1070MCU, AR91.30-P-0005MCV

cushion cover. 3 Remove the adhesive strips in the bonding areas (E, F) one after the other and glue the left heated seat cushion (R13/1) starting at the front onto the driver seat cushion (1)

4 Position areas (arrows B) of left heated seat cushion (R13/1) in recesses (arrows D) on driver seat cushion (1) If the left heated seat cushion (R13/1) is not fully inserted into the recesses (arrows D), the seat cushion cover may not be able to be fitted properly.

5 Remove the adhesive strips in the bonding areas (G, H) one after the other and glue the left heated seat cushion (R13/1) starting at the front onto the driver seat cushion (1)

6 Position areas (arrows A) of left heated seat cushion (R13/1) in recesses (arrows C) on driver seat cushion (1) If the left heated seat cushion (R13/1) is not fully inserted into the recesses (arrows C), the seat cushion cover may not be able to be fitted properly.

7 Remove the adhesive strips in the bonding areas (J, K) one after the other and glue the left heated seat cushion (R13/1) starting at the front onto the driver seat cushion (1)

8 Route wiring harness for seat heater (2) into cutout (arrow L) on driver seat cushion (1)

9 Install driver seat cushion (1)

AR91.10-P-1070MCU TESTING & REPAIR > REMOVE/INSTALL HEATED CUSHION ON FRONT SEAT CUSHION - AR91.30-P-0005MCV > MODEL 451.3/4 Front passenger seat Shown on code (S17) Seat heaters (FFO)

Unclip belt tension

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3589 · Applies to: 450, 451, 452, 454 · AR: AR91.30-P-0006MCU

10 Unclip belt tension sensor retaining plate (14) in rear area and remove

11 Fold backrest (8) forward

12 Remove bolts (9) of backrest (8) Installation: Position backrest (8) on seat console (7) and screw in bolts (9, 11) up to contact surface. Tighten bolts (11) starting from the front. Move backrest (8) to its rearmost position and lock in place.Tighten bolts (9) starting from the rear. While doing so, press the backrest (8) backwards.

*BA91.10- P-1002- 01P 13 Lift backrest (8) in vicinity of seat belt buckle (12) and expose seat belt buckle wiring harness (13) from seat console (7) Installation: Ensure that grommet (10) is seated correctly.

14 Remove bolts (11) from backrest (8) and remove backrest (8) The front passenger seat console (7) must not be dismantled any further.

15 Install in the reverse order

FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 TESTING & REPAIR > REMOVE/INSTALL HEATED CUSHION AT FRONT SEAT BACKREST - AR91.30-P-0006MCU > MODEL 451.3/4 with CODE (S17) Seat heaters (FFO)

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3590 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-1120MCU

1 Remove foam section (1) from front seat backrest The foam section (1) and the left seat heated cushion (R13/1) or the right seat heated cushion (R13/3) cannot be reused and must be replaced. AR91.10-P-1120MCU Install

2 Align left seat heated cushion (R13/1) or right seat heated cushion (R13/3), as illustrated, on foam section (1) The cutouts (arrows B) on the left heated seat cushion (R13/1) or right heated seat cushion (R13/3) must be over the attachment points (arrows A) of the backrest cover.

3 Pull off adhesive strips (2) one by one and glue left seat heated cushion (R13/1) or right seat heated cushion (R13/3) to foam section (1) starting from above If the left seat heated cushion (R13/1) or right seat heated cushion (R13/3) is not fully inserted into the recesses, this can lead to the proper assembly of the backrest cover no longer being possible. The left seat heated cushion (R13/1) or right seat heated cushion (R13/3) must be inserted into recesses of foam section (1) in area of fastening points (arrows A).

4 Install foam section (1) of front seat backrest

AR91.10-P-1120MCU Fig 1: Identifying Seat Heated Cushion Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL HEATED SEATS CONTROL UNIT - AR91.30-P-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3591 · Applies to: 450, 451, 452, 454 · AR: AR91.40-P-0630MCU

0030MCU > MODEL 451.3/4 with CODE (S17) Seat heaters (FFO)

Remove/install 1 Adjust driver seat to the rear 2 Pull front HS [SIH] control unit (N25/5) out of its bracket 3 Install in the reverse order 4 Check proper operation of seat heaters TESTING & REPAIR > REMOVE/INSTALL SEAT BELT WITH EMERGENCY TENSIONING RETRACTOR - AR91.40-P-0630MCU > MODEL 451.3/4 Shown on model on right side of vehicle up to 30.8.10 Fig 1: Locating Front HS Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove seat belt (4) with automatic

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3594 · Applies to: 450, 451, 452, 454 · AR: AR91.40-P-1011MCU

8 Remove seat belt (4) with automatic belt retractor (1) from vehicle (1) is replaced, the faulty automatic belt retractor (1) must be disposed of properly.See: ↓

Notes on disposing of airbag and emergency tensioning retractor units OS91.00- P-0001- 01A 9 Install in the reverse order

10 Check supplemental restraint system using STAR DIAGNOSIS When replacing the automatic belt retractor (1). AD00.00- P-2000- 04MCC SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1002-01G Bolt to upper seat belt guide bracket Nm 30 BA91.40-P-1004-01G Automatic belt retractor bolt Nm 30 TESTING & REPAIR > REMOVE/INSTALL EMERGENCY TENSIONING RETRACTOR - AR91.40-P-1011MCU > MODEL 451.3/4 as of 31.8.10 belt anchor fitting tensioner on driver-side

Remove/install

Risk of injury caused by performing testing or repair work on airbag or Store airbag units with deployment side facing up; do not expose to temperatures AS91.00- Z-0001- Fig 1: Identifying Emergency Tensioning Retractor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removal

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3599 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-1010MCU, AR91.10-P-1020MCU

Risk of injury caused by backrest suddenly folding forward if release lever is accidentally operated during inspection and repair work When working on the seat, be careful not to accidentally release the backrest mechanism allowing the seat to fold forward. Keep body parts clear of the backrest travel area. AS91.00-Z-0005-01V 1.1 Remove driver seat When removing seat belt buckle (1) from driver seat. AR91.10-P-1010MCU 1.2 Remove passenger seat When removing seat belt buckle (1) from front passenger seat. AR91.10-P-1020MCU 2 Expose seat belt buckle wiring harness (4), remove bolt (3) and remove seat belt buckle (1) from backrest frame (2)

AR91.40-P-1515- 01MCU Install

3 Install belt buckle (1)

AR91.40-P-1515- 02MCU

*BA91.10-P-1002-01P

*BA91.40-P-1003-01G 4.1 Install driver seat When installing seat belt buckle (1) on driver seat. AR91.10-P-1010MCU 4.2 Install front passenger seat When installing seat belt buckle (1) on front passenger seat. AR91.10-P-1020MCU FRONT SEATS Fig 1: Identifying Seat Belt Buckle Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Number

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3600 · Applies to: 450, 451, 452, 454 · AR: AR91.45-P-0500MCC

Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1003-01G Screw on seat belt buckle Nm 30 TESTING & REPAIR > REMOVE/INSTALL SEAT BELT GUIDE - AR91.45-P-0500MCC > MODEL 451.3/4 Removal of belt guide is shown with the foam section removed for sake of clarity Removing

1 Move the seat forward

2 Thread seat belt (2) out of belt guide (1)

3 Insert suitable screwdriver (5) from above (arrow A) between belt guide (1) and backrest cover

4 Release spring lock (4) by means of a screwdriver (5) by pressing downward on carrier (3) and fold belt guide (1) outward in direction of arrow (arrow C)

5 Remove screwdriver (5), release belt guide (1) from lower guide (arrow B) of carrier (3) and remove

Fig 1: Identifying Seat Belt Guide Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3601 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0050MCU

6 Insert belt guide (1) into lower guide (arrow B) of carrier (3)

7 Press belt guide (1) in direction of arrow (arrow D) Belt guide (1) must latch audibly in spring lock (4). 8 Thread seat belt (2) into belt guide (1)

9 Move seat back to its default position

TESTING & REPAIR > REMOVE/INSTALL KNEEBAG - AR91.60-P-0050MCU > MODEL 451.3/4 with CODE (294) Kneebag Shown on driver kneebag

Remove/install

Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on avoiding damage to electronic components due to electrostatic discharge

AH54.00- P-0001- 01A Fig 1: Identifying Kneebag Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Notes on performing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3602 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0623MCU

repair, body work and welding on vehicles with airbags and ETR units

AH91.00- P-0002- 01SM Notes on self-locking nuts and bolts

AH00.00- N-0001- 01A Legal requirements on handling and storing airbags and emergency tensioning retractor units

AH91.00- P-0004- 01A 1 Disconnect ground line of battery

AR54.10- P- 0003MCC 2 Remove dashboard lower section (4)

AR68.10- P- 1040MCU 3 Detach electrical connector (2) from kneebag (1) Installation: Make sure that routing of electrical wiring harness (3) is correct.

4 Unclip kneebag (1) from lower section of instrument panel (4) (arrows) The kneebag (1) must not be disassembled as it will then have to be replaced. Installation: If the kneebag (1) is replaced, the defective kneebag (1) has to be disposed of correctly.See: ↓

Notes on disposing of airbag and emergency tensioning retractor units OS91.00- P-0001- 01A 5 Unscrew nuts (6) and remove bracket (5) When replacing the kneebag (1). *BA91.60- P-1011- 01C 6 Install in the reverse order

7 Check supplemental restraint system using STAR DIAGNOSIS When replacing the kneebag (1). AD00.00- P-2000- 04MCC AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1011- 01C Nut, bracket to kneebag Nm 5 5 TESTING & REPAIR > REMOVE/INSTALL AIRBAG, SIDEBAG AND EMERGENCY TENSIONING RETRACTOR CONTROL UNIT - AR91.60-P-0623MCU > MODEL 451.3/4

Install in the reverse order

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3604 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0660MCU

5 Install in the reverse order

6 Read out fault memory and perform "Control unit initial startup" of restraint systems control unit (N2/7) Only perform when installing new restraint systems control unit (N2/7).

Connect STAR DIAGNOSIS and read out fault memory

AD00.00- P-2000- 04MCC AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1002- 01C Bolt, release unit to dashboard carrier Nm 10 10 TESTING & REPAIR > REMOVE/INSTALL AIRBAG UNIT ON THE STEERING WHEEL - AR91.60-P-0660MCU > MODEL 451.3/4

Remove/install

Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units

AH91.00- P-0002- 01SM Legal requirements on handling and storing airbags

AH91.00- P-0004- Fig 1: Identifying Driver Airbag Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

*BA91.60-P-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3611 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0710MCU

1007-01C 13 Remove sidebag unit (11) until electrical connector (10) is accessible

14 Release retainer of electrical connector (10)

15 Disconnect electrical connector (10) and remove sidebag unit (11) If sidebag unit (11) is replaced, the defective sidebag unit (11) must be disposed of properly.Refer to: ↓

Notes on disposing of airbag and emergency tensioning retractor units OS91.00-P- 0001-01A 16 Install in the reverse order

17 Check supplemental restraint system using STAR DIAGNOSIS When replacing sidebag unit (11).

Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P- 2000-04MCC AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1007- 01C Nut, sidebag to backrest Nm 10 10 TESTING & REPAIR > REMOVE/INSTALL SIDEBAG SENSOR - AR91.60-P-0710MCU > MODEL 451.3/4 Fig 4: Identifying Assembly Tool Set (450 589 07 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

DIAGNOSIS

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3613 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0715MCU

thoraxbag sensor (A54). Connect STAR DIAGNOSIS and read out fault memory

AD00.00- P-2000- 04MCC AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1006- 01C Bolt, sensor for head airbag/thoraxbag to body Nm 3 3 PARTS ORDERING NOTES Part no. Designation Quantity A 001 984 42 29 Screw 1 TESTING & REPAIR > REMOVE/INSTALL SEAT POSITION SENSOR - AR91.60-P-0715MCU

MODEL 451.3/4 as of 31.8.10 driver seat Remove/install

Notes on Fig 1: Identifying Seat Position Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BA91.60-P-1009-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3622 · Applies to: 450, 451, 452, 454 · AR: GF91.30-P-0003MCU

01C Screw, windowbag unit to roof frame Nm - BA91.60-P-1010- 01C Bolt, windowbag inflator Nm - BA91.60-P-1011- 01C Nut, bracket to kneebag Nm - BA91.60-P-1012- 01C Screw/bolt, kneebag bracket to crossmember Nm - BASIC KNOWLEDGE > SEAT HEATER (SIH) LOCATION OF COMPONENTS - GF91.30-P- 0003-02MCU > BASIC KNOWLEDGE > SEAT HEATER (SIH), FUNCTION - GF91.30-P-0003MCU > MODEL 451.3/4 with CODE (S17) Seat heaters (FFO) Fig 1: Locating Seat Heater (SIH) Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

At the same time, the heated seats control unit measures the interior temperature (once only) using an

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3624 · Applies to: 450, 451, 452, 454 · AR: PE91.30-P-2000MCU, GF91.30-P-5214MCC, GF54.25-P-4300MCU

integrated temperature sensor. The heated seats control unit energizes the respective heated cushion in heat-up mode at reduced output. The duration of the actuation in heat-up mode depends on the measured interior temperature. Then the heated cushion is actuated in continuous heating mode at 15 % of the maximum output. Because of the lower maximum output at level 1, the heated cushion is actuated for a longer period in heat-up mode compared to level 2. Switch over seat heater The heating level can be changed during the following operating conditions by pressing the heated seat switch: Heat-up mode Continuous heating mode The change is from level 2 to level 1 or from level 1 to level 2 via seat heater "Off" Changing the heating level during heat-up mode If the heated seat switch is pressed during heat-up mode the heated cushion is actuated by the heated seats control unit with the maximum heat output for the selected heating level. After the expiration of the heat-up period that was calculated before the heating level was changed, further actuation takes place in continuous heating mode using the selected heating level. The timer control is not interrupted when the heating level is changed. Changing the heating stage during continuous heating mode With stage 2 activated pressing the heated seat switch interrupts the energizing of the heated cushions for 2 minutes. Then the heated cushions are actuated in continuous heating mode at stage 1 With stage 1 activated pressing the heated seat switch causes the heated cushions to be actuated for 2.5 min in heat-up mode at stage 2. Then the heated cushions are actuated in continuous heating mode at stage 2. Switching off manually Press heated seat switch repeatedly until the integrated light-emitting diodes go out. After circuit 15 off the seat heater is switched off and the status when it was switched off is not saved.

Seat heater (SIH) location of components

GF91.30-P-0003- 02MCU Wiring diagram of seat heater (SIH)

PE91.30-P-2000MCU

Seat heater control unit, component description N25/5 GF91.30-P-5214MCC

Cockpit switch group, component description S6/1 GF54.25-P-4300MCU

BASIC KNOWLEDGE > SEAT HEATER (SIH) FUNCTION DESCRIPTION TABLE OF

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3625 · Applies to: 450, 451, 452, 454 · AR: GF91.30-P-0998MCU, GF91.30-P-0003MCU, PE91.30-P-2000MCU, GF91.30-P-9999MCU, GF91.30-P-5214MCC

CONTENTS - GF91.30-P-0998MCU > MODEL 451.3/4 with CODE (S17) Seat heaters (FFO)

Seat heater (SIH), function GF91.30-P-0003MCU

Seat heater (SIH) location of components GF91.30-P-0003-02MCU Seat heater wiring diagram PE91.30-P-2000MCU

Overview of system components for seat heater (SIH) GF91.30-P-9999MCU BASIC KNOWLEDGE > HEATED SEATS CONTROL UNIT, COMPONENT DESCRIPTION - GF91.30-P-5214MCC > MODEL 451.3/4 with CODE (S17) Heated seats (FFO) Location The heated seats control unit is in the driver footwell above the accelerator pedals. Task The heated seats control unit controls the actuation of the left seat heated cushion (R13/1) and the right seat heated cushion (R13/3). The heat-up time is map-controlled and dependent on the interior temperature and the request from the left seat heater switch (S6/1s3) and the right seat heater switch (S6/1s4). The interior temperature is determined by the heated seats control unit via an integrated sensor. BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS FOR SEAT HEATER (SIH) Fig 1: Locating Front HS (SIH) Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

- GF91.30-P-9999MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3626 · Applies to: 450, 451, 452, 454 · AR: GF91.30-P-9999MCU, GF91.30-P-5214MCC, GF54.25-P-4300MCU, GF91.30-P-0998MCC, GF91.60-P-0002MCU

MODEL 451.3/4 with CODE (S17) Seat heaters (FFO) Seat heater control unit, component description N25/5 GF91.30-P-5214MCC Cockpit switch group, component description S6/1 GF54.25-P-4300MCU Seat heater (SIH) function description table of contents

GF91.30-P-0998MCC BASIC KNOWLEDGE > SUPPLEMENTAL RESTRAINT SYSTEM (SRS), LOCATION OF COMPONENTS - GF91.60-P-0002-01MCU > BASIC KNOWLEDGE > SUPPLEMENTAL RESTRAINT SYSTEM (SRS), FUNCTION - GF91.60-P-0002MCU > MODEL 451.3/4 Fig 1: Locating Supplemental Restraint System (SRS) Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

In the event of an impact, the front interior lamp (E15/4) is automatically switched on. The restraint systems

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3631 · Applies to: 450, 451, 452, 454 · AR: PE91.00-P-2050MCU, PE91.00-P-2000MCU, GF91.60-P-4037MCU, GF91.60-P-4038MCU, GF91.60-P-4058MCC (+5 more)

control unit transmits the crash signal via CAN to the SAM control unit, which directly actuates the interior lamp. The interior lamp is only automatically switched on if the interior lamp switch (E15/4s1) has been pushed towards the rear.

Supplemental restraint system (SRS), location of components

GF91.60-P-0002- 01MCU Electrical function schematic for airbag (AB), emergency tensioning retractor (ETR)

PE91.00-P-2050MCU Wiring diagram of airbag (AB), emergency tensioning retractor (ETR)

PE91.00-P-2000MCU

Driver airbag, component description

GF91.60-P-4037MCU

Front passenger airbag, component description

GF91.60-P-4038MCU

Emergency tensioning retractor, component description

GF91.60-P-4058MCC

Head/thoraxbag, component description

GF91.60-P-4100MCU

Instrument cluster, component description A1 GF54.30-P-6000MCU

Head/thoraxbag sensor, component description A53, A54 GF91.60-P-4102MCU

Frontal acceleration sensor, component description B48/1, B48/2 GF91.60-P-4065MCU

Belt tension sensor, component description B48/3 GF91.60-P-4108MCU

Seat occupied recognition pressure sensor, component description B48/4 GF91.60-P-4067MCU

Interior lamp, component description E15/4 GF82.20-P-5221MCC

Restraint systems control unit, component description N2/7 GF91.60-P-4048MCU

ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MCU

SAM control unit, component description N10/10 GF54.21-P-4157MCU

Weight Sensing System (WSS) control unit, component description N110 GF91.60-P-4069MCU BASIC KNOWLEDGE > TABLE OF CONTENTS: FUNCTION DESCRIPTION OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - GF91.60-P-0999MCU > MODEL 451.3/4

Supplemental restraint system (SRS), function GF91.60-P-0002MCU

Supplemental restraint system (SRS), location of components GF91.60-P-0002- 01MCU

Electrical function diagram for airbag (AB), emergency

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3632 · Applies to: 450, 451, 452, 454 · AR: PE91.00-P-2050MCU, PE91.00-P-2000MCU, GF91.60-P-9998MCU, GF91.60-P-4038MCU

tensioning retractor (ETR) PE91.00-P-2050MCU Wiring diagram of airbag (AB), emergency tensioning retractor (ETR) PE91.00-P-2000MCU

Overview of supplemental restraint system (SRS) system components GF91.60-P-9998MCU BASIC KNOWLEDGE > DRIVER AIRBAG, COMPONENT DESCRIPTION - GF91.60-P- 4037MCU > MODEL 451.3/4 Location The airbag unit and the associated squibs are installed in the steering wheel. Task The driver is protected from injury in the event of a frontal impact by the airbag unit. The two-stage airbag unit is deployed by means of squib ignition by the restraint systems control unit (N2/7). BASIC KNOWLEDGE > FRONT PASSENGER AIRBAG, COMPONENT DESCRIPTION - GF91.60-P-4038MCU > MODEL 451.3/4 Fig 1: Locating Driver Airbag Unit, Driver Airbag Ignition Squib 1 And 2 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Location

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3633 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4048MCU

The airbag unit is located in the dashboard on the passenger side. Task The front passenger is protected from injury in the event of a frontal impact by the airbag unit. The two-stage airbag unit is deployed by means of squib ignition by the restraint systems control unit (N2/7). BASIC KNOWLEDGE > RESTRAINT SYSTEMS CONTROL UNIT, COMPONENT DESCRIPTION - GF91.60-P-4048MCU > MODEL 451.3/4 Location The restraint systems control unit is in the center on the underside of the crossmember beneath the instrument panel. Fig 1: Locating Front Passenger Airbag Unit & Front Passenger Airbag Ignition Squibs Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Restraint Systems Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Left ETR squib (R12/1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3635 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4058MCC

Right ETR squib (R12/2) Passenger airbag squib 1 (R12/4) Passenger airbag squib 2 (R12/5) Driver airbag squib 1 (R12/13) Driver airbag squib 2 (R12/14) Driver head/thoraxbag squib (R12/20) Front passenger head/thoraxbag squib (R12/21) Automatic child seat recognition airbag OFF indicator lamp (E16) BASIC KNOWLEDGE > EMERGENCY TENSIONING RETRACTOR COMPONENT DESCRIPTION - GF91.60-P-4058MCC > MODEL 451.3/4 Location The emergency tensioning retractor is located at the inside of the B-pillar. Task The emergency tensioning retractors take up the seat belt slack in the event of a frontal impact or rear-end collision and prevent the film reel effect of the seat belts. The close-fitting seat belt means that vehicle occupants are subjected to the deceleration forces acting on the body at an earlier stage. Triggering is conducted by the restraint systems control unit (N2/7) igniting the squibs. Fig 1: Locating Emergency Tensioning Retractor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > FRONTAL ACCELERATION SENSOR, COMPONENT

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3636 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4065MCU, GF91.60-P-4067MCU

DESCRIPTION - GF91.60-P-4065MCU > MODEL 451.3/4 Location The frontal acceleration sensors are located at the left and right on the front module. Task The frontal acceleration sensors determine the acceleration value of the vehicle front for the left and right sides of the vehicle. The restraint systems control unit (N2/7) uses these values to decide whether or not the emergency tensioning retractor or airbag units are deployed. BASIC KNOWLEDGE > SEAT OCCUPIED RECOGNITION PRESSURE SENSOR, COMPONENT DESCRIPTION - GF91.60-P-4067MCU > MODEL 451.3/4 Location The seat occupied recognition pressure sensor is fitted to the underside of the front passenger seat. Fig 1: Locating Frontal Acceleration Sensors Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Task

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3637 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4069MCU

The seat occupied recognition pressure sensor determines the weight on the front passenger seat by means of a pressure measurement from a seat mat filled with silicone. The value is used by the Weight Sensing System (WSS) control unit (N110) for determining the occupancy status of the front passenger seat. BASIC KNOWLEDGE > WEIGHT SENSING SYSTEM (WSS) CONTROL UNIT, COMPONENT DESCRIPTION - GF91.60-P-4069MCU > MODEL 451.3/4 Location The WSS control unit is located on the bottom of the front passenger seat. Fig 1: Locating Seat Occupied Recognition Pressure Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Task

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3639 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4102MCU

The head/thoraxbag units protect the driver and the front passenger from injury in the head and thorax areas in the event of a side-on collision. The integrated gas generator is deployed by means of squib ignition by the restraint systems control unit (N2/7). BASIC KNOWLEDGE > HEAD/THORAXBAG SENSOR, COMPONENT DESCRIPTION - GF91.60-P-4102MCU > MODEL 451.3/4 Location The head/thoraxbag sensors are installed in the left and right B-pillars beneath the automatic belt retractors. Fig 1: Locating Head/Thoraxbag Units Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Head/Thoraxbag Sensors Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Task

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3640 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-9998MCU, GF91.60-P-4037MCU, GF91.60-P-4038MCU, GF91.60-P-4058MCC, GF91.60-P-4100MCU

The head/thoraxbag sensors determine the acceleration value in the area of the B-pillar for the left or right side of the vehicle. The restraint systems control unit (N2/7) makes the decision whether to deploy the head/thoraxbags based on these values. After a successful self-test the head/thoraxbag sensors continuously transmit a signal to the restraint systems control unit. BASIC KNOWLEDGE > BELT TENSION SENSOR COMPONENT DESCRIPTION - GF91.60- P-4108MCU > MODEL 451.3/4 Location The belt tension sensor is located at the belt end fitting of the seat belt on the front passenger seat. Task The belt tension sensor measures the tension of the belt. This value is read in by the Weight Sensing System (WSS) control unit (N110) to enable any corrections to be made to the weight classification. BASIC KNOWLEDGE > OVERVIEW OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SYSTEM COMPONENTS - GF91.60-P-9998MCU > MODEL 451.3/4 Driver airbag, component description

GF91.60-P-4037MCU Front passenger airbag, component description

GF91.60-P-4038MCU Emergency tensioning retractor, component description

GF91.60-P-4058MCC Head/thoraxbag, component description

GF91.60-P-4100MCU Fig 1: Locating Belt Tension Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

WIRING DIAGRAMS > WIRING DIAGRAM OF AIRBAG (AB), EMERGENCY TENSIONING

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3653 · Applies to: 450, 451, 452, 454 · AR: PE91.00-P-2000MCU, OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU (+2 more)

RETRACTOR (ETR) - PE91.00-P-2000MCU > MODEL 451 up to 30.8.10 Wiring diagram of seat heater (SIH) PE91.30-P-2000-97MCU Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Further wiring diagrams PE54.00-P-1100MCU WIRING DIAGRAMS > WIRING DIAGRAM OF AIRBAG (AB), EMERGENCY TENSIONING RETRACTOR (ETR) - PE91.00-P-2000MCV > MODEL 451 as of 31.8.10 Wiring diagram of airbag (AB), emergency tensioning retractor (ETR) PE91.00-P-2000-97MCV Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and plug connectors GF00.19-P-1000MCU Fig 5: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (5 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

WIRING DIAGRAMS > WIRING DIAGRAM OF SEAT HEATER (SIH) - PE91.30-P-2000MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3656 · Applies to: 450, 451, 452, 454 · AR: PE91.30-P-2000MCU, OV00.01-P-1901MCU

MODEL 451 / (except 451.391 /491) Wiring diagram of seat heater (SIH) PE91.30-P-2000-97MCU Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Fig 1: Seat Heater (SIH) - Wiring Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Mark position of the bracket (5) on the

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3665 · Applies to: 450, 451, 452, 454 · AR: AP91.40-P-9150MCU

12 Mark position of the bracket (5) on the backrest cover (3) and make a cut out in the backrest cover (3) (arrows A)

13 Fold flaps so made on the backrest cover (3) inwards and pull backrest cover (3) over the bracket (5)

14 Place trim ring (10) on the bracket (5)

15 Push clamp (11) onto the bracket (5) and insert catch spring (12)

16 Insert armrest (1) into the bracket (5) in such a way that the chamfer (arrow B) points to the rear The catch spring (12) must be engaged in the armrest (1) axis.

17 Install driver seat (2) * not for USA AR91.10- P- 1000MCC

• for USA only AR91.10- P- 1010MCU AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1007-01C Nut, sidebag to backrest Nm 10 10 MAINTENANCE > CHECK SEAT BELTS AND SEAT BELT BUCKLES FOR EXTERNAL DAMAGE AND OPERATION - AP91.40-P-9150MCU > MODEL 451.3 /4 Checking

If the customer rejects replacement of a damaged seat belt, a corresponding remark should be made on the repair order

1 Pull belt out all the way and check for any signs of damage In the event of complaints about severed fibers, chafe marks or other damage, replace seat belt subject to separate repair order.

Remove/install seat belt with emergency tensioning retractor AR91.40- P- 0630MCU In the event of complaint, replace seat belt

Inspect lock function of inertia reel by

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3666 · Applies to: 450, 451, 452, 454 · AR: AR91.00-Z-9451CA

2 Inspect lock function of inertia reel by pulling sharply on belt webbing subject to separate repair order.

Remove/install seat belt with emergency tensioning retractor AR91.40- P- 0630MCU 3 Check that seat belt buckle engages correctly In the event of complaint, replace seat belt buckle subject to separate repair order.

Remove/install seat belt buckle (front seat) AR91.40- P- 1515MCU TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: SEATS, BUNKS, RESTRAINT SYSTEMS - AR91.00-Z-9451CA > MODEL 451

Remove and install handle for seat backrest adjustment MODEL 451.3 /4 AR91.10- P- 3470MCC

Remove/install airbag cutout switch MODEL 451.3 /4 AR91.60- P- 0681MCC

Remove/install airbag, sidebag and emergency tensioning retractor control unit MODEL 451.3 /4 AR91.60- P- 0623MCC

Remove/install airbag, sidebag and emergency tensioning retractor control unit MODEL 451.3 /4 AR91.60- P- 0623MCU

Remove/install airbag unit on the steering wheel MODEL 451.3 /4 AR91.60- P- 0660MCC

Remove/install airbag unit on the steering wheel MODEL 451.3 /4 AR91.60- P- 0660MCU

Remove/install cover for backrest at front seat MODEL 451.3 /4 AR91.10- P- 8656MCC

Remove/install cover for backrest at front seat MODEL 451.3 /4 AR91.10- P- 8656MCU

Remove/install driver seat MODEL 451.3 /4 AR91.10- P-

Remove/install seat cushion

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3669 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-1010MCU

MODEL 451.3 /4 3310MCC

Remove/install seat cushion MODEL 451.3 /4 Front passenger seat AR91.10- P- 3310MCU

Remove/install seat cushion cover MODEL 451.3 /4 AR91.10- P- 3312MCC

Remove/install seat cushion cover MODEL 451.3 /4 Driver seat AR91.10- P- 3312MCU

Remove/install seat cushion cover MODEL 451.3 /4 Front passenger seat AR91.10- P- 3312MCV

Remove/install seat cushion frame MODEL 451.3 /4 AR91.10- P- 3334MCC

Remove/install seat cushion frame MODEL 451.3 /4 Driver seat AR91.10- P- 3334MCU

Remove/install seat cushion frame MODEL 451.3 /4 Front passenger seat AR91.10- P- 3334MCV

Remove/install seat position sensor MODEL 451.3 /4 as of 31.8.10 driver seat AR91.60- P- 0715MCU

Remove/install sensor for sidebag/ windowbag MODEL 451.3 with CODE (I52) Head airbag AR91.60- P- 0730MCU

Remove/install sidebag sensor MODEL 451.3 /4 AR91.60- P- 0710MCC

Remove/install sidebag sensor MODEL 451.3 /4 AR91.60- P- 0710MCU

Removing, installing windowbag MODEL 451.3 with CODE (I52) Head airbag AR91.60- P- 0693MCU TESTING & REPAIR > REMOVE/INSTALL DRIVER SEAT - AR91.10-P-1010MCU > MODEL 451.3 /4 Shown on vehicle up to 30.8.10 with code (S17) Seat heater (FFO) and code (C54) Sound system 2

STAR DIAGNOSIS

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3672 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-1020MCU

04MCC FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1001-01P Bolt, seat to floor panel Nm 35 SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1001-01G Screw on belt end fitting Nm 35 TESTING & REPAIR > REMOVE/INSTALL PASSENGER SEAT - AR91.10-P-1020MCU > MODEL 451.3/4 Shown on vehicle with code (S17) seat heater (FFO) Fig 1: Identifying Passenger Seat Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Number

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3675 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-1070MCU, AR91.10-P-1120MCU

De ignation Model 451 3/4 BA91.40-P-1001-01G Screw on belt end fitting Nm 35 TESTING & REPAIR > REMOVE/INSTALL DRIVER SEAT CUSHION - AR91.10-P-1070MCU

MODEL 451.3 /4 Shown on code (S17) Seat heaters (FFO) Remove/install

1 Remove seat cushion cover from driver seat cushion (1) Installation: If the driver seat cushion (1) is replaced in vehicles with code (S17) Seat heater (FFO), a new left heated seat cushion (R13/1) must be installed.See: ↓ AR91.10- P- 3312MCU

Remove/install heated cushion on front seat cushion AR91.30- P- 0005MCU 2 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL FRONT SEAT BACKREST FOAM SECTION - AR91.10-P-1120MCU > MODEL 451.3 /4 Shown on code (S17) Seat heaters (FFO) Fig 1: Identifying Driver Seat Cushion And Left Seat Heated Cushion (With Code (S17) Seat Heaters- FFO) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

sensor retaining plate

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3681 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-3312MCU

10 sensor retaining plate (14) in rear area and remove

11 Fold backrest (8) forward

12 Remove bolts (9) of backrest (8) Installation: Position backrest (8) on seat console (7) and screw in bolts (9, 11) up to contact surface. Tighten bolts (11) starting from the front. Move backrest (8) to its rearmost position and lock in place.Tighten bolts (9) starting from the rear. While doing so, press the backrest (8) backwards.

*BA91.10- P-1002- 01P 13 Lift backrest (8) in vicinity of seat belt buckle (12) and expose seat belt buckle wiring harness (13) from seat console (7) Installation: Ensure that grommet (10) is seated correctly.

14 Remove bolts (11) from backrest (8) and remove backrest (8) The front passenger seat console (7) must not be dismantled any further.

15 Install in the reverse order

FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 TESTING & REPAIR > REMOVE/INSTALL SEAT CUSHION COVER - AR91.10-P-3312MCU

MODEL 451.3/4 Driver seat Shown on code (S17) Seat heaters (FFO)

TESTING & REPAIR > REMOVE/INSTALL SEAT CUSHION COVER - AR91.10-P-3312MCV >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3686 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-3312MCV

MODEL 451.3 / 4 Front passenger seat Shown on code (S17) Seat heaters (FFO) Fig 4: Identifying Padding Clip Pliers (454 589 03 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Seat Cushion Cover Components - Shown On Code (S17) Seat Heaters (FFO) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Attach the clip (11)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3694 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-3334MCU

17 Attach the clip (11) Only if the clip (11) has been installed and when the backrest frame (2) is being removed from the front passenger seat.

18 Clip the belt tension sensor connector (B48/3x1) to the retaining plate (10) When installing front passenger seat backrest frame (2).

19 Install foam part for backrest Before installing the foam part for the backrest, check the installation position (arrows) of the spring frame (7), and correct if necessary. AR91.10- P- 1120MCU 20 Insert grommet (6) into backrest frame (2), position seat belt buckle (1) with wiring harness for seat belt buckle (4) on backrest frame (2) and screw in bolt (5). *BA91.40- P-1003- 01G 21.1 Install driver seat When installing driver seat backrest frame (2). AR91.10- P- 1010MCU 21.2 Install front passenger seat When installing front passenger seat backrest frame (2). AR91.10- P- 1020MCU FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1003-01G Bolt on seat belt buckle Nm 30 TESTING & REPAIR > REMOVE/INSTALL SEAT CUSHION FRAME - AR91.10-P-3334MCU > MODEL 451.3 /4 Driver seat Shown on driver seat with code (S17) Seat heater (FFO)

Remove cable ties

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3696 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-3334MCV

3 Remove cable ties (8) and detach wiring harnesses (2) from holders (3) and expose them The number of wiring harnesses (2) depends on the vehicle equipment.

4 Place driver seat on guide rails

5 Remove driver seat cushion with seat cushion cover Do not remove the seat cushion cover from driver seat cushion. AR91.10- P- 1070MCU 6 Fold backrest (6) forward

7 Remove bolts (5) of backrest (6) Installation: Position backrest (6) on seat- cushion frame (4) and turn bolts (5) all the way in. Tighten the bolts (5) opposite the seat belt buckle, starting at the front. Move backrest (6) to its rearmost position and lock in place. Tighten bolts (5) in area of seat belt buckle, starting from rear. While doing so, press the backrest (6) backwards.

*BA91.10- P-1002- 01P 8 Remove backrest (6)

9 Remove bracket (3) on seat-cushion frame (4) When replacing seat-cushion frame (4).

10 Remove edge guards (7) on seat- cushion frame (4) When replacing seat-cushion frame (4).

11 Install in the reverse order

FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 TESTING & REPAIR > REMOVE/INSTALL SEAT CUSHION FRAME - AR91.10-P-3334MCV > MODEL 451.3/4 Front passenger seat

(14) in rear area and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3699 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-3470MCC

10 (14) in rear area and remove

11 Fold backrest (8) forward

12 Remove bolts (9) of backrest (8) Installation: Position backrest (8) on seat- cushion frame (7) and turn bolts (9, 11) all the way in. Tighten bolts (11), starting from the front. Move backrest (8) to its rearmost position and lock in place. Tighten bolts (9), starting from the rear. While doing so, press the backrest (8) backwards.

*BA91.10- P-1002- 01P 13 Raise backrest (8) in area of seat belt buckle (12) and expose wiring harness for seat belt buckle (13) Installation: Ensure that grommet (10) is seated correctly.

14 Remove bolts (11) from backrest (8) and remove backrest (8) The front passenger seat-cushion frame (7) may not be dismantled any further.

15 Install in the reverse order

FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 TESTING & REPAIR > REMOVE AND INSTALL HANDLE FOR SEAT BACKREST ADJUSTMENT - AR91.10-P-3470MCC > MODEL 451.3/4

5. Make cuts (5, 6) at cover (1) of backrest starting from above.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3702 · Applies to: 450, 451, 452, 454 · AR: AR91.10-P-8656MCU

The cuts (5, 6) must not be longer than the dimension specified in each case, as they will otherwise no longer be covered by the belt guide and the cover (1) must be replaced. TESTING & REPAIR > REMOVE/INSTALL COVER FOR BACKREST AT FRONT SEAT - AR91.10-P-8656MCU > MODEL 451.3 /4 Shown on code (S17) Seat heaters (FFO) Fig 1: Identifying Backrest Cover, Closing Strip And Rail Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

upwards

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3706 · Applies to: 450, 451, 452, 454 · AR: AR91.30-P-0005MCU

3 Pull out armrest (1) from the bracket (5)

4 Remove trim ring (3) and clamp (4)

Install

5 Place trim ring (3) on the bracket (5)

6 Push clamp (4) onto the bracket (5) and insert catch spring (2)

7 Insert armrest (1) into the bracket (5) in such a way that the chamfer (arrow B) points to the rear The catch spring (2) must be engaged in the armrest (1) axis. TESTING & REPAIR > REMOVE/INSTALL HEATED CUSHION ON FRONT SEAT CUSHION - AR91.30-P-0005MCU > MODEL 451.3 /4 with CODE (S17) Seat heater (FFO) driver seat Removing

1 Remove driver seat cushion (1) The driver seat cushion (1) and the left heated seat cushion (R13/1) cannot be re-used and must be replaced. AR91.10- P- 1070MCU Fig 1: Identifying Heated Seat Cushion Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3707 · Applies to: 450, 451, 452, 454 · AR: AR91.30-P-0005MCV

2 Align left heated seat cushion (R13/1) on driver seat cushion (1) as shown The cutouts (arrows A, B) on the left heated seat cushion (R13/1) must be above the attachment points (arrows C, D) for the seat cushion cover.

3 Remove the adhesive strips in the bonding areas (E, F) one after the other and glue the left heated seat cushion (R13/1) starting at the front onto the driver seat cushion (1)

4 Position areas (arrows B) of left heated seat cushion (R13/1) in recesses (arrows D) on driver seat cushion (1) If the left heated seat cushion (R13/1) is not fully inserted into the recesses (arrows D), the seat cushion cover may not be able to be fitted properly.

5 Remove the adhesive strips in the bonding areas (G, H) one after the other and glue the left heated seat cushion (R13/1) starting at the front onto the driver seat cushion (1)

6 Position areas (arrows A) of left heated seat cushion (R13/1) in recesses (arrows C) on driver seat cushion (1) If the left heated seat cushion (R13/1) is not fully inserted into the recesses (arrows C), the seat cushion cover may not be able to be fitted properly.

7 Remove the adhesive strips in the bonding areas (J, K) one after the other and glue the left heated seat cushion (R13/1) starting at the front onto the driver seat cushion (1)

8 Route wiring harness for seat heater (2) into cutout (arrow L) on driver seat cushion (1)

9 Install driver seat cushion (1)

AR91.10- P- 1070MCU TESTING & REPAIR > REMOVE/INSTALL HEATED CUSHION ON FRONT SEAT CUSHION - AR91.30-P-0005MCV > MODEL 451.3 /4 Front passenger seat Shown on code (S17) Seat heaters (FFO)

Unclip belt tension

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3710 · Applies to: 450, 451, 452, 454 · AR: AR91.30-P-0006MCU

10 Unclip belt tension sensor retaining plate (14) in rear area and remove

11 Fold backrest (8) forward

12 Remove bolts (9) of backrest (8) Installation: Position backrest (8) on seat console (7) and screw in bolts (9, 11) up to contact surface. Tighten bolts (11) starting from the front. Move backrest (8) to its rearmost position and lock in place.Tighten bolts (9) starting from the rear. While doing so, press the backrest (8) backwards.

*BA91.10- P-1002- 01P 13 Lift backrest (8) in vicinity of seat belt buckle (12) and expose seat belt buckle wiring harness (13) from seat console (7) Installation: Ensure that grommet (10) is seated correctly.

14 Remove bolts (11) from backrest (8) and remove backrest (8) The front passenger seat console (7) must not be dismantled any further.

15 Install in the reverse order

FRONT SEATS Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 TESTING & REPAIR > REMOVE/INSTALL HEATED CUSHION AT FRONT SEAT BACKREST - AR91.30-P-0006MCU > MODEL 451.3 /4 with CODE (S17) Seat heaters (FFO)

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3712 · Applies to: 450, 451, 452, 454 · AR: AR91.40-P-0630MCU

1 Adjust driver seat to the rear 2 Pull front HS [SIH] control unit (N25/5) out of its bracket 3 Install in the reverse order 4 Check proper operation of seat heaters TESTING & REPAIR > REMOVE/INSTALL SEAT BELT WITH EMERGENCY TENSIONING RETRACTOR - AR91.40-P-0630MCU > MODEL 451.3 /4 Shown on model on right side of vehicle up to 30.8.10 Fig 1: Identifying Front HS (SIH) Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove seat belt (4) with automatic

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3715 · Applies to: 450, 451, 452, 454 · AR: AR91.40-P-1011MCU

8 Remove seat belt (4) with automatic belt retractor (1) from vehicle (1) is replaced, the faulty automatic belt retractor (1) must be disposed of properly.See: ↓

Notes on disposing of airbag and emergency tensioning retractor units OS91.00- P-0001- 01A 9 Install in the reverse order

10 Check supplemental restraint system using STAR DIAGNOSIS When replacing the automatic belt retractor (1). AD00.00- P-2000- 04MCC SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1002-01G Bolt to upper seat belt guide bracket Nm 30 BA91.40-P-1004-01G Automatic belt retractor bolt Nm 30 TESTING & REPAIR > REMOVE/INSTALL EMERGENCY TENSIONING RETRACTOR - AR91.40-P-1011MCU > MODEL 451.3 /4 as of 31.8.10 belt anchor fitting tensioner on driver-side

Remove/install

Risk of injury caused by performing testing or repair Store airbag units with deployment side AS91.00- Fig 1: Identifying Emergency Tensioning Retractor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

FRONT SEATS

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3721 · Applies to: 450, 451, 452, 454 · AR: AR91.45-P-0500MCC

Number Designation Model 451.3/4 BA91.10-P-1002-01P Bolt of backrest frame to seat frame Nm 45 SEAT BELTS/EMERGENCY TENSIONING RETRACTORS Number Designation Model 451.3/4 BA91.40-P-1003-01G Screw on seat belt buckle Nm 30 TESTING & REPAIR > REMOVE/INSTALL SEAT BELT GUIDE - AR91.45-P-0500MCC > MODEL 451.3/4 Removal of belt guide is shown with the foam section removed for sake of clarity Removing

1 Move the seat forward

2 Thread seat belt (2) out of belt guide (1)

3 Insert suitable screwdriver (5) from above (arrow A) between belt guide (1) and backrest cover

4 Release spring lock (4) by

Fig 1: Identifying Seat Belt Guide Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install in the reverse order

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3723 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0623MCU

3 Install in the reverse order 4 Check proper operation of seat heaters TESTING & REPAIR > REMOVE/INSTALL AIRBAG, SIDEBAG AND EMERGENCY TENSIONING RETRACTOR CONTROL UNIT - AR91.60-P-0623MCU > MODEL 451.3 /4 MODIFICATION NOTES 25.8.08 Value modified: Bolt, release unit to dashboard carrier *BA91.60-P-1002-01C

Remove/install

Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units

AH91.00- P-0002- 01SM Notes on avoiding damage to electronic components due to electrostatic discharge

AH54.00- P-0001- 01A 1 Disconnect ground line of battery

AR54.10- P- 0003MCC 2 Remove vertical strut paneling

AR68.00- P- 1500MCC 3 Disconnect electrical connectors (1) from restraint systems control unit (N2/7)

Fig 1: Identifying Restraint System Control Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove bolts (2) and remove

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3724 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0660MCU

4 Remove bolts (2) and remove restraint systems control unit (N2/7) Installation: Tighten the bolts (2) by following the tightening sequence (a, b, c).

*BA91.60- P-1002- 01C 5 Install in the reverse order

6 Read out fault memory and perform "Control unit initial startup" of restraint systems control unit (N2/7) Only perform when installing new restraint systems control unit (N2/7).

Connect STAR DIAGNOSIS and read out fault memory

AD00.00- P-2000- 04MCC AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1002- 01C Bolt, release unit to dashboard carrier Nm 10 10 TESTING & REPAIR > REMOVE/INSTALL AIRBAG UNIT ON THE STEERING WHEEL - AR91.60-P-0660MCU > MODEL 451.3 /4

Remove/install

Risk of injury caused by performing testing or repair work on airbag or emergency tensioning Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these AS91.00- Z-0001- 01A Fig 1: Identifying Airbag Unit On Steering Wheel Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

instrument panel mounting

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3728 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0693MCU

01C instrument panel mounting BA91.60-P-1004- 01C Nut, front passenger airbag unit to instrument panel Nm 2 2 TESTING & REPAIR > REMOVING, INSTALLING WINDOWBAG - AR91.60-P-0693MCU > MODEL 451.3 with CODE (I52) Head airbag Shown on LH side

Remove/install

Risk of injury caused by performing testing or repair work on airbag or emergency tensioning retractor units. Store airbag units with deployment side facing up; do not expose to temperatures greater than 100°C. When working on these units, disconnect the power supply. AS91.00- Z-0001- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units

AH91.00- P-0002- 01SM Note on function reliability of windowbag

AH91.60- P-0693- 01B Fig 1: Identifying Windowbag Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

until electrical connector

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3734 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0710MCU

13 until electrical connector (10) is accessible

14 Release retainer of electrical connector (10)

15 Disconnect electrical connector (10) and remove sidebag unit (11) If sidebag unit (11) is replaced, the defective sidebag unit (11) must be disposed of properly.Refer to: ↓

Notes on disposing of airbag and emergency tensioning retractor units OS91.00- P-0001- 01A 16 Install in the reverse order

17 Check supplemental restraint system using STAR DIAGNOSIS When replacing sidebag unit (11).

Connect STAR DIAGNOSIS and read out fault memory

AD00.00- P-2000- 04MCC AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1007- 01C Nut, sidebag to backrest Nm 10 10 TESTING & REPAIR > REMOVE/INSTALL SIDEBAG SENSOR - AR91.60-P-0710MCU > MODEL 451.3 /4 Fig 4: Identifying Assembly Tool Set (450 589 07 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

DIAGNOSIS

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3736 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0715MCU

head/thoraxbag sensor (A54). Connect STAR DIAGNOSIS and read out fault memory

AD00.00- P-2000- 04MCC AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1006- 01C Bolt, sensor for head airbag/thoraxbag to body Nm 3 3 PARTS ORDERING NOTES Part no. Designation Quantity A 001 984 42 29 Screw 1 TESTING & REPAIR > REMOVE/INSTALL SEAT POSITION SENSOR - AR91.60-P-0715MCU

MODEL 451.3 /4 as of 31.8.10 driver seat Remove/install

Notes on Fig 1: Identifying Seat Position Sensor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

avoiding damage

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3737 · Applies to: 450, 451, 452, 454 · AR: AR91.60-P-0730MCU

to electronic components due to electrostatic discharge

AH54.00- P-0001- 01A 1 Remove driver seat

AR91.10- P- 1010MCU 2 Place driver seat (1) onto suitable base

3 Detach driver seat adjustment detection sensor connector (X28/10) from seat cushion frame Release shackle (arrow A) of driver seat adjustment detection sensor connector (X28/10).

4 Expose electrical wiring harness (2) of driver seat adjustment detection sensor (B3)

5 Remove bolt (3) from driver seat adjustment detection sensor (B3)

6 Remove driver seat adjustment detection sensor (B3) from seat rail (4) Use suitable tool to pry pin (arrow B) of driver seat adjustment detection sensor (B3) out of seat rail (4), then lift up tab of driver seat adjustment detection sensor (B3) towards arrow and remove driver seat adjustment detection sensor (B3) from seat rail (4). Installation: Check pin (arrow B) and collar (arrow C) are correctly seated in seat rail (4).

7 Install in the reverse order

8 Check driver seat adjustment detection sensor (B3) with Star Diagnosis When replacing driver seat adjustment detection sensor (B3). AD00.00- P-2000- 04MCC TESTING & REPAIR > REMOVE/INSTALL SENSOR FOR SIDEBAG/WINDOWBAG - AR91.60-P-0730MCU > MODEL 451.3 with CODE (I52) Head airbag

BASIC KNOWLEDGE > SEAT HEATER (SIH), FUNCTION - GF91.30-P-0003MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3746 · Applies to: 450, 451, 452, 454 · AR: GF91.30-P-0003MCU

MODEL 451.3 /4 with CODE (S17) Seat heaters (FFO) General information With the integrated seat heater, it is possible to heat the seat cushions and backrests in two heating stages. The heated cushions are heated until they reach the defined maximum temperature. The maximum energizing time depends on the interior temperature. At level 2, the energizing takes place with a higher heat output than at level 1. The maximum temperature is therefore reached more quickly at level 2. The function status is indicated by two light-emitting diodes that are integrated in the heated seat switches. Fig 1: Locating Seat Heater (SIH) Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Seat Heater (SIH) Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Changing the heating stage during continuous heating mode

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3748 · Applies to: 450, 451, 452, 454 · AR: PE91.30-P-2000MCU, GF91.30-P-5214MCC, GF54.25-P-4300MCU, GF91.30-P-0998MCU, GF91.30-P-0003MCU (+1 more)

With stage 2 activated pressing the heated seat switch interrupts the energizing of the heated cushions for 2 minutes. Then the heated cushions are actuated in continuous heating mode at stage 1 With stage 1 activated pressing the heated seat switch causes the heated cushions to be actuated for 2.5 min in heat-up mode at stage 2. Then the heated cushions are actuated in continuous heating mode at stage 2. Switching off manually Press heated seat switch repeatedly until the integrated light-emitting diodes go out. After circuit 15 off the seat heater is switched off and the status when it was switched off is not saved.

Seat heater (SIH) location of components

GF91.30-P-0003-02MCU Wiring diagram of seat heater (SIH)

PE91.30-P-2000MCU

Seat heater control unit, component description N25/5 GF91.30-P-5214MCC

Cockpit switch group, component description S6/1 GF54.25-P-4300MCU BASIC KNOWLEDGE > SEAT HEATER (SIH) FUNCTION DESCRIPTION TABLE OF CONTENTS - GF91.30-P-0998MCU > MODEL 451.3 /4 with CODE (S17) Seat heaters (FFO)

Seat heater (SIH), function GF91.30-P-0003MCU

Seat heater (SIH) location of components GF91.30-P-0003-02MCU Seat heater wiring diagram PE91.30-P-2000MCU

Overview of system components for seat heater (SIH) GF91.30-P-9999MCU BASIC KNOWLEDGE > HEATED SEATS CONTROL UNIT, COMPONENT DESCRIPTION - GF91.30-P-5214MCC > MODEL 451.3 /4 with CODE (S17) Heated seats (FFO) Location The heated seats control unit is in the driver footwell above the accelerator pedals.

Task

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3749 · Applies to: 450, 451, 452, 454 · AR: GF91.30-P-9999MCU, GF91.30-P-5214MCC, GF54.25-P-4300MCU, GF91.30-P-0998MCC

The heated seats control unit controls the actuation of the left seat heated cushion (R13/1) and the right seat heated cushion (R13/3). The heat-up time is map-controlled and dependent on the interior temperature and the request from the left seat heater switch (S6/1s3) and the right seat heater switch (S6/1s4). The interior temperature is determined by the heated seats control unit via an integrated sensor. BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS FOR SEAT HEATER (SIH) - GF91.30-P-9999MCU > MODEL 451.3 /4 with CODE (S17) Seat heaters (FFO) Seat heater control unit, component description N25/5 GF91.30-P-5214MCC Cockpit switch group, component description S6/1 GF54.25-P-4300MCU Seat heater (SIH) function description table of contents

GF91.30-P-0998MCC BASIC KNOWLEDGE > SUPPLEMENTAL RESTRAINT SYSTEM (SRS), LOCATION OF COMPONENTS - GF91.60-P-0002-01MCU > Fig 1: Locating Front HS (SIH) Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > SUPPLEMENTAL RESTRAINT SYSTEM (SRS), FUNCTION -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3750 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-0002MCU

GF91.60-P-0002MCU > MODEL 451.3 /4 Fig 1: Locating Supplemental Restraint System (SRS) Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

In the event of an impact, the front interior lamp (E15/4) is automatically switched on. The restraint systems

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3755 · Applies to: 450, 451, 452, 454 · AR: PE91.00-P-2050MCU, PE91.00-P-2000MCU, GF91.60-P-4037MCU, GF91.60-P-4038MCU, GF91.60-P-4058MCC (+5 more)

control unit transmits the crash signal via CAN to the SAM control unit, which directly actuates the interior lamp. The interior lamp is only automatically switched on if the interior lamp switch (E15/4s1) has been pushed towards the rear.

Supplemental restraint system (SRS), location of components

GF91.60-P-0002- 01MCU Electrical function schematic for airbag (AB), emergency tensioning retractor (ETR)

PE91.00-P-2050MCU Wiring diagram of airbag (AB), emergency tensioning retractor (ETR)

PE91.00-P-2000MCU

Driver airbag, component description

GF91.60-P-4037MCU

Front passenger airbag, component description

GF91.60-P-4038MCU

Emergency tensioning retractor, component description

GF91.60-P-4058MCC

Head/thoraxbag, component description

GF91.60-P-4100MCU

Instrument cluster, component description A1 GF54.30-P-6000MCU

Head/thoraxbag sensor, component description A53, A54 GF91.60-P-4102MCU

Frontal acceleration sensor, component description B48/1, B48/2 GF91.60-P-4065MCU

Belt tension sensor, component description B48/3 GF91.60-P-4108MCU

Seat occupied recognition pressure sensor, component description B48/4 GF91.60-P-4067MCU

Interior lamp, component description E15/4 GF82.20-P-5221MCC

Restraint systems control unit, component description N2/7 GF91.60-P-4048MCU

ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MCU

SAM control unit, component description N10/10 GF54.21-P-4157MCU

Weight Sensing System (WSS) control unit, component description N110 GF91.60-P-4069MCU

BASIC KNOWLEDGE > TABLE OF CONTENTS: FUNCTION DESCRIPTION OF

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3756 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-0999MCU, GF91.60-P-0002MCU, PE91.00-P-2050MCU, PE91.00-P-2000MCU, GF91.60-P-9998MCU (+1 more)

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) - GF91.60-P-0999MCU > MODEL 451.3 /4

Supplemental restraint system (SRS), function GF91.60-P-0002MCU

Supplemental restraint system (SRS), location of components GF91.60-P-0002-01MCU Electrical function diagram for airbag (AB), emergency tensioning retractor (ETR) PE91.00-P-2050MCU Wiring diagram of airbag (AB), emergency tensioning retractor (ETR) PE91.00-P-2000MCU

Overview of supplemental restraint system (SRS) system components GF91.60-P-9998MCU BASIC KNOWLEDGE > DRIVER AIRBAG, COMPONENT DESCRIPTION - GF91.60-P- 4037MCU > MODEL 451.3 /4 Location The airbag unit and the associated squibs are installed in the steering wheel. Task The driver is protected from injury in the event of a frontal impact by the airbag unit. The two-stage airbag unit is deployed by means of squib ignition by the restraint systems control unit (N2/7). BASIC KNOWLEDGE > FRONT PASSENGER AIRBAG, COMPONENT DESCRIPTION - GF91.60-P-4038MCU > MODEL 451.3 /4 Fig 1: Identifying Driver Airbag Unit, Driver Airbag Ignition Squib 1 And 2 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Location

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3757 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4048MCU

The airbag unit is located in the dashboard on the passenger side. Task The front passenger is protected from injury in the event of a frontal impact by the airbag unit. The two-stage airbag unit is deployed by means of squib ignition by the restraint systems control unit (N2/7). BASIC KNOWLEDGE > RESTRAINT SYSTEMS CONTROL UNIT, COMPONENT DESCRIPTION - GF91.60-P-4048MCU > MODEL 451.3 /4 Location The restraint systems control unit is in the center on the underside of the crossmember beneath the instrument panel. Fig 1: Identifying Front Passenger Airbag Unit, Front Passenger Airbag Ignition Squib 1 And 2 Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Restraint Systems Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Left ETR squib (R12/1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3759 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4058MCC

Right ETR squib (R12/2) Passenger airbag squib 1 (R12/4) Passenger airbag squib 2 (R12/5) Driver airbag squib 1 (R12/13) Driver airbag squib 2 (R12/14) Driver head/thoraxbag squib (R12/20) Front passenger head/thoraxbag squib (R12/21) Automatic child seat recognition airbag OFF indicator lamp (E16) BASIC KNOWLEDGE > EMERGENCY TENSIONING RETRACTOR COMPONENT DESCRIPTION - GF91.60-P-4058MCC > MODEL 451.3 /4 Location The emergency tensioning retractor is located at the inside of the B-pillar. Task The emergency tensioning retractors take up the seat belt slack in the event of a frontal impact or rear-end collision and prevent the film reel effect of the seat belts. The close-fitting seat belt means that vehicle occupants are subjected to the deceleration forces acting on the body at an earlier stage. Triggering is conducted by the restraint systems control unit (N2/7) igniting the squibs. Fig 1: Identifying Emergency Tensioning Retractor, Driver GUS Squid And Front Passenger GUS Squib Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > FRONTAL ACCELERATION SENSOR, COMPONENT

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3760 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4065MCU, GF91.60-P-4067MCU

DESCRIPTION - GF91.60-P-4065MCU > MODEL 451.3 /4 Location The frontal acceleration sensors are located at the left and right on the front module. Task The frontal acceleration sensors determine the acceleration value of the vehicle front for the left and right sides of the vehicle. The restraint systems control unit (N2/7) uses these values to decide whether or not the emergency tensioning retractor or airbag units are deployed. BASIC KNOWLEDGE > SEAT OCCUPIED RECOGNITION PRESSURE SENSOR, COMPONENT DESCRIPTION - GF91.60-P-4067MCU > MODEL 451.3 /4 Location The seat occupied recognition pressure sensor is fitted to the underside of the front passenger seat. Fig 1: Identifying Driver-Side And Passenger-Side Frontal Acceleration Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Task

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3761 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4069MCU

The seat occupied recognition pressure sensor determines the weight on the front passenger seat by means of a pressure measurement from a seat mat filled with silicone. The value is used by the Weight Sensing System (WSS) control unit (N110) for determining the occupancy status of the front passenger seat. BASIC KNOWLEDGE > WEIGHT SENSING SYSTEM (WSS) CONTROL UNIT, COMPONENT DESCRIPTION - GF91.60-P-4069MCU > MODEL 451.3 /4 Location The WSS control unit is located on the bottom of the front passenger seat. Fig 1: Locating Seat Occupied Recognition Pressure Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Task

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3763 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4102MCU

The head/thoraxbag units protect the driver and the front passenger from injury in the head and thorax areas in the event of a side-on collision. The integrated gas generator is deployed by means of squib ignition by the restraint systems control unit (N2/7). BASIC KNOWLEDGE > HEAD/THORAXBAG SENSOR, COMPONENT DESCRIPTION - GF91.60-P-4102MCU > MODEL 451.3 /4 Location The head/thoraxbag sensors are installed in the left and right B-pillars beneath the automatic belt retractors. Fig 1: Identifying Head/Thoraxbag Unit, Driver And Front Passenger Head/Thoraxbag Squib Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Driver And Front Passenger Head/Thoraxbag Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Task

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3764 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-9998MCU, GF91.60-P-4037MCU, GF91.60-P-4038MCU, GF91.60-P-4058MCC

The head/thoraxbag sensors determine the acceleration value in the area of the B-pillar for the left or right side of the vehicle. The restraint systems control unit (N2/7) makes the decision whether to deploy the head/thoraxbags based on these values. After a successful self-test the head/thoraxbag sensors continuously transmit a signal to the restraint systems control unit. BASIC KNOWLEDGE > BELT TENSION SENSOR COMPONENT DESCRIPTION - GF91.60- P-4108MCU > MODEL 451.3 /4 Location The belt tension sensor is located at the belt end fitting of the seat belt on the front passenger seat. Task The belt tension sensor measures the tension of the belt. This value is read in by the Weight Sensing System (WSS) control unit (N110) to enable any corrections to be made to the weight classification. BASIC KNOWLEDGE > OVERVIEW OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SYSTEM COMPONENTS - GF91.60-P-9998MCU > MODEL 451.3 /4 Driver airbag, component description

GF91.60-P-4037MCU Front passenger airbag, component description

GF91.60-P-4038MCU Emergency tensioning retractor, component description

GF91.60-P-4058MCC Fig 1: Locating Belt Tension Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Head/thoraxbag, component description

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3765 · Applies to: 450, 451, 452, 454 · AR: GF91.60-P-4100MCU, GF54.30-P-6000MCU, GF91.60-P-4102MCU, GF91.60-P-4065MCU, GF91.60-P-4108MCU (+5 more)

GF91.60-P-4100MCU Instrument cluster, component description A1 GF54.30-P-6000MCU Head/thoraxbag sensor, component description A53, A54 GF91.60-P-4102MCU Frontal acceleration sensor, component description B48/1, B48/2 GF91.60-P-4065MCU Belt tension sensor, component description B48/3 GF91.60-P-4108MCU Seat occupied recognition pressure sensor, component description B48/4 GF91.60-P-4067MCU Interior lamp, component description E15/4 GF82.20-P-5221MCC Restraint systems control unit, component description N2/7 GF91.60-P-4048MCU ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MCU SAM control unit, component description N10/10 GF54.21-P-4157MCU Weight Sensing System (WSS) control unit, component description N110 GF91.60-P-4069MCU Table of contents: Function description of supplemental restraint system (SRS)

GF91.60-P-0999MCU MISCELLANEOUS NOTES > NOTES ON DISPOSING OF AIRBAG AND EMERGENCY TENSIONING RETRACTOR UNITS - OS91.00-P-0001-01A > All models In the Federal Republic of Germany, the airbag and emergency tensioning retractor units must be rendered unusable according to the accident prevention and safety regulations and the EU Directive on End-of-life Vehicles.

Airbag and emergency tensioning retractor units must be forwarded in their original packaging, via the familiar MeRSy disposal channel (Renz), for proper and environmentally-friendly scrapping. In all countries except national regulations governing proper disposal need to be complied with. These safety precautions are necessary because pyrotechnic devices can inflict injuries when activated improperly. WIRING DIAGRAMS > OVERVIEW OF WIRING DIAGRAMS FOR SEATS, BUNKS, RESTRAINT SYSTEMS - PE91.00-P-1100MCU > MODEL 451 PE91.00-P- 2000MCU Wiring diagram of airbag (AB), emergency tensioning retractor (ETR) MODEL 451 to 30.8.10 PE91.00-P-2000MCU

PE91.00-P-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3766 · Applies to: 450, 451, 452, 454 · AR: PE91.00-P-2000MCV, PE91.00-P-2050MCU, PE91.30-P-2000MCU, PE91.00-P-2000MCU

2000MCV Wiring diagram of airbag (AB), emergency tensioning retractor (ETR) MODEL 451 as of 31.8.10 PE91.00-P-2000MCV PE91.00-P- 2050MCU Electrical function schematic for airbag (AB), emergency tensioning retractor (ETR) MODEL 451 PE91.00-P-2050MCU PE91.30-P- 2000MCU Wiring diagram of seat heater (SIH) MODEL 451 except 451.391 /491 PE91.30-P-2000MCU WIRING DIAGRAMS > WIRING DIAGRAM OF AIRBAG (AB), EMERGENCY TENSIONING RETRACTOR (ETR) - PE91.00-P-2000MCU > MODEL 451 up to 30.8.10 PE91.00-P- 2000-97MCU Wiring diagram of airbag (AB), emergency tensioning retractor (ETR)

PE91.00-P- 2000-97MCU OV00.01-P- 1901-03MCC Use of wiring diagrams

OV00.01-P- 1901-03MCC OV00.01-P- 1901MCU Search aid for all wiring diagram groups

OV00.01-P- 1901MCU OV00.01-P- 1001-27MC Abbreviations for wiring diagrams

OV00.01-P- 1001-27MC OV00.01-P- 1001-28MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P- 1001-28MC GF00.19-P- 1000MCU Location and assignment of line and connectors

GF00.19-P- 1000MCU GF00.19-P- 2000MCU Location and assignment of ground points

GF00.19-P- 2000MCU GF00.19-P- 3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)

GF00.19-P- 3000MCU PE54.00-P- 1100MCU

Further wiring diagrams PE54.00-P- 1100MCU WIRING DIAGRAMS > WIRING DIAGRAM OF AIRBAG (AB), EMERGENCY TENSIONING RETRACTOR (ETR) - PE91.00-P-2000-97MCU > Code: Designation: Position: A1 Instrument cluster 35L A45 Fanfare horns and airbag clock spring contact 18H A45x1 Clock spring contact and airbag connector

A53 Driver head/thorax sensor 14L A54 Front passenger head/thorax sensor 10L

WIRING DIAGRAMS > WIRING DIAGRAM OF AIRBAG (AB), EMERGENCY TENSIONING

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3771 · Applies to: 450, 451, 452, 454 · AR: PE91.00-P-2000MCV

RETRACTOR (ETR) - PE91.00-P-2000MCV > MODEL 451 as of 31.8.10 PE91.00-P- 2000-97MCV Wiring diagram of airbag (AB), emergency tensioning retractor (ETR)

PE91.00-P- 2000-97MCV OV00.01-P- 1901-03MCC Use of wiring diagrams

OV00.01-P- 1901-03MCC Fig 3: Airbag (AB), Emergency Tensioning Retractor (ETR) - Wiring Diagram (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

R12/13

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3780 · Applies to: 450, 451, 452, 454 · AR: PE91.00-P-2050MCU

Driver airbag ignition squib 1 13H R12/14 Driver airbag ignition squib 2 13J R12/20 Driver head/thoraxbag squib 9J R12/21 Front passenger head/thoraxbag squib 9J S68/3 Driver seat belt buckle restraint systems switch 10E S68/4 Front passenger seat belt buckle restraint systems switch 10E X11/4 Data link connector 12C WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR AIRBAG (AB), EMERGENCY TENSIONING RETRACTOR (ETR) - PE91.00-P-2050MCU > MODEL 451 PE91.00-P- 2050-99MCU Electrical function diagram for airbag (AB), emergency tensioning retractor (ETR)

PE91.00-P- 2050- 99MCU PE91.00-P- 2050-60MCU Legend of electrical function diagram for airbag (AB), emergency tensioning retractor (ETR)

PE91.00-P- 2050- 60MCU OV00.01-P- 1901- 03MCC Use of wiring diagrams

OV00.01-P- 1901-03MCC OV00.01-P- 1901MCU Search aid for all wiring diagram groups

OV00.01-P- 1901MCU OV00.01-P- 1001-27MC Abbreviations for wiring diagrams

OV00.01-P- 1001-27MC OV00.01-P- 1001-28MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P- 1001-28MC GF00.19-P- 1000MCU Location and assignment of line and connectors

GF00.19-P- 1000MCU GF00.19-P- 2000MCU Location and assignment of ground points

GF00.19-P- 2000MCU GF00.19-P- 3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)

GF00.19-P- 3000MCU PE07.00-P- 1100MCU

Further wiring diagrams PE07.00-P- 1100MCU PE42.00-P- 1100MCU

Further wiring diagrams PE42.00-P- 1100MCU PE54.00-P- 1100MCU

Further wiring diagrams PE54.00-P- 1100MCU

WIRING DIAGRAMS > WIRING DIAGRAM OF SEAT HEATER (SIH) - PE91.30-P-2000MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3783 · Applies to: 450, 451, 452, 454 · AR: PE91.30-P-2000MCU

MODEL 451 / (except 451.391 /491) PE91.30-P- 2000-97MCU Wiring diagram of seat heater (SIH)

PE91.30-P- 2000-97MCU OV00.01-P- 1901-03MCC Use of wiring diagrams

OV00.01-P- 1901-03MCC OV00.01-P- 1901MCU Search aid for all wiring diagram groups

OV00.01-P- 1901MCU OV00.01-P- 1001-27MC Abbreviations for wiring diagrams

OV00.01-P- 1001-27MC OV00.01-P- 1001-28MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P- 1001-28MC GF00.19-P- 1000MCU Location and assignment of line and connectors

GF00.19-P- 1000MCU GF00.19-P- 2000MCU Location and assignment of ground points

GF00.19-P- 2000MCU GF00.19-P- 3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)

GF00.19-P- 3000MCU PE54.00-P- 1100MCU

Further wiring diagrams PE54.00-P- 1100MCU Fig 2: Airbag (AB), Emergency Tensioning Retractor (ETR) Electrical Function Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

locking lug (1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3812 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

01MCC 5 Prepare wheel well locking lug (1) and mating surfaces on body for installation

AR63.20-P-0013- 02MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install

6 Fit wheel well locking lug (1) and weld in

AR63.20-P-0013- 03MCC 7 Partially install side wall paneling and weld in Model 451.3 AR63.10-P- 0115MCC

Model 451.4 AR63.10-P- 0115MCO 8 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

9 Prime area to be repaired using primer filler

10 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC

Sealant BR00.45-Z-1003- 01A 11 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 12 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 13 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 14 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- Sealant, white, 310 ml, DB supply A 001 989 63 20

Zinc dust paint suitable for spot

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3833 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

welding *BR00.45-Z-1001- 07A Install

6 Install A-pillar outer bottom section (1) and weld in

AR63.20-P-1102- 03MCO 7 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

8 Prime area to be repaired using primer filler

9 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC

Sealant BR00.45-Z-1003- 01A 10 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 11 Paint area repaired and adjacent surfaces Notes on paintwork repairs

AH98.00-P-9408- 02MCC 12 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 13 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunchenGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42

paneling (1) and weld in

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3839 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

03MCO 6 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

7 Prime area to be repaired using primer filler

8 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC

Sealant BR00.45-Z-1003- 01A 9 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 10 Paint area repaired and adjacent surfaces Notes on paintwork repairs

AH98.00-P-9408- 02MCC 11 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 12 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunchenGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR > REMOVE UPPER A-PILLAR REINFORCEMENT - AR63.20-P-1113- 01MCO >

Paint area repaired and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3846 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

23 Paint area repaired and adjacent surfaces Notes on paintwork repairs

AH98.00-P-9408- 02MCC 24 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 25 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunchenGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR > REMOVE LOWER A-PILLAR REINFORCEMENT - AR63.20-P-1114- 01MCO > 1. Expose spot welds on lower A-pillar reinforcement (1) and cut out (areas A, B, C, D, E, F, G, H, K and L).

for lower A-pillar

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3854 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

reinforcement (1) on body 02MCO

Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 9 Prepare lower A-pillar reinforcement (1) for installation

AR63.20-P-1114- 03MCO

Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install

10 Install lower A-pillar reinforcement (1)

AR63.20-P-1114- 04MCO 11 Install upper A-pillar outer paneling

AR63.20-P- 1105MCO 12 Install lower outer A-pillar

AR63.20-P- 1102MCO 13 Install side wall reinforcement

AR63.20-P- 0862MCC 14 Install side wall paneling

AR63.10-P- 0115MCO 15 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

16 Prime area to be repaired using primer filler

17 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC

Sealant BR00.45-Z-1003- 01A 18 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 19 Paint area repaired and adjacent surfaces Notes on paintwork repairs

AH98.00-P-9408- 02MCC 20 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 21 Reinstall all detachable parts removed

Clean welds and sheet metal

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3906 · Applies to: 450, 451, 452, 454 · AR: AR97.10-P-4000MCC, AR97.20-P-1500FF

7 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

8 Prime area to be repaired using primer filler

9 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003-01A 10 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A 11 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 12 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 13 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunichGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 13A Blind rivet 6.4 x 14 A 003 990 35 97 TESTING & REPAIR > PARTIALLY REMOVE MAIN FLOOR PANEL - AR63.40-P-1180- 24MCC >

Paint area repaired and adjacent

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3918 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF, AR63.40-P-1180MCD

29 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 30 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 31 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1092- 02A Adhesive kit, body, 2-component adhesive A 009 989 36 71 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunichGermanyTel. +49-899268- 0Fax +49- 899101978www.Loctite.de TESTING & REPAIR > PARTIALLY REPLACE MAIN FLOOR PANEL - AR63.40-P-1180MCD

MODEL 451.3/4 Rear main floor panel Shown on model 451.3

Apply additional cavity

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3933 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

26 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 27 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1092- 02A Adhesive kit, body, 2-component adhesive A 009 989 36 71 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunichGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 13A Blind rivet 6.4 x 14 A 003 990 35 97 TESTING & REPAIR > REMOVE CROSSMEMBER BELOW FRONT SEAT - AR63.40-P- 1190-01MCC > Fig 1: Identifying Spot Welds On Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Apply additional cavity

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3957 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF, AR63.40-P-1193MCC

12 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 13 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunchenGermanyTel. +49 899268-0Fax +49 899101978www.Loctite.de TESTING & REPAIR > REPLACE CROSSMEMBER MOUNTING CONSOLE ON BOTTOM FRONT REAR FLOOR ASSEMBLY - AR63.40-P-1193MCC > MODEL 451.3/4 Shown on model 451.3 MODIFICATION NOTES 30.1.09 Information on alternative repair method added (structural bonding eliminated) Removing

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. AS00.00-Z-0007-01A Risk of injury caused by Always wear protective AS00.00-Z-0017-01A Fig 1: Replacing Crossmember Mounting Console On Bottom Front Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

and fix in place using manual

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4248 · Applies to: 450, 451, 452, 454 · AR: AR97.10-P-4000MCC, AR97.20-P-1500FF

temporary fasteners 10 Rivet new diagonal strut console (1) with Polygrip 6.4 x 14 flat/round head rivets (areas D, E and F) Rivet *BR00.45-Z-1001- 13A 11 Clean sheet metal flange with wire brush and clean areas to repaired

12 Prime area to be repaired using primer filler

13 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003- 01A 14 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 15 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 16 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 17 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunichGermanyTel. +49-899268- 0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 13A Blind rivet 6.4 x 14 A 003 990 35 97 TESTING & REPAIR > REMOVE/INSTALL DIAGONAL STRUT CONSOLE ON

The repair method u ing riveting

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4250 · Applies to: 450, 451, 452, 454 · AR: AR97.10-P-4000MCC

described here can be replaced by plug welding if required. Adapt preparatory work accordingly.

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Expose spot welds on diagonal strut console (1) and cut out (areas A and B)

4 Remove damaged diagonal strut console (1)

Install

5 Fit new diagonal strut console (1) with diagonal strut and fix in place using vise grip pliers. When fitting, observe correct distances.

6 Drill Ø 6.5 mm rivet holes (areas C and D).

7 Remove new diagonal strut console (1) and diagonal strut

8 Debur rivet holes on diagonal strut console (1) and body on both sides

9 Fit new diagonal strut console (1) and fix in place using manual temporary fasteners

10 Rivet new diagonal strut console (1) with Polygrip 6.4 x 14 flat/round head rivets (areas C and D) Rivet *BR00.45-Z-1001- 13A 11 Clean sheet metal flange with wire brush and clean areas to repaired

12 Prime area to be repaired using primer filler

13 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003- 01A 14 Supplement standard underbody protection with permanent Underfloor protection BR00.45-Z-1001- 05A

underbody ealant

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4251 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF

15 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 16 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 17 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunichGermanyTel. +49-899268- 0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 13A Blind rivet 6.4 x 14 A 003 990 35 97 TESTING & REPAIR > REMOVE TANK SUPPORT - AR61.10-P-5708-01MCC > Fig 1: Identifying Right Tank Support & Drilling Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

body

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4258 · Applies to: 450, 451, 452, 454 · AR: AR97.10-P-4000MCC

01FF Generally conventional tools are required for body work, additional tools required are listed above. Pneumatic/hydraulic blind rivet tool gotis://K_68-80_06.0

The repair method using riveting described here can be replaced by plug welding if required. Adapt preparatory work accordingly.

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Remove right tank support (1)

AR61.10-P-5708- 01MCC 4 Prepare connecting points on right tank support (1) on body

AR61.10-P-5708- 02MCC 5 Prepare right tank support (1) for installation

AR61.10-P-5708- 03MCC Install

6 Install right tank console (1) The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR61.10-P-5708- 04MCC Adhesive BR00.45-Z-1092- 02A Rivet BR00.45-Z-1001- 13A 7 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

8 Prime area to be repaired using primer filler

9 Supply standard seam seals with body sealant

AR97.10-P-4000MCC Sealant BR00.45-Z-1003- 01A 10 Supplement standard underbody Underfloor protection BR00.45-Z-1001-

protection with permanent

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4259 · Applies to: 450, 451, 452, 454 · AR: AR97.20-P-1500FF, AR61.10-P-5708MCD

underbody sealant 05A 11 Paint area repaired and adjacent surfaces

Notes on paintwork repairs AH98.00-P-9408- 02MCC 12 Apply additional cavity preservation

AR97.20-P-1500FF Teroson protective wax *BR00.45-Z-1008- 05A 13 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1092- 02A Adhesive kit, body, 2-component adhesive A 009 989 36 71 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunichGermanyTel. +49-899268- 0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 13A Blind rivet 6.4x14 A 003 990 35 97 TESTING & REPAIR > REPLACE TANK SUPPORT - AR61.10-P-5708MCD > MODEL 451.3/4 (except 451.391 /491) Tankkonsole links Illustrated on model 451.3

Remove detachable parts in the

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4261 · Applies to: 450, 451, 452, 454 · AR: AR97.10-P-4000MCC, AR97.20-P-1500FF

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Remove left tank support (1)

AR61.10-P-5708- 01MCD Install

4 Install left tank support (1)

AR61.10-P-5708- 04MCD Rivet *BR00.45-Z-1001- 13A 5 Clean sheet metal flange with wire brush and clean areas to repaired

6 Prime area to be repaired using primer filler

7 Supply standard seam seals with body sealant

AR97.10-P-4000MCC Sealant BR00.45-Z-1003- 01A 8 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 9 Paint area repaired and adjacent surfaces

Notes on paintwork repairs AH98.00-P-9408- 02MCC 10 Apply additional cavity preservation

AR97.20-P-1500FF Teroson protective wax *BR00.45-Z-1008- 05A 11 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunichGermanyTel. +49-

accordingly

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4267 · Applies to: 450, 451, 452, 454 · AR: AR97.10-P-4000MCC, AR97.20-P-1500FF

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fire-resistant weld protection blanket to prevent damage from flying sparks.

3 Expose spot welds on mounting console for bulkhead (1) and cut out (areas A, B and C)

4 Remove damaged mounting console for bulkhead (1).

5 Level cut spot welds.

Install

6 Fit new mounting console for bulkhead (2) with bulkhead. When fitting, observe correct distances.

7 Drill Ø 6.5 mm rivet holes (areas D, E and F)

8 Remove drilling shavings with wet/dry vacuum cleaner.

9 Remove new mounting console for bulkhead (2) and bulkhead.

10 Deburr rivet holes on new mounting console for bulkhead (2) and body on both sides.

11 Fit new mounting console for bulkhead (2) and fasten with manual temporary fasteners.

12 Rivet new mounting console for bulkhead (2) with Polygrip 6.4 x 14 flat round head rivet (areas D, E and F) Rivet *BR00.45-Z-1001- 13A 13 Prime area to be repaired using primer filler

14 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant *BR00.45-Z-1003- 01A 15 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 16 Apply additional cavity

AR97.20-P-1500FF