Fortwo_451_2009_Equipment_Instructions_125p.pdf

125 excerpts.

2009 ACCESSORIES & BODY, CAB

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 1 · Applies to: 451

Electrical System, Equipment & Instructions - Fortwo (Cabrio) GENERAL INFORMATION INFORMATION ON PREVENTING DAMAGE TO ELECTRONIC COMPONENTS DUE TO ELECTROSTATIC DISCHARGE - AH54.00-P-0001-01A All models Electrostatic charge Every contact and each physical separation of materials or any movement of solid substances, fluids or particulate loaded gases can generate electrostatic charges. Plastics generally produce the highest electrostatic charge. We come across electrostatic charge or discharge in lots of everyday situations, e.g. with: l Combs l Walking on carpets or plastic floors l Putting on and removing textiles made with synthetic fiber l Disembarking from the vehicle l Contact between various electrostatically chargeable packaging materials in shelves or in the transport container The following electrostatic discharge (E lectro S tatic D ischarge (ESD)) can be so strong that a small electric shock is detected. Even the smallest discharges which people cannot detect can cause lasting damage to electronic components and control units. Effects and consequences of ESD Electronic components and control units are very sensitive to ESD. The damage is often not immediately obvious, but becomes apparent some time later. In order to avoid failures and damage due to ESD in vehicle electronics, various procedures and safety precautions must be taken into account and followed. Risks of damage occur during transport, handling, testing, removal and installation of electronic components in production as well as during repair work. The following electronic components listed as an example can be damaged by ESD: l Airbag components l Control units, in particular their bus connections (Control Area Network (data bus/CAN bus) (CAN), local interconnect network (LIN) etc.) l Sensors l Mechatronic components (actuators etc.) l Antenna amplifier l Receivers and displays (Radio, TV, GPS, telephone etc.)

Modes of behavior and safety precautions

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 2 · Applies to: 451

l Electrostatic discharge from the fitter (e.g. due to brief contact with the vehicle body). l Suitable clothing, e.g. made of cotton. l Wear ESD safety shoes with conductive soles. l Keep workplace clean, remove unnecessary objects such as common plastics. l Special anti-static seat cushion protectors must be used when performing repair work inside a vehicle. l Leave replacement parts in the original packaging for as long as possible, Do not cut open seals, but cut open carefully. l The ESD workplace must conform to the ESD guidelines. ESD protection gotis://E 82 04.0 l Before unpacking, discharge ESD protective packaging at the ESD workplace. l Avoidance of contact with electrostatic chargeable materials such as PE, PVC, styrofoam. l Use only original packaging or specially labeled and defined packaging and transport materials. l Electronic components which have been removed must be put down on an ESD workplace. l Touch connectors on electronic components and in the wiring harness on the housing only. Do not touch the pins and contacts! l Electronic components must be installed before they are connected so that potential equalization with the body can take place. l Shelves and worktables must stand directly on the floor, there must not be any insulating materials between the base of the shelves/feet and the floor. If the above mentioned insulators cannot be removed, the shelves and work tables must be grounded (e.g. low-resistance electrical connection/line from metal shelf to a heating pipe). l Put down conductive transport container/box in a non insulated manner (e.g. on a wooden pallet), otherwise no potential equalization takes place. l Do not place control units and electronic components removed from the vehicle on electrostatically chargeable materials, such as PE, PVC, styrofoam. The electrostatic charge is transferred to the control unit or electronic component. An ESD service kit or a connected ESD table mat must be used. Training We strongly advise that each company should appoint a trained ESD officer in accordance with DIN EN 61340-5-1. The ESD officer can hold employee training courses. The objective of the training course measures is to familiarize the employees with the essential difficulties and effects of ESD: l Creation of discharging l Reasoning behind safety precautions l Effects and consequences of ESD l ESD rules of conduct and safety precautions

Returning electronic components in warranty and goodwill cases

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 3 · Applies to: 451

When returning electronic components it is absolutely essential to observe the procedure and safety precautions listed. Electrostatic charge or discharge mean the original fault can be falsified or overlaid. This can lead to distorted fault symptoms in the case of the fault analysis of the component concerned. NOTES ON BATTERY - AH54.10-P-0001-01A All models General information on batteries l Do not store batteries over a longer period at a storage point with direct solar radiation. l Discharged or defective batteries can freeze, therefore store free from frost. l Avoid polarity reversal and short-circuits. l Do not place tool or other conducting objects on the battery (risk of short-circuit). l Before removal and installation of batteries all switchable current consumers should be switched off, as well as the engine switched off so that inadvertent arcing is ruled out. l Always disconnect the negative terminal first and always connect the positive terminal first. l Only charge batteries with DC, 10 % of the capacity is recommended as charging current for slow charging and 50 % of the capacity recommended for fast charging. l Only switch on the charger after connecting to the terminals and switch off before disconnecting. l We recommend greasing the batteries slightly with battery terminal grease. l If the battery is to remain in the parked vehicle for a longer time, the negative terminal should be disconnected. l If possible batteries should be kept clean and dry. l Batteries should not be stored over a longer period without recharging. Notes on lead-gel batteries (additional battery for special bodies) l Lead-gel batteries are free from gassing, acid does not run out of them and are completely independent of position and maintenance free. l When fast charging ensure that the housing of the lead-gel battery does not heat up excessively otherwise a pressure relief valve will be opened and the lead-gel battery will be defective. Notes on lead acid batteries l Always store lead lead-acid batteries horizontally to prevent acid leaking out and do not tilt during transportation. l When fast charging ensure that the housing of the lead-acid battery does not heat up excessively. NOTES ON SCN CODING OF CONTROL UNITS - AH54.21-P-0004-01X Model 129, 163, 164, 168, 169, 170, 171, 199, 203, 204, 208, 209, 211, 215, 216, 219, 220, 221, 230, 240, 245, 251 Model 461, 463 Model 450, 451, 452, 454 Model 636, 639 Model 906

The "Software Calibration Number" (SCN) is specified by law in Europe and USA for all control units

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 4 · Applies to: 451 · AR: AP54.10-P-5410MCC

relevant to exhaust emission as of model year 2002. Accordingly the software and coding of such a control unit must be clearly identifiable by means of the SCN. As a number the SCN consists of 16 numbers. The first 10 places correspond to the object number to be coded (mostly object number of control unit software). The next 2 places designate the manufacturing plant or field organization, in which the vehicle has been coded. The last 4 places are a number of the variants of the coding string of the vehicle-specific as-built configuration. This number is serially numbered for each newly formed variant. If special equipment has been installed or removed in the vehicle (e.g. retrofitting a telephone), these retrofit codes must be added to the central system before requesting the SCN coding data. The appropriate national organization must be contacted (MPC) for this. MAINTENANCE BATTERIES - CHECKING AND CORRECTING FLUID LEVEL - AP54.10-P-5410MCC MODEL 451.3 (except 451.334) MODEL 451.3 (except 451.380) MODEL 451.4 (except 451.480) Fig. 1: Identifying Battery Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Removing Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into AS54.10-Z-0001-01A

TESTING & REPAIR

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 5 · Applies to: 451 · AR: AR54.00-Z-9451CA, AR68.30-P-1340MCC, AR68.30-P-1340MCE, AR54.21-P-0018MCE, AR54.10-P-1130MCC (+5 more)

TESTING AND REPAIR WORK: SMART: ELECTRICAL SYSTEM, EQUIPMENT AND INSTRUMENTS - AR54.00-Z-9451CA MODEL 451 skin and eyes from battery acid or when handling damaged lead-acid batteries suitable and appropriately marked containers. Notes on battery AH54.10-P-0001-01A 1 Remove footrest on the passenger- side Left-hand drive vehicles AR68.30-P-1340MCC Right-hand drive vehicles AR68.30-P-1340MCE 2 Unscrew nut (3) 3 Unclip the retaining clip (2) on the bracket (1) and remove bracket (1) On right-hand drive vehicles the bracket (1) is only raised until the stop plugs (4) are accessible. Checking 4 Remove stop plugs (4) on the battery (G1) and check fluid level in the battery (G1) In each cell the fluid must reach the web let into the filler opening (arrow). Correct 5 Correct the battery acid level with distilled water Refill distilled water up to the web (arrow). 6 Screw in plug (4) Install 7 Insert bracket (1) and clip in retaining clip (2) at the bracket (1) 8 Tighten nut (3) Installation: Replace self-locking nut (3). 9 Install footrest on the passenger- side Left-hand drive vehicles AR68.30-P-1340MCC Right-hand drive vehicles AR68.30-P-1340MCE Perform initial startup of control units MODEL 451.3/4 AR54.21-P-0018MCE Charge battery MODEL 451.3/4 AR54.10-P-1130MCC Check condition of battery MODEL 451.3/4 AR54.10-P-1129MCC Check quiescent current consumption MODEL 451.3/4 AR54.10-P-1030MCE Control unit flashing MODEL 451.3/4 AR54.21-P-0012MCC Control unit flashing MODEL 451.3/4 AR54.21-P-0012MCU Disable/enable high-voltage system MODEL 451.391/491 with ENGINE 780.009 AR54.10-P-1160MEV Disconnect/connect battery ground line MODEL 451.3/4 AR54.10-P-0003MCC Disconnecting and connecting electrical cables from battery MODEL 451.3/4 AR54.18-P-0002MCC

Remove/install additional instruments MODEL 451.3/4 up to 30.8.10 with

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 6 · Applies to: 451 · AR: AR54.30-P-6080MCC, AR54.30-P-6080MCF, AR54.10-P-0005MCC, AR54.10-P-0005MCE, AR54.10-P-5106MEV (+5 more)

CODE (V31) Cockpit clock and tachometer package AR54.30-P-6080MCC Remove/install additional instruments MODEL 451.3/4 as of 31.8.10 with CODE (V31) Cockpit clock and tachometer package AR54.30-P-6080MCF Remove/install battery MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle AR54.10-P-0005MCC Remove/install battery MODEL 451.3## /4## 2# with CODE (RHD) Right-hand drive vehicle AR54.10-P-0005MCE Remove/install battery charger of high-voltage battery MODEL 451.391/491 with ENGINE 780.009 AR54.10-P-5106MEV Remove/install battery sensor MODEL 451.334 /380 /480 AR54.10-P-0002MCC Remove/install charger feed socket MODEL 451.391/491 with ENGINE 780.009 AR54.10-P-5109MEV Remove/install cockpit switch group MODEL 451.3/4 AR54.25-P-1000MCC Remove/install combination switch MODEL 451.3/4 AR54.25-P-2800MCC Remove/install cruise control switch MODEL 451.3/4 with CODE (V27) Cruise control/Temposet AR54.25-P-2803MCC Remove/install electric motor charge line to 12-volt battery MODEL 451.391/491 with ENGINE 780.009 AR54.10-P-5107MEV Remove/install electric power soft top relay MODEL 451.4 AR54.15-P-1000MCO Remove/install electrical line from battery to starter/alternator MODEL 451.3 (except 451.380 /391) MODEL 451.4 (except 451.480 /491) AR54.18-P-0006MCC Remove/install electrical line from battery to starter/alternator MODEL 451.3/4 (except 451.391 /491) AR54.18-P-0006MCU Remove/install electrical lines from the on-board electrical system battery to the starter-alternator control unit MODEL 451.334 /380 /480 AR54.10-P-0100MCC Remove/install external socket communications control unit MODEL 451.391/491 with ENGINE 780.009 AR54.10-P-5108MEV Remove/install fanfare horns MODEL 451.3/4 with CODE (V55) Twin-tone horn AR54.35-P-1555MCC Remove/install front SAM control unit MODEL 451.3/4 AR54.21-P-1254MCC Remove/install front SAM control unit MODEL 451.3/4 AR54.21-P-1254MCU Remove/install high-voltage battery MODEL 451.391/ 491 AR54.10-P-1140MEV Remove/install high-voltage distributor MODEL 451.391/491 with ENGINE 780.009 AR54.10-P-1400MEV Remove/install high-voltage line between high-voltage distributor and PTC heater booster MODEL 451.391/491 with ENGINE 780.009 AR54.10-P-1402MEV Remove/install ignition/starter switch lock cylinder MODEL 451.3/4 AR54.25-P-1030MCC Remove/install ignition/starter switch lock cylinder MODEL 451.3/4 AR54.25-P-1030MCU

DISCONNECT/CONNECT BATTERY GROUND LINE - AR54.10-P-0003MCC

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 7 · Applies to: 451 · AR: AR54.10-P-0003MCC, AR54.10-P-0050MEV, AR54.30-P-6015MCC, AR54.30-P-6015MCU, AR54.15-P-0051MCU (+5 more)

MODEL 451.3/4 Fig. 2: Identifying Ground Cable And Battery Courtesy of MERCEDES-BENZ OF NORTH AMERICA. MODIFICATION NOTES Remove/install inertia switch MODEL 451.391/491 with ENGINE 780.009 AR54.10-P-0050MEV Remove/install instrument cluster MODEL 451.3/4 AR54.30-P-6015MCC Remove/install instrument cluster MODEL 451.3/4 AR54.30-P-6015MCU Remove/install main fuse of positive line MODEL 451.3/4 (except 451.391 /491) Starter/alternator prefuse AR54.15-P-0051MCU Remove/install main fuse of positive line MODEL 451.3/4 Main fuse of SAM [signal acquisition and actuation module] control unit AR54.15-P-0051MCV Remove/install main fuse of positive line MODEL 451.391/491 with ENGINE 780.009 AR54.15-P-0051MEV Remove/install main fuse of secondary air injection pump MODEL 451.3/4 (except 451.391 /491) AR54.15-P-0050MCU Remove/install outside temperature indicator sensor MODEL 451.3/4 AR54.30-P-6341MCC Remove/install signaling horn MODEL 451.3/4 except CODE (V55) Twin-tone horn AR54.35-P-1556MCC Remove/install signaling horn MODEL 451.3/4 AR54.35-P-1556MCU Remove/install starter-alternator control unit MODEL 451.334 /380 /480 AR54.21-P-0300MCC Remove/install start/stop switch MODEL 451.334 /380 /480 AR54.25-P-4000MCC Remove/install three-phase line from starter-alternator to control unit MODEL 451.334 /380 /480 AR54.18-P-2000MCC Remove/install wiper switch MODEL 451.3/4 AR54.25-P-0003MCC Remove/install 12 Volt socket MODEL 451.3/4 AR54.10-P-1000MCC Replace desiccant cartridge of high- voltage battery MODEL 451.391/ 491 AR54.10-P-1171MEV Replace SAM fuses MODEL 451.3/4 AR54.15-P-2001MCC Treatment of battery if vehicle taken out of service MODEL 451.3/4 AR54.10-P-0006MCC

Check condition of battery and enable high voltage system added

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 8 · Applies to: 451

10.6.10 Check condition of battery and enable high voltage system added Steps 1 and 2 22.9.10 Information on required radio code on vehicles with code (527) High- Line radio, added 13.1.11 Adaptation of audio settings added Step 9 Remove/install Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers. AS54.10-Z- 0001-01A Risk of death when touching components on vehicles with high- voltage system Do not touch components and open lines of high-voltage system. Persons with electronic implants (e.g. cardiac pacemakers) must never work on high- voltage systems. AS54.00-Z- 0001- 02MEV Note on high-voltage battery Model 451.391/491 AH54.10-P- 0006- 01MEV Note on high-voltage system Model 451.391/491 AH54.00-P- 0011- 01MEV Notes on battery AH54.10-P- 0001-01A Notes on AGM battery Model 451.334/380/480 AH54.10-P- 0002- 01MCC On vehicles with code (527) High- Line radio, before the ground line (1) is disconnected, it must be ensured that the radio code is available to allow the radio to be put into operation at a later stage. 1 Check condition of battery (G1), if necessary replace battery (G1) Only with model 451.391/491 if during the further course of work, work is to be conducted on the high voltage vehicle electric system. The high voltage system cannot be enabled if the battery (G1) is defective: Before replacing the battery (G1) on model 451.391/491 no further work may be performed on the high-voltage vehicle electrical system. AR54.10-P- 1129MCC 2 Carry out disconnection of high-voltage system Only with model 451.391/491 if during the further course of work, work is to be conducted on the high voltage vehicle electric system. AR54.10-P- 1160MEV AD00.00-P-

REMOVE/INSTALL BATTERY - AR54.10-P-0005MCC

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 9 · Applies to: 451 · AR: AR54.10-P-0005MCC

MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle Fig. 3: Identifying Battery Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 3 Connect STAR DIAGNOSIS and read out fault memory Installation: If necessary, delete fault memory. 2000- 04MCC 4 Remove foot support on passenger side Left-hand drive vehicles AR68.30-P- 1340MCC Right-hand drive vehicles AR68.30-P- 1340MCE 5 Disconnect ground line (1) from the negative terminal of the battery (G1) 6 Install in the reverse order 7 Set time in the instrument cluster and on the additional instrument 8 Enter radio code On vehicles with code (527) High-Line radio 9 Adapt audio settings On vehicles with code (527) High-Line radio Notes on audio settings AH82.60-P- 0002- 01MCC Remove/install 1 Disconnect battery ground line AR54.10-P- 0003MCC 2 Take off cover (1) 3 Disconnect positive line (3) from battery (G1) 4 Remove clip (2) of the positive line (3) on the bracket (4) Installation: Replace clip (2). 5 Remove nut (6) and take off Installation: Replace self-locking nut

TREATMENT OF BATTERY IF VEHICLE TAKEN OUT OF SERVICE - AR54.10-P-0006MCC

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 10 · Applies to: 451 · AR: AR54.10-P-0006MCC, AR54.10-P-1000MCC, AR54.10-P-1129MCC, AR54.10-P-0003MCC, AR54.10-P-1130MCC

MODEL 451.3/4 REMOVE/INSTALL 12 VOLT SOCKET - AR54.10-P-1000MCC MODEL 451.3 /3 bracket (4) (6) 6 Detach vent hose (5) from battery (G1) 7 Remove battery (G1) If the battery (G1) is replaced, the defective battery (G1) must be disposed of correctly. See: v Dispose of battery OS54.10-P- 0001-01Z 8 Install in the reverse order Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers. AS54.10-Z-0001-01A Notes on battery AH54.10-P-0001-01A 1 Check battery condition, charge battery if necessary On no account leave battery in discharged state otherwise sulfate deposits will form on the plates. Plates with sulfate deposits indicate initial damage to the battery and result in premature failure. AR54.10-P-1129MCC 2 Disconnect battery ground line This prevents any battery discharge through closed-circuit accessories (e.g. clock). AR54.10-P-0003MCC 3 Charge battery Every 4 weeks. On no account leave battery in discharged state otherwise sulfate deposits will form on the plates. Plates with sulfate deposits indicate initial damage to the battery and result in premature failure. AR54.10-P-1130MCC

Fig. 4: Identifying 12 Volt Socket Components

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 11 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Remove/install 1 Insert pliers (2) into interior socket (X58/1) and turn until pliers (2) arrest 169589003700 2 Carefully pull out metal insert in interior socket (X58/1) approx. 1.5 cm with pliers (2) 169589003700 3 Remove bolts (3) 4 Swivel the trim of the vertical strut (1) backwards in the lower area and remove until the electrical connector (5) of the interior socket (X58/1) as well as the electrical connector (4) of the data link connector (X11/4) are accessible 5 Separate the electrical connector (5) of the interior socket (X58/1) and electrical connector (4) of the data link connector (X11/4) 6 Remove vertical strut paneling (1) 7 Unclip interior socket (X58/1) from rear of vertical strut paneling (1) and remove toward front Installation: Before installing in the trim of the vertical strut, pull out the metal insert of the interior socket (X58/1) (1) using

Fig. 5: Identifying Pliers (169 589 00 37 00)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 12 · Applies to: 451 · AR: AR54.10-P-1030MCE

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. CHECK QUIESCENT CURRENT CONSUMPTION - AR54.10-P-1030MCE MODEL 451.3/4 Fig. 6: Identifying Ground Cable And Battery Courtesy of MERCEDES-BENZ OF NORTH AMERICA. the pliers (2). 8 Install in the reverse order Removing Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers. AS54.10-Z-0001-01A Notes on battery AH54.10-P-0001-01A Notes on AGM battery Model 451.334/380/480 AH54.10-P-0002- 01MCC 1 Connect STAR DIAGNOSIS then read-out and erase diagnostic trouble code memory AD00.00-P-2000- 04MCC 2 Close Star Diagnosis

Remove foot support on

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 13 · Applies to: 451 · AR: AR68.30-P-1340MCC, AR68.30-P-1340MCE, AR54.10-P-1130MCC

3 Remove foot support on passenger side Left-hand drive vehicles AR68.30-P-1340MCC Right-hand drive vehicles AR68.30-P-1340MCE 4 Measure battery voltage at battery terminals Standard digital multimeter gotis://E_15/54_06.0 If the battery voltage is less than 12.2 V: v Charge battery (G1) AR54.10-P-1130MCC 5 Withdraw ignition key 6 Switch off all consumers on board the vehicle 7 Disconnect all external consumers (e.g. chargers, MP3 player, amplifier etc.) 8 Open doors and liftgate 9 Lock rotary tumblers on doors and liftgate The interior illumination in the vehicle must go out. 10 Lock the vehicle using the central locking with open doors and liftgate A waiting time of at least 6 mins. must be waited after locking the vehicle. Measure 11 Set multimeter to highest possible current measurement range Standard digital multimeter gotis://E_15/54_06.0 12 Connect multimeter between ground line (1) and negative terminal on battery (G1) without any interruption To prevent any voltage reset, the current flow must not be interrupted. When fitting the multimeter, bridge the negative terminal of the battery (G1) beforehand. 13 Measure no-load current 14 Remove fuses one by one from the SAM control unit and localize the faulty control unit or defective consumer If the value for the no-load current measurement: l On vehicles without code (V01) Antitheft alarm system (FFO) exceeds 40 mA. l On vehicles with code (V01) Antitheft alarm system (FFO) exceeds 50 mA. Wait in each case for at least 6 mins. until the next measurement to enable the activated bus to return to idle. If the fuse of the defective

CHECK BATTERY - AR54.10-P-1129-01A

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 14 · Applies to: 451 · AR: GF54.15-P-0800MCC, GF54.15-P-0800MCU, AR68.30-P-1340MCC, AR68.30-P-1340MCE

Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers. TEST AND ADJUSTMENT VALUES FOR THE BATTERY consumer or control unit is removed, the no-load current drops immediately. The fuse and relay assignment enables the increased no-load current consumption to be restricted to specific control units and consumers. To restrict the increased no- load current consumption yet further, the consumers and control units protected by the fuse in question must be removed one after the other. * not for USA Fuse and relay box, as-built configuration GF54.15-P-0800MCC * for USA only Fuse and relay box, as-built configuration GF54.15-P-0800MCU 15 Remove multimeter without breaking the circuit and attach ground line (1) to negative terminal Install 16 Install foot support on passenger side Left-hand drive vehicles AR68.30-P-1340MCC Right-hand drive vehicles AR68.30-P-1340MCE 17 Open vehicle using central locking system 18 Unlock rotary tumblers on doors and liftgate 19 Connect STAR DIAGNOSIS then read-out and erase diagnostic trouble code memory AD00.00-P-2000- 04MCC Number Designation 12 AH 30 AH 35 Ah 46 AH BE54.10-P-1002- 01A Cold test current as per EN A 170 540 520 420

TEST AND ADJUSTMENT VALUES FOR THE BATTERY

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 15 · Applies to: 451

TEST AND ADJUSTMENT VALUES FOR THE BATTERY TEST AND ADJUSTMENT VALUES FOR THE BATTERY On model 414 the battery has to be disconnected for the tests to avoid any damage. Perform test for remaining vehicles with battery installed and connected where possible. Do not connect tester to jump start or charging terminal point, always connect it directly with the battery. Battery tester gotis://E_15/54_02. 0 All test steps and entries must be performed thoroughly, otherwise the test result will be distorted. Test prerequisites: l Tester with software release 2.0 l Ignition off l Rotary light switch in position "0" If the message "Surface voltage" is displayed during the test, the tester has detected that the battery voltage is apparently too high. This increased voltage can be reduced as follows: l Battery installed: Decrease increased voltage as per the specifications of the tester (e.g. switch on driving lights). l Battery removed: reduce increased voltage using a suitable volt/amp(s) tester (load battery for approx. 60 s with 20 A to 30 A amps). As an example, the test procedure for passenger cars is described below. l Audio component (e.g. radio) switched off l Battery voltage higher than 12.4 V l Good contact of the tester on the battery 1. Clip tester (1) on to battery. Number Designation 60 Ah VRLA 60 AH 62 AH BE54.10-P-1002- 01A Cold test current as per EN A 680 510 480 Number Designation 70 Ah VRLA 74 AH 80 Ah VRLA 84 AH BE54.10-P-1002- 01A Cold test current as per EN A 760 680 800 700 Number Designation 90 Ah VRLA 95 Ah VRLA 100 Ah BE54.10-P-1002- 01A Cold test current as per EN A 950 850 760

Once the tester is connected the current measured battery voltage is displayed for approx. 2 s. If a

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 16 · Applies to: 451

so-called "System noise" is detected by the tester, check whether all consumers are switched off and wait (for approx. 2 min), until the quiescent current is minimized and the bus systems are switched off. Fig. 7: View Of Clip Tester Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 2. Follow the menu and select according to the situation: l In vehicle (battery connected to on-board electrical system) l Not in vehicle (battery disconnected from on-board electrical system) Confirm selection with "Enter".

Fig. 8: Display Battery Selection

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 17 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 3. Follow the menu and select according to the situation: l 12-114 AH (battery capacity 12-114 Ah) l AH > (battery capacity > or =115 Ah) Confirm selection with "Enter". Fig. 9: Display Battery Selection - Battery Capacity Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 4. Follow menu and select battery type: l Normal l VRLA Confirm selection with "Enter". Fig. 10: Display Battery Selection - Battery Type Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 5. Follow the menu selection and select the test standard for the cold cranking amps. The test standard is printed on behind the specification of the cold cranking amps. If the imprint of the test standard is not available, select the cold cranking amps "EN".

Example: 12 V 46 Ah 420 A --> Select EN.

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 18 · Applies to: 451

Confirm selection with "Enter". Fig. 11: Display Selection Of Battery Testing For Cold Cranking Amps Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 6. Read off cold cranking amps and enter in tester. Example: 12 V 46 Ah 420 cold cranking amps --> 420 A. Confirm input with "Enter". The battery test starts after confirmation of the cold cranking amps entry. The test result or one of the following messages appears after approx. 15 s: l Test code --> Step 7 l Vehicle model --> Step 9 l Temperature > 0°C/< 0°C --> Step 10 l Before charging/After charging --> Step 11 l Surface voltage DETECTED (see above)

Fig. 12: Display Test Result Of Cold Cranking Amps

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 19 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 7. Read off test code with "Enter" and continue accordingly: l "Battery in good condition": No further measures required. l "Charge and test": Fully charge battery and retest (battery voltage > 12.4 V). 8. Print out test code and file in a tamperproof manner. l "Replace battery": Replace battery if this message appears. 9. Follow the menu and select test mode: l Cars l Taxi Confirm selection with "Enter".

Fig. 13: Display Selection Of Test Mode - Cars And Taxi

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 20 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 10. Follow the menu and select test mode: l > 0°C l < 0°C Confirm selection with "Enter". If this message appears, the battery condition cannot be evaluated. Fig. 14: Display Selection Of Test Mode - Above 0°C And Below 0°C Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 11. Follow the menu and select test mode: l BEFORE CHARGE l AFTER CHARGE Confirm selection with "Enter".

Fig. 15: Display Selection Of Test Mode - Before Charge And After Charge

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 21 · Applies to: 451 · AR: AR54.10-P-1129MCC, AR68.30-P-1340MCC, AR68.30-P-1340MCE, AR54.10-P-0005MCC, AR54.10-P-0005MCE (+1 more)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 12. Perform additional menu-assisted function (e.g. starting several times and switching on consumers). Only in taxi test mode if displayed in menu. CHECK CONDITION OF BATTERY - AR54.10-P-1129MCC MODEL 451.3/4 Remove Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers. AS54.10-Z-0001-01A Notes on battery AH54.10-P-0001-01A Notes on AGM battery Model 451.334/380/480 AH54.10-P-0002- 01MCC 1 Connect STAR DIAGNOSIS and read out fault memory Erase fault memory and eliminate repairing faults. AD00.00-P-2000- 04MCC 2 Remove foot support on passenger side Left-hand drive vehicles AR68.30-P-1340MCC Right-hand drive vehicles AR68.30-P-1340MCE Check 3 Visual inspection of battery for external leaks The battery must be replaced in the event of leaks. See: v Remove/install battery Left-hand drive vehicles AR54.10-P-0005MCC Right-hand drive vehicles AR54.10-P-0005MCE Dispose of battery OS54.10-P-0001-01Z 4 Check fluid level and correct if necessary Except model 451.334/380/480, Not when the battery has been AP54.10-P-5410MCC

TEST AND ADJUSTMENT VALUES FOR THE BATTERY

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 22 · Applies to: 451 · AR: AR54.10-P-1130MCC, AR68.30-P-1340MCC, AR68.30-P-1340MCE

CHARGE BATTERY - AR54.10-P-1130MCC MODEL 451.3/4 REMOVE/INSTALL MAIN FUSE OF SECONDARY AIR INJECTION PUMP - AR54.15-P- 0050MCU MODEL 451.3/4 (except 451.391 /491) replaced. 5 Check battery AR54.10-P-1129-01A Cold test current Midtronics battery tester gotis://E_15/54_02.0 *BE54.10-P-1002-01A Install 6 Install foot support on passenger side Left-hand drive vehicles AR68.30-P-1340MCC Right-hand drive vehicles AR68.30-P-1340MCE Number Designation 42 AH 60 Ah VRLA 61 AH 62 AH BE54.10-P-1002- 01A Cold test current as per EN A 340 680 540 480 Remove/install Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries No fire, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers. AS54.10-Z- 0001-01A Notes on battery AH54.10-P- 0001-01A Notes on AGM battery Model 451.334/380/480 AH54.10-P- 0002- 01MCC 1 Remove battery Pull vent hose out of the hole in the battery recess. Left-hand drive vehicles AR54.10-P- 0005MCC Right-hand drive vehicles AR54.10-P- 0005MCE 2 Charge battery according to operating instructions of charger With a battery which is not low- maintenance remove the stop plugs, check acid level and correct if necessary. 3 Install in the reverse order

Fig. 16: Locating Secondary Air Injection Pump Fuse

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 23 · Applies to: 451 · AR: AR54.15-P-0051MCU, AR54.15-P-0051MCV, AR68.00-P-1500MCC, AR54.10-P-0003MCC

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. REMOVE/INSTALL MAIN FUSE OF POSITIVE LINE - AR54.15-P-0051MCU MODEL 451.3/4 (except 451.391 /491) Starter/alternator prefuse Fig. 17: Locating Starter/Alternator Fuse Courtesy of MERCEDES-BENZ OF NORTH AMERICA. REMOVE/INSTALL MAIN FUSE OF POSITIVE LINE - AR54.15-P-0051MCV Remove/install 1 Remove vertical strut paneling (1) AR68.00-P-1500MCC 2 Pull fuse of secondary air injection pump (F36) out of fuse holder (2) 3 Install in the reverse order Remove/install 1 Disconnect battery ground line AR54.10-P-0003MCC 2 Unclip top cover (2) from bottom cover (1) and remove top cover (2) as well as bottom cover (1) 3 Unscrew nuts (3) and remove starter/alternator fuse (F58) Replace self- locking nuts (3). 4 Install in the reverse order

MODEL 451.3/4

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 24 · Applies to: 451 · AR: AR54.15-P-1000MCO, AR54.10-P-0003MCC

Main fuse of SAM [signal acquisition and actuation module] control unit Fig. 18: Locating SAM Prefuse Courtesy of MERCEDES-BENZ OF NORTH AMERICA. REMOVE/INSTALL ELECTRIC POWER SOFT TOP RELAY - AR54.15-P-1000MCO 30.11.06 MODEL 451.4 Fig. 19: Identifying Electric Power Soft Top Relay Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Remove/install 1 Disconnect battery ground line AR54.10-P-0003MCC 2 Invert casing (1) backwards 3 Unlock cover (2) in the marked area (arrow) and fold up 4 Unscrew nuts (3) and remove SAM prefuse (F91) Replace self- locking nuts (3). 5 Install in the reverse order Remove/install 1 Remove cover (1) on the left luggage compartment trim

REPLACE SAM FUSES - AR54.15-P-2001MCC

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 25 · Applies to: 451 · AR: AR54.15-P-2001MCC

MODEL 451.3/4 Fig. 20: Identifying Bolts, Standard Fuses, SAM Control Unit, Mini And Maxi Fuses Courtesy of MERCEDES-BENZ OF NORTH AMERICA. DISCONNECTING AND CONNECTING ELECTRICAL CABLES FROM BATTERY - AR54.18-P- 0002MCC MODEL 451.3/4 2 Guide the wiring harness of the soft top (2) out of the body opening and expose 3 Push back the foam casing (3) on the open soft top relay (K66/1) or on the close soft top relay (K66/2) 4 Detach open soft top relay (K66/1) or close soft top relay (K66/2) 5 Install in the reverse order 1 Turn off ignition 2 Adjust left seat to the rear Replace standard fuses (2) or mini fuses (3) 3 Pull out damaged standard fuse (2) or mini fuse (3) and replace Replace maxi fuses (4) 4 Unclip SAM control unit (N10/10) in the rear area (arrow) and fold down forwards 5 Unscrew bolts (1) and carefully lower SAM control unit (N10/10) downwards until the maxi fuses (4) are accessible 6 Remove damaged maxi fuse (4) and replace 7 Position SAM control unit (N10/10) on crossmember under instrument panel and fasten in place using the bolts (1) 8 Clip in SAM control unit (N10/10) in correct area (arrow)

Fig. 21: Identifying Battery Components

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 26 · Applies to: 451 · AR: AR54.18-P-0006MCU, AR54.10-P-0003MCC

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. REMOVE/INSTALL ELECTRICAL LINE FROM BATTERY TO STARTER/ALTERNATOR - AR54.18-P-0006MCU MODEL 451.3/4 (except 451.391 /491) Fig. 22: Identifying Electrical Line Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Remove/install 1 Disconnect battery ground line AR54.10-P-0003MCC 2 Take off cover (1) 3 Disconnect positive line (2) from battery (G1) 4 Install in the reverse order

Fig. 23: Identifying Electrical Line, Grommet, Bracket And Brake Line

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 27 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Shown on model 451.4 with code (I01) Air conditioning Plus Fig. 24: Identifying Electrical Line, Nuts, Brackets, Generator And Starter Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Shown on model 451.4 with code (I01)

Air conditioning Plus

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 28 · Applies to: 451

Remove/install 1 Disconnect ground line of battery (G1) AR54.10-P- 0003MCC 2 Remove cover (2) 3 Unscrew nut (4) and place electrical line (3) to one side 4 Detach positive terminal (6) of electrical line (1) to the battery (G1) 5 Unclip holder (5) of electrical line (1) on battery tray The brackets (5, 8, 14, 15) and the bracket (arrow A) as well as the protective covers on the electrical line (1) are present on the new electrical line (1), when reusing the old electrical line (1) ensure that it is not damaged. Risk of death caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00-Z- 0010-01A 6 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver gotis://G_58.0_01.1 7 Release rear drive module AR01.00-P- 3050MCU 8 Release grommet (7) of electrical line (1) from battery recess Installation: Ensure that grommet (7) is seated correctly. 9 Mark the position of brackets (5, 8, 14, 15), the bracket (arrow A) as well as the bracket (11) and bracket (arrow B) on the electrical line (1) 10 Unclip bracket (8) and bracket (arrow A) of electrical line (1) on underfloor 11 Unclip electrical line (1) from holder (9) on brake line (10) 12 Unclip electrical line (1) from bracket (11) and bracket (arrow B) 13 Unscrew nut (12) on starter (M1) and remove electrical line (1) 14 Unclip bracket (14) of electrical line (1) on intake manifold 15 Unclip holder (15) of electrical line (1) Unscrew nut (13) on alternator

REPAIR WIRING HARNESS BY MEANS OF AXIAL SOLDER CONNECTORS - AR54.18-P-

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 29 · Applies to: 451

0100-06A 1. Expose damaged cable or plug/coupling in easily accessible position and cut off. Separate cores in wiring harness offset by approx. 45 mm. Fig. 25: Identifying Wiring Harness Offset Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 2. Cut new section of cable to match old cable. 3. Remove 15 mm of insulation at end of cables. Pull cut-off insulation off the line while turning. 16 (G2) and remove electrical line (1) 17 Route electrical line (1) out and then remove Route electrical line (1) accurately, as otherwise the line may suffer from chafing and crushing. Installation: Replace damaged bracket (5, 8, 14, 15) and bracket (arrow A). The new brackets (5, 8, 14, 15) as well as bracket (arrow A) should be attached in exactly the same position of the electrical line (1). Make sure that the new holders (5, 8, 14, 15) and the holder (arrow A) are not twisted through 180° when secured to the electrical line (1). 18 Transfer all markings made to the electrical line (1) to the new electrical line (1) When replacing the electrical line (1). This ensures that the brackets (5, 8, 14, 15), the bracket (arrow A) as well as the bracket (11) and bracket (arrow B) are positioned at exactly the same point on the new electrical line (1), their position should be corrected if necessary. 19 Install in the reverse order

Fig. 26: Identifying Cable Insulation Dimensions

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 30 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 4. Select axial solder connector by means of cable cross-section. 5. Push the axial solder connector on line beyond the solder point. Push on the thinner side of the axial solder connector first. Fig. 27: Pushing On Axial Solder Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 6. Twist the line ends together. 7. Push back the axial solder connector on the transposition while turning.

Fig. 28: Twisting Line Ends

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 31 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 8. Heat up axial solder connector with a preheated hot air blower (with electronic temperature control) to 400°C. Hot air blower gotis://E 15/54 12. 0 Use welding bead catcher in the vehicle interior in order to avoid damage due to liquid solder. Until the soldering ring has dissolved and the covering has positioned itself properly around the lines. Fig. 29: Heating Axial Solder Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 9. Check soldered point. It must not be possible to see the soldering ring of the axial soldered connector any more. The covering must contact the lines properly.

Fig. 30: Identifying Correct And Incorrect Position Of Soldered Point

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 32 · Applies to: 451 · AR: AR54.21-P-0012MCU

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 10. Apply axial solder connector to the lines and wrap repaired area round with fabric tape. The axial solder connectors must not lie directly above one another. Fig. 31: Wrapping Repaired Area Courtesy of MERCEDES-BENZ OF NORTH AMERICA. CONTROL UNIT FLASHING - AR54.21-P-0012MCU MODEL 451.3/4 Flashing 1 Connect STAR DIAGNOSIS Connect STAR DIAGNOSIS and read out fault memory AD00.00-P-2000- 04MCC 2 Enter vehicle identification number in Diagnosis Assistance system and open main menu with "Button F2" 3 Select menu "Systems" in main menu and confirm with

SCN CODING WITH SDFLASH ONLINE - AR54.21-P-0013-02MCC

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 33 · Applies to: 451

The following work instructions describes the procedure for Online SCN coding with "SDflash". "SDflash" is the product designation of the program for determining the SCN coding and parameterization data. "Button F3" 4 Select the control unit to be flashed in the "systems" menu and confirm with the "F3 button" The following control units can be flashed: l N3/10 (ME-SFI [ME] control unit) l N10/10 (SAM control unit) l N15/6 (Sprintshift control module) l N47-5(ESP control unit) 5 Select the "Control unit adaptations" in the selected menu of the corresponding control unit and confirm with the "F3 button" 6 Select the submenu "Program control unit" in the "Control unit adaptations" menu and confirm with the "F3 button" 7 Select the "hard drive menu: Version Month/ Year (year/month/day)" and confirm with the "F3 button" The information on the flashing systems appears in the display. 8 Start the flashing process by pressing the "F3 button" Programming lasts about 3 minutes. 9 Select the "online (networked STAR DIAGNOSIS unit)" menu or "offline (no networked STAR DIAGNOSIS unit)" menu and start SCN coding by confirming with the "F3 button" Only if the SCN coding command appears in the display. We recommend always performing SCN coding with SDflash online. Only perform Offline SCN coding with a non-networked STAR DIAGNOSIS. SCN coding with SDflash Online AR54.21-P-0013- 02MCC Offline SCN coding AR54.21-P-0013- 04MCC Notes on SCN coding of control units AH54.21-P-0004-01X 10 Close STAR DIAGNOSIS

Prerequisite for Online SCN coding with "SDflash":

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 34 · Applies to: 451

l Networked STAR DIAGNOSIS diagnosis system l Access to "SDflash" with corresponding rights SCN coding with "SDflash" 1. Confirm note on sequence of SCN coding with the "F2 button". 2. Select "Operation step 1: Determine vehicle data for online SCN coding from the vehicle" menu and confirm with the "F3 button". 3. Confirm the correct vehicle identification number with the "F3 button". The note that the vehicle data determination was successful appears in the display. 4. Select "Operation step 2: online query SDflash" menu and confirm with the "F3 button". 5. Press "F2 button" for starting the online query. 6. Press "F2 button" for starting the web browser. The web page of the aftersales platform appears in the display. 7. Select the symbol (house) which is located in the top third of the web page. 8. Enter user name and password and select logging on symbol. The applications available appear in the display. 9. Select "SDflash" in the display. 10. Select symbol (Start) in the display. The message that the SCN coding and the coding string formation has been successfully finished appears in the display. 11. After "When the inquiry about the coding data has finished, proceed with the F2 button" appears in the display, press the "F2 button". 12. Select "Operation step 2: Perform SCN coding" menu and confirm with "F3 button". 13. Confirm the correct vehicle identification number with the "F3 button". 14. Press "F3 button" and transfer coding data to the control unit. 15. Once "Switch on ignition" appears in the display, switch on ignition. The coding process starts automatically and lasts about 10 seconds. 16. Once "Switch off ignition" appears in the display, switch off ignition. 17. After the coding process has finished the order event log for the documentation of the SCN repair order appears. This order event log must be filled in completely, then printed out with the "F11 button" and enclosed with the repair order. 18. Finish SCN coding by pressing the "F2 button". The online SCN coding of the control unit is thus successfully completed.

OFFLINE SCN CODING - AR54.21-P-0013-04MCC

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 35 · Applies to: 451 · AR: AR54.21-P-0018MCE

The following work instructions describe the procedure for offline SCN coding. Precondition for offline SCN coding: l STAR DIAGNOSIS diagnosis system with printer and fax machine l Correct adjustment of date and time in STAR DIAGNOSIS l Special equipment which was subsequently installed in or removed from the vehicle, must be redocumented in the vehicle documentation system (FDOK). Offline SCN coding 1. Confirm note on sequence of SCN coding with the "F2 button". 2. Prepare the inquiry form by pressing the "F4 button". 3. Print out inquiry form by pressing the "F11 button". 4. Send the printed-out inquiry form to fax number +49 180511 6373. The inquiry result must be faxed back immediately. 5. Enter "coding string", "SCN" and "check digit [2]" in the corresponding input fields in the diagnosis assistance system and confirm with the "F3 button". 6. Once the coding process has finished the event log on the documentation of the repair order appears. This event log must be filled in completely, then printed out with the "F11 button" and enclosed with the repair order. 7. Finish SCN coding by pressing the "F2 button". SCN coding of the control unit is thus successfully concluded. PERFORM INITIAL STARTUP OF CONTROL UNITS - AR54.21-P-0018MCE MODEL 451.3/4 Startup 1 Connect Star Diagnosis AD00.00-P-2000- 04MCC 2 Enter vehicle identification number in Diagnosis Assistance system (DAS) and open main menu with "F2" button 3 Select menu "Systems" in main menu and confirm with "Button F3" 4 In the "Systems" menu, select the control unit for initial startup and confirm with the "F3" button An "initial startup" is required when replacing the following control units: l Instrument cluster (A1)

REMOVE/INSTALL FRONT SAM CONTROL UNIT - AR54.21-P-1254MCU

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 36 · Applies to: 451 · AR: AR54.21-P-1254MCU

MODEL 451.3/4 l Weight Sensing System (WSS) control unit (N110) with code (494) USA version Starter-alternator control unit (N129) with model 451.334/380/480 l Electronic selector lever module control unit (N15/5) l Restraint systems control unit (N2/7) l Heater and A/C operating unit (N23) with code (I01) A/C Plus l CDI control unit (N3/9) with engine 660 l ME-SFI [ME] control unit (N3/10) with engine 132 l SAM control unit (N10/10) l Automated manual transmission control unit (N15/6) l ESP control unit (N47-5) l Steering assist control unit (N68) l TPM [RDK] control unit (N88) with code (494) USA version 5 In the menu for the selected control unit, choose the "Initial startup" menu item and confirm with the "F3" button 6 Confirm "Notes for initial startup of control unit" with "F2" button 7 Select the "online (networked STAR DIAGNOSIS unit)" menu or "offline (no networked STAR DIAGNOSIS unit)" menu and start by pressing the "F3" button 8 Follow the further instructions in DAS. 9 Close Star Diagnosis

Fig. 32: Identifying Front SAM Control Unit Components

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 37 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Remove/install Notes on avoiding damage to electronic components due to electrostatic discharge AH54.00-P- 0001-01A 1 Turn off ignition 2 Disconnect ground line of battery AR54.10-P- 0003MCC 3 Adjust the left front seat to the rear 4 Unclip left tweeter from the dashboard and place to one side with the electric line connected Vehicles up to 30.8.10 with code (C17) Sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO) or Vehicles with code (C54) Sound system 2 AR82.62-P- 1000MCC 5 Unclip SAM control unit (N10/10) in the rear area (arrow A) and fold down forwards 6 Unscrew bolts (1) and carefully lower the SAM control unit (N10/10) until the electrical connectors (3) are accessible 7 Unclip cover (5) on SAM control unit (N10/10) 8 Unscrew nut (6) and remove positive battery cable (4) If the nut (6) is detached from the positive battery cable (4), it must be replaced by a collar nut. Remove additional fuses (2) with The number of additional fuses may vary (2) depending on the vehicle model and

REMOVE/INSTALL WIPER SWITCH - AR54.25-P-0003MCC

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 38 · Applies to: 451 · AR: AR54.25-P-0003MCC

MODEL 451.3/4 Fig. 33: Identifying Wiper Switch Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 9 connector on SAM control unit (N10/10) equipment. Remove additional fuses (2) with connector as the connectors are coded. 10 Separate electrical connectors (3) and electrical connector (arrow B) 11 Remove SAM control unit (N10/10) from the vehicle 12 Install in the reverse order 13 Flash the SAM control unit (N10/10) When replacing the SAM control unit (N10/10). AR54.21-P- 0012MCU Remove/install 1 Remove steering column cover AR68.30-P- 2000MCC 2 Unclip catch hook (3) on right wiper switch (S4/4) 3 Lift right wiper switch (S4/4) upwards from the guides (4) and remove to one side until the electrical connector (1) is accessible 4 Detach electrical connector (1) on the right wiper switch (S4/4) and remove the right wiper switch (S4/4) 5 Release cap (2) by applying suitable knife to right wiper switch (S4/4) and remove When replacing right wiper switch (S4/4). 6 Install in the reverse order 7 Conduct function test of

REMOVE/INSTALL COCKPIT SWITCH GROUP - AR54.25-P-1000MCC

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 39 · Applies to: 451 · AR: AR54.25-P-1000MCC, AR54.25-P-1030MCU

MODEL 451.3/4 Fig. 34: Removing/Installing Cockpit Switch Group Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig. 35: Identifying Wedge Tool (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. REMOVE/INSTALL IGNITION/STARTER SWITCH LOCK CYLINDER - AR54.25-P-1030MCU MODEL 451.3/4 right wiper switch (S4/4) Remove/install 1 Loosen cockpit switch group (S6/1) using assembly wedge (3) and remove until the electrical connector (1) is accessible *110589035900 2 Separate electrical connector (1) and remove cockpit switch group (S6/1) Check retaining clips (2), replace is necessary. 3 Install in the reverse order

Fig. 36: Identifying Ignition/Starter Switch Lock Cylinder Components

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 40 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Removing 1 Remove transponder coil and put to one side with electrical line connected AR80.35-P- 4515MCU 2 Remove clamp (2) 3 Insert transmitter key (3) into the lock cylinder of the ignition/starter switch (1) and switch on ignition (circuit 15) Ensure that the selector lever is located in position "P". 4 Slide in feeler gauge (4), on the left side as shown, between the lock cylinder of the ignition/starter switch (1) and electronic selector lever module control unit (N15/5) Use blade of feeler gauge (4) with the thickness of 0.15 mm. 5 Pull out lock cylinder of ignition/starter switch (1) with transmitter key (3) upwards If necessary move the feeler gauge (4) slightly, so that the locking device (5) is released from the bracket (arrow). Install 6 Insert lock cylinder of ignition/starter switch (1) with transmitter key (3) in the electronic selector lever module control unit (N15/5) Ensure that the selector lever is located in position "P". The lock cylinder of the ignition/starter switch (1) must engage audibly in the electronic selector lever module (N15/5) control unit. 7 Remove transmitter key (3) 8 Install transponder coil AR80.35-P-

REMOVE/INSTALL COMBINATION SWITCH - AR54.25-P-2800MCC

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 41 · Applies to: 451 · AR: AR54.25-P-2800MCC, AR54.25-P-2803MCC

MODEL 451.3/4 Fig. 37: Identifying Combination Switch Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. REMOVE/INSTALL CRUISE CONTROL SWITCH - AR54.25-P-2803MCC MODEL 451.3/4 with CODE (V27) Cruise control/Temposet 4515MCU Remove/install 1 Remove steering column cover AR68.30-P- 2000MCC 2 Unclip catch hook (3) on combination switch (S4) 3 Lift combination switch (S4) upwards from the guides (4) and remove to one side until the electrical connector (1) is accessible 4 Detach electrical connector (1) on the combination switch (S4) and remove combination switch (S4) 5 Release cap (2) by applying suitable knife to combination switch (S4) and remove When replacing the combination switch (S4). 6 Install in the reverse order 7 Conduct function test of combination switch (S4)

Fig. 38: Identifying Cruise Control Switch Components

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 42 · Applies to: 451 · AR: AR54.30-P-6015MCU

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. REMOVE/INSTALL INSTRUMENT CLUSTER - AR54.30-P-6015MCU MODEL 451.3/4 Remove/install 1 Remove front cover (1) from steering wheel spokes AR46.10-P- 0105MCC 2 Unclip electrical wiring harness (3) from mounting (arrows) of front cover (1) 3 Unscrew left and right bolts (2) Installation: Carefully tighten bolts (2) and make sure that the front covering (1) is not damaged as otherwise it will have to be replaced. 4 Remove left cruise control switch (S112s4) and right cruise control switch (S112s5) The left cruise control switch (S112s4) and right cruise control switch (S112s5) are designed as a unit and they cannot be separated. Installation: Check left cruise control switch (S112s4) and right cruise control switch (S112s5) are correctly seated in the front cover (1). 5 Install in the reverse order

Fig. 39: Identifying Instrument Cluster, Clips And Connector

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 43 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. PARTS ORDERING NOTES Remove/install Notes on avoiding damage to electronic components due to electrostatic discharge AH54.00- P-0001- 01A 1 Pull the instrument cluster (A1) in the direction of the arrow out of the dashboard upper section until the connector (2) on the instrument cluster (A1) is accessible Check position of clamps (1). When removing the instrument cluster (A1) there is the danger that the clamps (1) can fall through the openings (arrows A) in the instrument cluster (A1). 2 Unlock connector (2) on the instrument cluster (A1), detach and remove instrument cluster (A1) backwards Clamps (1), which have fallen into instrument cluster (A1) when removing, must be got out again otherwise a short circuit in the instrument cluster can occur (A1). This must only take place through the opening a (arrow A). Disassembling the instrument cluster (A1) is not permissible. 3 Remove clamps (1) on top part of dashboard or on instrument cluster (A1) Installation: The clamps (1) are to be replaced by the clamps (1) listed in the Parts ordering notes table. Insert new clamps (1) in the top part of the dashboard. 4 Install in the reverse order 5 Set clock in the instrument cluster (A1) Part no. Designation Quantity A 203 988 28 78 Clamp 2

REMOVE/INSTALL ADDITIONAL INSTRUMENTS - AR54.30-P-6080MCC

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 44 · Applies to: 451 · AR: AR54.30-P-6080MCC, AR54.30-P-6080MCF

MODEL 451.3/4 as of 31.8.10 with CODE (V31) Cockpit clock and tachometer package Fig. 40: Identifying Additional Instruments Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. REMOVE/INSTALL ADDITIONAL INSTRUMENTS - AR54.30-P-6080MCF MODEL 451.3/4 as of 31.8.10 with CODE (V31) Cockpit clock and tachometer package Remove/install 1 Remove instrument cluster (A1) * not for USA AR54.30-P- 6015MCC * for USA only AR54.30-P- 6015MCU 2 Remove covering (2) of additional instruments (A15) 3 Remove bolt (3) of additional instruments (A15) 4 Adjust driver seat to the rear 5 Unhook wiring harness for additional instruments (1) from holders (arrows) at bottom of instrument panel upper section The wiring harness additional instrument (1) can be accessed from the driver footwell. 6 Detach the additional instrument connector (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)

Fig. 41: Identifying Additional Instruments Components

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 45 · Applies to: 451 · AR: AR54.30-P-6341MCC

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. REMOVE/INSTALL OUTSIDE TEMPERATURE INDICATOR SENSOR - AR54.30-P-6341MCC MODEL 451.3/4 Remove/install 1 Remove instrument cluster (A1) * not for USA AR54.30-P- 6015MCC * for USA only AR54.30-P- 6015MCU 2 Remove covering (2) of additional instruments (A15) 3 Remove bolt (3) of additional instruments (A15) 4 Adjust driver seat to the rear 5 Unhook wiring harness for additional instruments (1) from holders (arrows) at bottom of instrument panel upper section The wiring harness additional instrument (1) can be accessed from the driver footwell. 6 Detach the additional instrument connector (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)

Fig. 42: Identifying Outside Temperature Indicator Sensor Components

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 46 · Applies to: 451 · AR: AR54.35-P-1556MCU

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. REMOVE/INSTALL SIGNALING HORN - AR54.35-P-1556MCU MODEL 451.3/4 Fig. 43: Identifying Horn And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA. SAFETY PRECAUTIONS Remove/install 1 Turn the steering to the left 2 Pull the outside temperature display temperature sensor (B14) out of the front module (2) 3 Unplug electrical connector (1) and remove outside temperature indicator temperature sensor (B14). 4 Install in the reverse order Remove/install 1 Remove front CBS AR88.00-P- 1010MCC 2 Disconnect electrical connectors from horn (H2) Installation: Carry out a function test after connecting the electrical connectors to the horn (H2). 3 Unscrew bolt (1) and remove horn (H2) 4 Install in the reverse order

SAFETY INFORMATION: ELECTRICAL SYSTEM, EQUIPMENT AND INSTRUMENTS -

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 47 · Applies to: 451 · AR: AS54.00-Z-9999ZZ

AS54.00-Z-9999ZZ MODEL all RISK OF EXPLOSION FROM GAS. RISK OF POISONING AND BURNS FROM SWALLOWING BATTERY ELECTROLYTE. RISK OF INJURY TO EYES AND SKIN AS RESULT OF CAUSTIC BURNS FROM BATTERY ELECTROLYTE OR FROM HANDLING DAMAGED LEAD-ACID BATTERIES. - AS54.10-Z-0001-01A No fire, sparks, naked flames or smoking. Wear acid-resistant gloves, clothing and eye protection. Pour battery electrolyte only into suitable and appropriately marked containers. Possible hazards Risk of explosion A highly explosive gas mixture is produced when charging lead-acid batteries. Risk of poisoning If battery electrolyte is swallowed , this can result in manifestations of poisoning such as headaches, dizziness, stomach pain, respiratory paralysis, unconsciousness, vomiting and cramps. Battery electrolyte mist causes caustic burns to the eyes. If swallowed, this can result in caustic burns to the mucous membranes and respiratory passages. The absorption of lead in the body can cause damage to blood, nerves and kidneys; in addition, lead compounds are considered to represent a reproductive hazard. Injury hazard Battery electrolyte contains sulfuric acid which can cause severe caustic burns to skin and eyes. Strict caution is required when handling damaged lead-acid batteries (removing from vehicle damaged in accident) Risk of death when touching components on vehicles with high-voltage on-board electrical system MODEL all AS54.00-Z-0001-01A Risk of death when touching components on vehicles with high-voltage system MODEL 451.391/491 AS54.00-Z-0001- 02MEV Risk of explosion from gas. Risk of poisoning and burns from swallowing battery electrolyte. Risk of injury to eyes and skin as result of caustic burns from battery electrolyte or from handling damaged lead-acid batteries. MODEL all AS54.10-Z-0001-01A Risk of injury caused by contact with battery gel when handling damaged lead- gel batteries MODEL all AS54.10-Z-0001-02A

because of the sharp edges on the fractured housing and direct contact with the lead plates.

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 48 · Applies to: 451

Protective measures/rules of conduct ¡ Charge lead-acid batteries only in well ventilated areas. ¡ No fire, sparks, naked flames or smoking. ¡ Do not place any tool or other conducting objects onto the lead-acid battery (risk of short-circuit). ¡ Disconnect and remove lead-acid batteries for charging. ¡ Always disconnect negative terminal first of all; always connect positive terminal first of all. ¡ Do not switch on the charger until after it has been connected to the terminals; switch it off before disconnecting. ¡ Keep lead-acid batteries and battery electrolyte away from unauthorized persons. Pour battery electrolyte only into suitable and appropriately marked containers. ¡ Always store lead-acid batteries horizontally. ¡ Ensure the gassing line is properly connected. ¡ Ensure the gassing line does not have any kinks and is not blocked at any point. ¡ Pay attention to instructions for use of the particular lead-acid battery and the operating instructions of the vehicle. ¡ Wear acid-resistant clothing and eye protection with side guards. First-aid measures Eye contact l Rinse out eyes immediately with plenty of water. Skin contact Take off moistened clothing. l Immediately neutralize acid splashes on skin or clothing with acid converter or soap suds and rinse off with plenty of water. Inhaling battery electrolyte mist l Take the affected person out into the fresh air. Swallowing battery electrolyte l Have the person affected drink plenty of water with the addition of activated charcoal. As a general rule, the person affected should consult a medical service or doctor after first-aid has been rendered. Fire protection measures Suitable extinguishing agents

¡ CO2 and dry extinguishing agent

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 49 · Applies to: 451

Fig. 44: Identifying Warning Instructions For Lead-Acid Batteries Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Warning instructions for lead-acid batteries RISK OF INJURY CAUSED BY CONTACT WITH BATTERY GEL WHEN HANDLING DAMAGED LEAD-GEL BATTERIES - AS54.10-Z-0001-02A No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and safety glasses. Potential risks Risk of poisoning If battery gel is swallowed this can cause poisoning symptoms such as headaches, dizziness, stomach aches, respiratory paralysis, unconsciousness, vomiting, caustic burns and cramps. The absorption of lead in the body can cause damage to blood, nerves and kidneys; in addition, lead compounds are considered to represent a reproductive hazard. Risk of injury Battery electrolyte gel is just as caustic as normal electrolyte fluid and can cause serious caustic burns to the skin and eyes. Strict caution is required when handling damaged lead-gel batteries (e.g. when removing from a vehicle damaged in an accident) due to the sharp edges on a broken housing and direct contact with the lead plates. Safety precautions and rules of conduct ¡ No fires, sparks, open flames or smoking. ¡ Keep tools and other conductive objects away from lead-gel batteries (risk of short-circuit). ¡ Disconnect and remove lead-gel batteries for charging.

¡ Always disconnect negative terminal before positive terminal and always connect positive

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 50 · Applies to: 451 · AR: AZ54.30-P-0001MCC

terminal before negative terminal ¡ Switch on the charging equipment only after connecting to the terminals and switch off the charging equipment before disconnecting from the terminals. ¡ Keep lead-gel batteries away from unauthorized persons (especially children). ¡ Observe the instructions of the particular lead-gel battery and the operator's manual of the vehicle. ¡ Wear acid-resistant clothing and eye protection with side guards. ¡ Only fill gel into suitable and appropriately marked containers. First aid measures Eye contact l Rinse out eyes immediately with plenty of water. Skin contact l Remove affected clothing. l Immediately neutralize acid or gel on skin or clothing with acid converter or soap suds and rinse off with plenty of water. Swallowing battery gel l Have the person affected drink plenty of water with the addition of activated charcoal. As a general rule, always consult a medical service or doctor after first-aid has been rendered. Fire protection measures Suitable extinguishing agents ¡ CO2 and dry extinguishing agent RETROFITTING & CONVERSION RETROFIT ADDITIONAL INSTRUMENTS - AZ54.30-P-0001MCC MODEL 451.3/4 up to 30.8.10

Fig. 45: Identifying Cover And Cutouts

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 51 · Applies to: 451 · AR: AZ54.30-P-0001MCD

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig. 46: Identifying Additional Instruments Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. RETROFIT ADDITIONAL INSTRUMENTS - AZ54.30-P-0001MCD Remove 1 Remove cover (1) on center console AR68.20-P- 2350MCC Install 2 Make the cutouts (2) to match the perforation (arrows) on the cover (1) 3 Position additional instruments (A15) on dashboard upper section and fasten in place using the bolts (3) 4 Connect additional instruments connector (A15x1) The plug for the additional instrument connector (A15x1) is located in the attachment between the air vents. If the plug for the additional instrument connector (A15x1) has not been clipped into the attachment, then the wiring harness is to be tied back and down in a loop. 5 Fit cover (1) onto center console AR68.20-P- 2350MCC 6 Set clock of additional instruments (A15) 7 Add special equipment to the vehicle data card and to the online vehicle data card Code (V31) Cockpit clock and tachometer package to be added.

MODEL 451.3/4 as of 31.8.10

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 52 · Applies to: 451

Parts scope for additional instrument (A15) Fig. 47: Identifying Cover, Screw And Additional Instruments Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig. 48: Removing Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig. 49: Identifying Additional Instruments Components

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 53 · Applies to: 451 · AR: AR54.30-P-6015MCC, AR54.30-P-6015MCU

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Remove 1 Adjust driver seat to the rear 2 Remove instrument cluster (A1) * not for USA AR54.30-P-6015MCC * for USA only AR54.30-P-6015MCU 3 Detach covering (3) with clip remover, as shown, and remove Clip remover *452589016300 Install 4 Slide wiring harness for additional instruments (6) through the left opening and under the covering (3) towards the instrument cluster 5 Clip additional instruments (A15) into instrument panel 6 Bend into the footwell and route wiring harness for additional instrument (6) at the bottom of the instrument panel upper section towards the instrument cluster 7 Hook wiring harness for additional instruments (6) into holders (arrow C and B) at bottom on instrument panel upper section 8 Detach black, 3-pin connector (5) from vehicle wiring harness in area of instrument cluster (A1) 9 Connect black, 3-pin connector (5) and black, 3-pin coupling (6.1) of The additional instruments connector

Fig. 50: Identifying Snap-Release Tool (452 589 01 63 00)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 54 · Applies to: 451 · AR: AZ54.30-P-0001MCD

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. PARTS ORDERING NOTES TORQUE SPECIFICATIONS TIGHTENING TORQUES: SMART: ELECTRICAL SYSTEM, EQUIPMENT AND INSTRUMENTS wiring harness for additional instruments (6) (A15x1) is now complete. 10 Use bolt (1) to tighten additional instruments (A15) 11 Clip cover (2) over the bolt (1) on the additional instruments (A15) 12 Move driver seat back to its default position 13 Install in the reverse order 14 Set clock of additional instruments (A15) 15 Connect Star Diagnosis AD00.00-P-2000- 04MCC 16 Enter special equipment on the vehicle data card and the online vehicle data card Code (V31) Cockpit clock and tachometer package to be added. 17 Disconnect Star Diagnosis AD00.00-P-2000- 04MCC 18 Document retrofitted equipment using vehicle documentation (VeDoc) Attach "Additional instruments (A15) retrofitted as per AZ54.30-P-0001MCD" note under field organization text for design group 54. Part no. Designation Quantity DG 54 (see EPC) Additional instruments 1 DG 54 (see EPC) Screw 1 DG 54 (see EPC) Cover 1

- BA54.00-Z-9999CZ

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 55 · Applies to: 451 · AR: BA54.00-Z-9999CZ, BE54.00-Z-9999CZ

MODEL all TEST & ADJUSTMENT VALUES TEST AND ADJUSTMENT VALUES: SMART: ELECTRICAL SYSTEM, EQUIPMENT AND INSTRUMENTS - BE54.00-Z-9999CZ MODEL all TEST VALUES FOR BATTERY, VOLTAGE SUPPLY - BE54.10-P-1000-01A All MODIFICATION NOTES TEST AND ADJUSTMENT VALUES FOR THE BATTERY TEST AND ADJUSTMENT VALUES FOR THE BATTERY Battery MODEL 454.0, 451.391 /491 BA54.10-P-1000-01E Battery MODEL 451.391/491 BA54.10-P-1000-01H Control units/base module MODEL 450, 451.334 /380 /480 BA54.21-P-1000-01B Signaling system MODEL 450.3 BA54.35-P-1000-01B Wiring harness MODEL 450.3 /4 BA54.18-P-1000-02A Test values for battery, voltage supply MODEL all BE54.10-P-1000-01A 24.2.06 Cold test current 12 AH Number Designation 12 AH 30 AH 35 Ah 42 AH BE54.10-P- 1001-01A Battery test at 20°C Acid density kg/dm3 -

or =1,24 > or =1,24 - Maximum permissible difference between individual battery cells kg/dm3 - 0,04 0,04 - Load current A - 90 100 - Load time s - 10 10 - Voltage VV - approx.10 approx.10 - BE54.10-P- 1002-01A Cold test current as per EN A 170 540 520 340 Number Designation 46 AH 60 Ah VRLA 60 AH 61 AH BE54.10-P- 1001-01A Battery test at 20°C Acid density kg/dm3 or =1,24 - - - Maximum permissible kg/dm3 0,04 - - -

TEST AND ADJUSTMENT VALUES FOR THE BATTERY

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 56 · Applies to: 451 · AR: GF54.15-P-0800MCU

TEST AND ADJUSTMENT VALUES FOR THE BATTERY BASIC KNOWLEDGE FUSE AND RELAY BOX, AS-BUILT CONFIGURATION - GF54.15-P-0800MCU MODEL 451.3/4 difference between individual battery cells Load current A 140 - - - Load time s 10 - - - Voltage VV approx.10 - - - BE54.10-P- 1002-01A Cold test current as per EN A 420 680 510 540 Number Designation 62 AH 70 Ah VRLA 74 AH 80 Ah VRLA BE54.10- P-1001- 01A Battery test at 20°C Acid density kg/dm3

or =1,24 - or =1,24 - Maximum permissible difference between individual battery cells kg/dm3 0,04 - 0,04 - Load current A 190 - 265 - Load time s 10 - 10 - Voltage VV approx.10 - approx.10 - BE54.10- P-1002- 01A Cold test current as per EN A 480 760 680 800 Number Designation 84 AH 90 Ah VRLA 95 Ah VRLA 100 Ah BE54.10-P- 1001-01A Battery test at 20°C Acid density kg/dm3 - - - or =1,24 Maximum permissible difference between individual battery cells kg/dm3 - - - 0,04 Load current A - - - 300 Load time s - - - approx.10 Voltage VV - - - approx.10 BE54.10-P- 1002-01A Cold test current as per EN A 700 950 850 760

Fig. 51: Locating SAM Control Unit

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 57 · Applies to: 451 · AR: PE54.25-P-2000MCU, PE54.25-P-2000MCV, PE54.25-P-2000MCW

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. FUSE AND RELAY BOX FUSE ASSIGNMENT - GF54.15-P-1255-20MCU Fuse and relay assignment of SAM control unit (N10/10) (front side) Fuse and relay box fuse assignment Engine 132.9 GF54.15-P-1255-20MCU Engine 780.0 GF54.15-P-1255-20MEV Fuse and relay box relay assignment Model 451.3/4 (except 451.391/491) GF54.15-P-1255-21MCU Model 451.391/491 GF54.15-P-1255-21MEV Fuse assignment of fuses in the interior on passenger side Model 451.3/4 (except 451.391/491) GF54.15-P-1256-24MCU Model 451.391/491 GF54.15-P-1256-24MEV Wiring diagram electrical center Sheet 1 PE54.25-P-2000MCU Sheet 2 PE54.25-P-2000MCV Sheet 3 PE54.25-P-2000MCW

Fig. 52: Identifying Fuse Sockets Of Front Side SAM Control Unit

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 58 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fuse and relay assignment of SAM control unit (N10/10) (back side) Fig. 53: Identifying Fuse Sockets And Electrical Connectors Of Back Side SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Position Fuse Identification color Fused function Fuse rating in amperes (A) 1 N10/10f1 transparent Starter (M1) 25 2 N10/10f2 transparent Wiper motor (M6/1) 25 3 N10/10f3 Yellow Power window convenience feature control unit (N57/2) (with code (V43) Power window) 20 4 N10/10f4 transparent Blower motor (M2) 25

N10/10f5

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 59 · Applies to: 451

5 N10/10f5 red Left front fog lamp (E5/1) (with code (V07) front fog lamp (FFO)) Right front fog lamp (E5/2) (with code (V07) Front fog lamp (FFO)) 10 6 N10/10f6 brown Right taillight (E4e2) Right parking lamp (E6/14) Left license plate lamp (E19/1) Right license plate lamp (E19/2) 7.5 7 N10/10f7 brown Left taillight (E3e2) Left parking light (E6/13) 7.5 8 N10/10f8 transparent Secondary air injection pump relay (K64) ME-SFI [ME] control unit (N3/10) Electronic selector lever module control unit (N15/5) Automated manual transmission control unit (N15/6) Cylinder 1 ignition coil (T1/1) Cylinder 2 ignition coil (T1/2) Cylinder 3 ignition coil (T1/3) 25 9 N10/10f9 brown O2 sensor downstream of CAT (G3/1) Adjustable camshaft timing solenoid (Y49) External air shutoff valve (Y50) Activated charcoal canister shutoff valve (Y58) 7.5 10 N10/10f10 blue O2 sensor upstream of CAT (G3/2) Secondary air injection pump switchover valve (Y32) Cylinder 1 fuel injection valve (Y62/1) Cylinder 2 fuel injection valve (Y62/2) Cylinder 3 fuel injection valve (Y62/3) 15 11 N10/10f11 transparent ESP control unit (N47-5) 25 12 N10/10f12 red Instrument cluster (A1) Additional instruments (A15) Microwave sensor (B32) (with code (V01) Vehicle theft alarm (FFO)) Rain sensor / light sensor (B38) (with code (V54) Rain/light sensor) Alarm siren with inclination sensor (H3/2) (with code (V01) Vehicle theft alarm (FFO)) Left turn signal lamps/brake light relay (K52/11) Right turn signal lamps/brake light relay (K52/12) Mirror heater relay (K97) Automated manual transmission control unit (N15/6) TPM [RDK] control unit (N88) Combination switch (S4) 10

Cockpit switch group (S6/1)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 60 · Applies to: 451

Data link connector (X11/4) 13 N10/10f13 blue Spare fuse 15 14 N10/10f14 blue Refrigerant compressor (A9) (with code (I01) Air conditioning Plus) Charge air fan motor (M44) 15 15 N10/10f15 blue smart radio 9 (A2/1) (with code (C57) smart radio 9) smart radio 10 (A2/2) (with code (C50) smart radio 10) Front interior lamp (E15/4) (with vehicles up to production date 1.9.10) Soft top OPEN relay (K66/1) (on model 451.4) Soft top CLOSE relay (K66/2) (on model 451.4) 15 16 N10/10f16 blue Fuel pump with fuel gauge sensor (M3/3) ME-SFI [ME] control unit (N3/10) 15 17 N10/10f17 blue Rear-end door wiper motor (M6/4) (with model 451.3) 15 18 N10/10f18 red Instrument cluster (A1) Yaw rate sensor for lateral and longitudinal acceleration (B24/15) Seat occupied recognition pressure sensor (B48/4) Automatic child seat recognition airbag OFF indicator lamp (E16) Restraint systems control unit (N2/7) ESP control unit (N47-5) Steering angle sensor (N49) Steering assist control unit (N68) (with code (V26) Power steering, EPS (FFO)) Driver side seat belt buckle restraint systems switch (S68/3) Front passenger-side seat belt buckle restraint systems switch (S68/4) 10 19 N10/10f19 Brown ME-SFI [ME] control unit (N3/10) Automated manual transmission control unit (N15/6) Data link connector (X11/4) TPM [RDK] control unit (N88) 7,5 20 N10/10f20 red smart radio 9 (A2/1) (with code (C57) smart radio 9) smart radio 10 (A2/2) (with code (C50) smart radio 10) Heater/air conditioning operating unit (N23) (for code (I01) Air conditioning Plus) Front seat heater (SIH) control unit (N25/5) (with code (S17) Seat heater 10

(FFO))

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 61 · Applies to: 451

Right wiper switch (S4/4) Outside mirror adjustment switch (S50) (with code (V21) Electrically adjustable and heated outside mirrors (FFO)) Soft top operation (S84) (on model 451.4) 21 N10/10f21 blue Interior socket (X58/1) 15 22 N10/10f22 brown Left low beam (E1e2) 7.5 23 N10/10f23 brown Right low beam (E2e2) 7.5 24 N10/10f24 blue Electronic selector lever module control unit (N15/5) 15 25 N10/10f25 brown Right high beam (E2e1) 7.5 26 N10/10f26 brown Left high beam (E1e1) 7.5 27 N10/10f27 brown ME-SFI [ME] control unit (N3/10) 7.5 28 N10/10f28 orange Heated rear window (R1) 40 29 N10/10f29 green Soft top OPEN relay (K66/1) (on model 451.4) Soft top CLOSE relay (K66/2) (on model 451.4) 30 30 N10/10f30 orange Automated manual transmission control unit (N15/6) 40 31 N10/10f31 Yellow Horn (H2) Right door CL motor (M14/5) Left front door central locking motor (M14/6) Rear-end door CL [ZV] motor (M14/7) Fuel filler flap CL [ZV] motor (M14/10) Horn switch (S4/2) 20 32 - - vacant - 33 N10/10f33 red Ignition/starter switch (S2/1) 50 34 N10/10f34 orange ESP control unit (N47-5) 40 35 N10/10f35 green Steering assist control unit (N68) (with code (V26) Power steering, EPS (FFO)) 30 36 N10/10f36 orange Secondary air injection pump (M33) R1 - brown Mirror heater relay (K97) (with code (V21) Electrically adjustable and heated outside mirrors (FFO)) 7.5 R2 - brown Stop light switch (S9/1) 7.5 R3 - - VACANT - R4 - - vacant - R5 - - vacant - R6 - - vacant - R7 - - Front interior lamp (E15/4) (with vehicles as of production date 2.9.10) - R8 - Yellow Sound system amplifier (for vehicles as of production date 2.9.10 with code (C17) Sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO)) 20

FUSE AND RELAY BOX RELAY ASSIGNMENT - GF54.15-P-1255-21MCU

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 62 · Applies to: 451

Fig. 54: Identifying SAM Control Unit And Relay Sockets Courtesy of MERCEDES-BENZ OF NORTH AMERICA. FUSE ASSIGNMENT OF FUSES IN THE INTERIOR ON PASSENGER SIDE - GF54.15-P-1256- 24MCU Fig. 55: Locating Secondary Air Injection Pump Fuse, Starter/Alternator Fuse And SAM Prefuse R9 - transparent Front seat heater (SIH) control unit (N25/5) (with code (S17) Seat heater (FFO)) 25 Position Relay Switched function A K52/11 Left turn signal/stop lamp relay B K52/12 Right turn signal/stop lamp relay C K97 Mirror heater relay (with code (V21) Electrically adjustable and heated outside mirrors (FFO))

Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 63 · Applies to: 451 · AR: GF54.21-P-4157MCU

COMPONENT DESCRIPTION FOR THE SAM CONTROL UNIT - GF54.21-P-4157MCU MODEL 451.3/4 Location The SAM control unit is located in the footwell on the passenger side. Task The SAM control unit supplies control units and electrical components with voltage via limit switches. The individual control units and electrical components are fused via the fuse and relay blocks contained in the SAM control unit. Fig. 56: Locating SAM Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA. The SAM control unit controls the following functions: l Drive authorization l Central locking l Exterior lighting l Interior lighting Fuse Clamping device Wire Identification Fused function Rating in amperes (A) F36 30 4.0 RD Secondary air injection pump (M33) 50 F58 30 16.0 RD Starter (M1), alternator (G2) 200 F91 30 16.0 RD SAM control unit (N10/10) 100

l Wiper system

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 64 · Applies to: 451

l Rear window defroster l Heated outside mirror (with code (V21) Electrically adjustable and heated outside mirror (FFO)) l Anti-theft alarm system (with code (V01) Anti-theft alarm system (FFO)) l Soft top (with model 451.4) Requests are conveyed to the SAM control unit via data bus systems or via read-in switches and sensors. The SAM control unit is a subscriber on the Controller Area Network (data bus/CAN bus) (CAN). The following components are read in to control the functions: Via local interconnect network interior 1 (LIN B): l Rain sensor / light sensor (B38) (with code (V54) Rain/light sensor) l Tachometer (A15p4) (with code (V31) Cockpit clock and tachometer package) Via local interconnect network interior 2 (LIN C): l Alarm siren with inclination sensor (H3/2) (with code (V01) Vehicle theft alarm (FFO)) l Microwave sensor (B32) (with code (V01) Vehicle theft alarm (FFO)) Components read in directly: l Transmitter key l Transponder coil (L11) l Wiper motor (M6/1) l Rear-end door wiper motor (M6/4) (on model 451.3) l Heated rear window switch (N23s1) l Ignition/starter switch (S2/1) l Combination switch (S4) l Fanfare horns switch (S4/2) (except code (I75) Leather sport steering wheel incl. steering wheel rocker switch system) l Right wiper switch (S4/4) l Hazard flasher switch (S6/1s1) l Front fog lamp switch (S6/1s8) (with code (V07) Front fog lamp (FFO)) l (S6/1s9TPM [RDK] switch) l Tow-away protection /Interior protection switch (S6/1s10) (with code (V01) Vehicle theft alarm (FFO)) l Inside unlock CL (ZV) switch (S6/1s11) l Inside lock CL (ZV) switch (S6/1s12) l Stop light switch (S9/1) l Remote trunk opening switch (S15) (on model 451.3) l Trunk lid rotary tumbler microswitch (S17/8) (on model 451.4)

l Soft top operation (S84) (on model 451.4)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 65 · Applies to: 451

l Soft top microswitch (S84/37) (on model 451.4) l Left roof cassette microswitch (S84/38) (on model 451.4) l Right roof cassette microswitch (S84/40) (on model 451.4) l Right door rotary tumbler microswitch (S87/6) l Left door rotary tumbler microswitch (S87/7) l Right rear soft top microswitch (S84/39) (on model 451.4) l Left rear soft top microswitch (S84/41) (on model 451.4) l Tailgate handle switch (S88/9) The following components are actuated directly to carry out the functions: l Refrigerant compressor (A9) (with code (I01) Air conditioning Plus) l Left front lamp unit (E1) ¡ Left high beam (E1e1) ¡ Left low beam (E1e2) ¡ Left turn signal lights (E1e5) ¡ Left standing lights (E6/13) l Right front lamp unit (E2) ¡ Right high beam (E2e1) ¡ Right low beam (E2e2) ¡ Right turn signal lights (E2e5) ¡ Right standing lights (E6/14) l Left taillamp (E3) ¡ Left turn signal lights (E3e11) ¡ Left taillight (E3e2) - Left brake light l Right taillamp (E4) ¡ Right brake light/turn signal lights (E4e11) ¡ Right taillight (E4e2) l Left front fog lamp (E5/1) (with code (V07) front fog lamp (FFO)) l Right front fog lamp (E5/2) (with code (V07) Front fog lamp (FFO)) l Front interior lamp (E15/4) l Left license plate lamp (E19/1) l Right license plate lamp (E19/2) l Center high-mounted stop lamp (E21) l Left auxiliary turn signal lamp (E22/1) l Right auxiliary turn signal lamp (E22/2) l Horn (H2) l Open soft top relay (K66/1) (model 451.4) l Close soft top relay (K66/2) (model 451.4) l Left turn signal lamps/brake light relay (K52/11)

l Right turn signal lamps/brake light relay (K52/12)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 66 · Applies to: 451 · AR: GF54.21-P-6000MCC

l Blower motor (M2) l Fuel pump with fuel gauge sensor (M3/3) l Wiper motor (M6/1) l Rear-end door wiper motor (M6/4) (model 451.3) l Electrical soft top motor (M12/6) (model 451.4) l Left soft top drive (M12/7) (model 451.4) l Right soft top drive (M12/8) (model 451.4) l Right door CL motor (M14/5) l Left front door central locking motor (M14/6) l Rear-end door CL [ZV] motor (M14/7) l Fuel filler flap CL [ZV] motor (M14/10) l Mirror heater (M21/1r1) (with code (V21) Electrically adjustable and heated outside mirror (FFO)) l Mirror heater (M21/2r1) (with code (V21) Electrically adjustable and heated outside mirror (FFO)) l Heated rear window (R1) RAIN/LIGHT SENSOR, COMPONENT DESCRIPTION - GF54.21-P-6000MCC MODEL 451.3/4 with CODE (V54) Rain/light sensor Fig. 57: Locating Rain Sensor/Light Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Location The rain/light sensor is located on the inside of the windshield below the inside rearview mirror. Task To measure the light intensity and degree of wetting of the windshield

Function principle of rain sensor

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 67 · Applies to: 451 · AR: GF54.22-P-2200MCC

Fig. 58: Identifying Rain Sensor Principle Function Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Infrared light is radiated from the infrared transmitter unit and led to the windshield. The intensity of the light reflected at the windshield is measured by the infrared receiver unit If the windshield is dry in the area of the rain/light sensor (picture A), then the light is reflected almost completely and the infrared receiver unit measures a high light intensity If the windshield is wetted in the area of the rain/light sensor (picture B), then part of the light is scattered from the windshield glass. As a result the intensity of the reflected light reduces and the infrared receiver unit measures a lower light intensity. The light intensity measured by the infrared receiver unit represents a measure for the degree of wetting of the windshield. The smaller the measured light intensity the greater the degree of wetting of the windshield. Function principle of light sensor The light sensor measures the light intensity striking it from outside. The resistance in the light sensor drops as the light intensity reduces. The information from the rain/light sensor is passed on to the SAM control unit (N10/10) via the local interconnect network interior 1 (LIN B). DATA LINK CONNECTOR COMPONENT DESCRIPTION - GF54.22-P-2200MCC MODEL 451.3/4 Shown on LHD model

Fig. 59: Locating Data Link Connector

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 68 · Applies to: 451 · AR: GF54.25-P-4300MCU

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Location The data link connector is located in the footwell on the driver-side. Task The data link connector is the interface for the connection of STAR DIAGNOSIS to the Controller Area Network (data bus/CAN bus) (CAN). COCKPIT SWITCH GROUP, COMPONENT DESCRIPTION - GF54.25-P-4300MCU MODEL 451.3/4

Fig. 60: Identifying Cockpit Switch Group Components

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 69 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Location The cockpit switch group is located in the center console. Task The cockpit switch group reads in the switching requirements and passes these on to the following control units: l Front HS [SIH] control unit (N25/5) (with code (S17) Seat heaters (FFO)) ¡ Left seat heater switch ¡ Right seat heater switch l SAM control unit (N10/10) ¡ Hazard warning flasher switch ¡ Inside unlock CL [ZV] switch ¡ Inside lock CL [ZV] switch ¡ Rear fog lamp switch - Front fog lamps switch ¡ Towing-away protection switch INSTRUMENT CLUSTER (IC [K]), DISPLAY INSTRUMENT AND WARNING SYSTEMS - GF54.30-P-0002-08MCU Shown on code (K07) Speedometer (miles)

Fig. 61: Identifying Instrument Cluster And Warning Switch Systems Displays

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 70 · Applies to: 451 · AR: GF54.30-P-0002MCU

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. INSTRUMENT CLUSTER (IC), FUNCTION - GF54.30-P-0002MCU MODEL 451.3/4 Fig. 62: Instrument Cluster Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA. General The instrument cluster has the following tasks: l Vehicle speed display l Output of the important operating condition of the vehicle l Warning at critical vehicle operating conditions (visual and acoustic)

l Information display for various systems

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 71 · Applies to: 451

l Display for maintenance interval display Networking The instrument cluster functions as a gateway between CAN and CAN-B. Display elements l Left turn signal indicator lamp l Right turn signal indicator lamp l High beam indicator lamp l Alternator charge monitoring and warning lamp l Brake fluid and parking brake warning lamp l Seat belt warning lamp l Airbag indicator and warning lamp l ABS indicator lamp l Electric steering indicator lamp l "CHECK ENGINE" MIL l Oil pressure warning lamp l ESP warning lamp l Coolant temperature warning lamp l Tire pressure monitor warning lamp l Low beam indicator lamp l Electronic speedometer (A1p8) l Multifunction display (A1p13) l Tank cap monitoring warning lamp All indicator and warning lamps are light emitting diodes. Operation The lower left button in the instrument cluster can be used to switchover the multifunction displays. The lower right button in the instrument cluster can adjust the instrument cluster illumination at circuit 15 ON and circuit 58 ON in five dimmer stages to match individual requirements. Activate Circuit 15 ON activates the instrument cluster. The multifunction display shows the current content at any given time, switches on the instrument cluster illumination and the needle for the speed display is shown on the display field. After circuit 15 OFF the instrument cluster remains active for another 30 s. The speed display needle disappears from the display field behind a cover.

For circuit 15 OFF the instrument cluster can be activated under the following preconditions:

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 72 · Applies to: 451 · AR: PE54.30-P-2001MCU

l Circuit 58 ON The instrument cluster illumination is switched on and the current contents of the multifunction display are displayed. After circuit 58 OFF the instrument cluster remains active for another 30 s. l By pressing a button on the instrument cluster. The multifunction display illumination is switched on for 30 s and the current content displayed. Acoustic signals The following acoustic signals are produced and output via the sound signal generator integrated in the instrument cluster: l Turn signal indicator l Warning and information signals Turn signal indicator The turn signal indicator is always accompanied by an acoustic clicking sound generated in the same rhythm. The acoustic turn signal indicator is actuated with: l Turn signaling (at double frequency if a turn signal lamp fails) l Hazard warning flashing Warning and information signals A warning or signal tone is emitted: l When the standing lights are switched on, the transmitter key removed and the driver door open (light warning) l When the driver door is opened while the engine is running and a gear engaged (door warning) l As confirmation that the daytime running lights have been activated or deactivated (with code (K06) Daytime running lights) l If at circuit 15 On and with the doors closed, the driver seat belt buckle restraint systems switch (S68/3) is not closed (seat belt reminder warning) l If the driver seat belt buckle restraint systems switch or the front passenger seat belt buckle restraint systems switch (S68/4) is not closed when the front passenger seat is occupied and the vehicle speed is v > 25 km/h (seat belt reminder warning) l After circuit 15 Off and after removing the transmitter key, when the vehicle was locked using the emergency function Actuation in each instance is via the CAN by the SAM control unit. Instrument cluster (IC [K]), display instrument and warning systems GF54.30-P-0002-08MCU Wiring diagram large instrument (instrument cluster) PE54.30-P-2001MCU

TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF INSTRUMENT CLUSTER (IC) -

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 73 · Applies to: 451 · AR: GF54.30-P-0997MCU, GF54.30-P-2001MCU, PE54.30-P-2051MCU, GF54.30-P-3025MCU, GF54.30-P-3041MCU (+3 more)

GF54.30-P-0997MCU MODEL 451.3/4 INDICATOR/WARNING MESSAGES, FUNCTION - GF54.30-P-2001MCU MODEL 451.3/4 Shown on code (K07) Speedometer (miles) Electrical function schematic for instrument cluster (KI) PE54.30-P-2051MCU Indicator/warning messages, function GF54.30-P-2001MCU Display speed, function GF54.30-P-3025MCU Display operating conditions, function GF54.30-P-3041MCU Instrument cluster (IC), function GF54.30-P-0002MCU Instrument cluster (IC [K]), display instrument and warning systems GF54.30-P-0002-08MCU Wiring diagram large instrument (instrument cluster) PE54.30-P-2001MCU Electrical function schematic for instrument cluster (KI) PE54.30-P-2051MCU Indicator/warning messages, function GF54.30-P-2001MCU Display speed, function GF54.30-P-3025MCU Display operating conditions, function GF54.30-P-3041MCU Overview of system components, instrument cluster (IC) component description GF54.30-P-9996MCU

Fig. 63: Identifying Indicator/Warning Messages Displays

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 74 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Function Various alternatives are available to the instrument cluster for the output of messages: Visual indicator/warning message via ¡ Indicator/warning lamps ¡ Multifunction display Acoustic indicator/warning messages via ¡ internal tone signal generator Visual indicator/warning messages via indicator/warning lamps Turn signal indicator lamps These are activated differently according to function: ¡ Turn signaling ¡ Hazard warning flasher The turn signal flasher is always accompanied by an acoustic clicking sound generated in the same rhythm. Turn signaling: During turn signaling the corresponding turn signal indicator lamp is actuated. Actuation takes place via the Controller Area Network (data bus/CAN bus) (CAN) by the SAM control unit (N10/10). If one of the following lamps malfunctions, the corresponding turn signal indicator lamp is then actuated at doubled-up frequency by the SAM control unit. ¡ Left turn signal lamp (E1e5) ¡ Right turn signal lamp (E2e5) ¡ Left additional turn signal lamp (E22/1) ¡ Right additional turn signal lamp (E22/2) ¡ Left brake/turn signal lights (E3e11) ¡ Right brake/turn signal lights (E4e11) Hazard warning flasher: When the hazard warning flashers are on the two turn signal indicator lamps in the instrument cluster are actuated. High beam indicator lamp

Actuation is conducted when the high beam is switched on over CAN by the SAM control unit.

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 75 · Applies to: 451

Alternator charge indicator/warning lamp If there is a fault in the alternator (G2) the alternator charge monitoring and warning lamp is actuated. Actuation take place via the CAN from the ME control unit (N3/10). Brake fluid and parking brake warning lamp Actuation takes place over the CAN under the following preconditions: l From the SAM control unit for an actuated parking brake l From the ESP control unit (N47-5) at a minimum brake fluid level in the reservoir l From the ESP control unit for a fault of the Electronic Stability Program (Electronic-Stability- Program) Seat belt warning lamp The seat belt warning lamp lights permanently for t = 6s when at circuit 15 ON the driver seat belt buckle restraint systems switch (S68/3) is not closed. A warning tone is also emitted for t = 6 s. As from a vehicle speed of 25 km/h the seat belt warning lamp starts to flash on and off for t = 60 s, when the driver seat belt buckle restraint systems switch or the front passenger seat belt buckle restraint system switch (S68/4) (when front passenger occupied) is not closed. A warning tone is emitted in parallel. The warning tone is emitted in three phases, whereby the frequency changes every 20 s. After this, only the seat belt warning lamp is permanently actuated. The seat belt reminder warning (optical and acoustic) is terminated, as soon as the seat belt buckle restraint system switches are closed by putting on the seat belts. Furthermore, the seat belt reminder warning is also canceled, when the vehicle speed is 0 km/h and the driver door open. The cycle is restarted: l If at v > 25 km/h one of the seat belts which is being applied is removed again and as a result one of the seat belt buckle restraint systems switch is opened l when the driver door is closed again and the vehicle speed is > 25 km/h The signal for activating the seat belt warning lamp comes from the restraint systems control unit (N2/7) via CAN-B. Airbag indicator and warning lamp The airbag indicator and warning lamp is actuated when there is a fault in the supplemental restraint system (SRS) or the supplemental restraint system has been triggered. Actuation takes place by the restraint systems control unit via CAN. ABS indicator lamp The ABS indicator lamp is actuated when a malfunction occurs in the antilock brake system. Actuation takes place over CAN by the ESP control unit.

Electric steering indicator lamp

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 76 · Applies to: 451

The electric steering indicator lamp is activated, when a malfunction in the electric steering is given. Actuation takes place by the power steering control unit via CAN (N68). "CHECK ENGINE" indicator lamp The CHECK ENGINE indicator lamp is actuated if a fault is present in the injection system, ignition system or exhaust emission system. Actuation takes place by the ME control unit via CAN. Oil pressure warning lamp The oil pressure warning lamp is actuated, if there is no or little oil pressure built up in the engine's oil circuit. Actuation takes place by the ME control unit via CAN. ESP warning lamp Actuation takes place over CAN by the ESP control unit under the following preconditions: l The ESP warning lamp flashes on and off during a system control intervention at a frequency of 2.5 Hz. l The ESP warning lamp comes on when there is a system fault or when the system is switched off Coolant temperature warning lamp The warning lamp is actuated, when the coolant temperature is too high. Actuation takes place by the ME control unit via CAN. Tire pressure monitor warning lamp Actuation takes place via CAN from the TPM [RDK] control unit (N88) under the following preconditions: l when a manual reset has taken place or l when a pressure loss was determined A manual reset is indicated by repeated flashing of the tire pressure monitor warning lamp, a pressure loss through the lamp being permanently on. Low beam indicator lamp Actuation is conducted when the low beam is switched on over CAN by the SAM control unit. Tank cap monitoring warning lamp If the ME control unit detects a tank cap which is not closed, it sends a corresponding signal on the. The instrument cluster receives the signal and actuates the tank cap monitoring warning lamp constantly.

Indicator lamp test

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 77 · Applies to: 451

An indicator lamp test is carried out for "terminal 15 ON". In doing so all indicator and warning lamps are actuated with the exception of the following lamps: l Left tern signal indicator lamp l Right turn signal indicator lamp l High beam indicator lamp The indicator lamp test is terminated as soon as an engine speed of > 480 RPM is reported by the ME control unit via CAN. Visual indicator/warning messages via the multifunction display The multifunction display's gear indicator shows the following warning message when the instrument cluster is actuated: l Drive authorization system: The system is activated or a malfunction has occurred. Actuation takes place over CAN by the SAM control unit. l CAN failure: flashes when the CAN is inoperative. Actuation takes place, when the instrument cluster does not receive any data or only implausible data from the CAN. l Shifting system: A malfunction has occurred in the shifting system. Actuation takes place by the automated manual transmission control unit via CAN. Acoustic indicator/warning message over internal tone signal generator The acoustic warning and information signals are produced by an internal tone signal generator. An acoustic feedback occurs for the following function states: l Flasher ON With direction flashing and warning flashing, in parallel with the visual feedback, an acoustic feedback takes place in the form of flasher clicking. Actuation takes place via the SAM control unit. l Lights on reminder warning (warning tone) If the driver door is opened when the standing light or low beams are switched on, a warning tone is output. The status of the left door rotary tumbler microswitch (S87/7) is read in by the SAM control

unit which requests acoustic feedback.

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 78 · Applies to: 451 · AR: GF54.30-P-3025MCU, GF54.30-P-6000MCU, GF91.60-P-4048MCU, GF07.61-P-6000MCU, GF54.21-P-4157MCU (+3 more)

l Door warning (warning tone) l Daytime running lights activated or deactivated (signal tone) (with code (K06) Daytime running lights) l Seat belt reminder warning DISPLAY SPEED, FUNCTION - GF54.30-P-3025MCU MODEL 451.3/4 Shown on code (K07) Speedometer (miles) Fig. 64: Identifying Instrument Cluster And Electronic Speedometer Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Vehicle speed display 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 N68 For vehicles with code (V26) Power steering, EPS (FFO) GF46.35-P-7100MCU Tire pressure monitor control unit, component description N88 GF40.15-P-5124MCU

The electronic speedometer is used to display vehicle speed. The speedometer is driven by a stepper motor.

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 79 · Applies to: 451 · AR: GF54.30-P-3041MCU, GF54.30-P-6000MCU, GF42.45-P-5118MCU

Measuring the vehicle speed The instrument cluster receives from the ESP control unit (N47-5) the wheel speeds required for the computation of vehicle speed via the Controller Area Network (data bus/CAN bus) (CAN). The tire size is taken into account when calculating the speed. Coding takes place using STAR DIAGNOSIS. Assessment of wheel speed signals: l The wheel speed signals are compared against each other and thus checked in terms of plausibility. If there are no significant deviations, the vehicle speed is calculated from the rotational speed of the left front wheel. l If the individual wheel speed signals vary substantially, the speed signals may be faulty or the vehicle may be cornering. If, by comparing the wheel speeds on both sides of the vehicle, the instrument cluster determines that the car is cornering, the vehicle speed is calculated from the mean value of the front wheel speeds. l If the comparisons indicate one or more faulty wheel speed signals, the vehicle speed is then calculated on the basis of highest wheel speed. This also applies if an error message is received instead of a wheel speed signal. The travel distance is determined as for the vehicle speed. DISPLAY OPERATING CONDITIONS, FUNCTION - GF54.30-P-3041MCU MODEL 451.3/4 Shown on code (K07) Speedometer (miles) Fig. 65: Identifying Indicator Displays Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Gear indicator in manual mode The gear indicator displays the current gear engaged. Instrument cluster, component description A1 GF54.30-P-6000MCU ESP control unit, component description N47-5 GF42.45-P-5118MCU

The corresponding information from the automated manual transmission control unit (N15/6) is read in over

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 80 · Applies to: 451

the Controller Area Network (data bus/CAN bus) (CAN) from the instrument cluster. If the automated manual transmission control unit establishes that a higher gear would be better for the current engine speed, accelerator pedal position and vehicle speed, a gear change is suggested in the gear indicator: l Arrow up: Shift up one gear l Arrow down: Shift down one gear The gearshift recommendation is oriented towards a consumption-specific driving style. Gear indicator in automatic mode The selected driving stage is shown in the gear indicator. The following displays are possible: l "P": Parking position l "R": Reverse gear l "N": Neutral l "D": Drive position The corresponding information from the automated manual transmission control unit is read in over CAN by the instrument cluster. Fuel level and reserve indicator The fuel supply is shown to the driver over the fuel level and reserve indicator by means of eight segments. The data sent from the fuel level sensor (M3/3b1) to the ME-SFI [ME] control unit (N3/10) is read in over the CAN by the instrument cluster. The reserve area is equivalent to an amount of 1 gal. If the reserve area is reached, the fuel pump symbol starts to flash on and off and the remaining fuel is displayed in increments of 0.13 gal in the multifunction display. In the event of any malfunction the segments in the fuel level and reserve indicator start to flash on and off. Maintenance interval display The maintenance interval display draws the driver's attention to a service that is due soon. Roughly one month beforehand and every time the engine is started, the maintenance interval display is displayed for 10 seconds, and the line of the main odometer shows the remaining distance or remaining time. Meaning of maintenance interval displays: l One wrench = Oil service plus l Two wrenches = Maintenance

The left button on the instrument cluster can be used to confirm the display on the maintenance interval

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 81 · Applies to: 451

display. The maintenance interval display is shown for 10 s by briefly pressing the button in the right of the instrument cluster twice. Trip odometer The display area for the trip odometer is 0 to 9999.9 kilometers or miles (with code (K07) Speedometer (miles)). Once the maximum reading is reached the display is automatically reset to zero. Manual reset: Keep pressing the left button until the trip odometer appears in the multifunction display. After pressing the left button again for 1 s the display starts to flash on and off. Continue to press and hold the left button. The display is reset to zero. The trip distance remains stored even when the battery (G1) is disconnected. Odometer The main odometer reading is shown either in kilometers or miles, as soon as the instrument cluster is activated. The range for the main odometer is from 0 to 999,999 kilometers or miles. If the maximum mileage is reached, the counter is not reset to zero. In this case, the instrument cluster should be replaced. The internal counter continues to operate however. The main odometer reading is stored for at least 10 years, even if the voltage supply is disconnected. Outside temperature indicator The instrument cluster takes the following data into consideration when determining the outside temperature value: l Outside temperature value directly from outside temperature display temperature sensor (B14) l Internal vehicle speed signal from instrument cluster l Coolant temperature value via CAN from the ME-SFI [ME] control unit l Engine running time over CAN from ME-SFI [ME] control unit The instrument cluster processes this data and actuates the outside temperature indicator accordingly. The dependency of the outside temperature indicator on the speed, the engine running time and the coolant temperature prevents too high a temperature being displayed through radiant heat when the vehicle is stationary or moving slowly. Falling temperature values are always allowed. The display's response pattern varies as temperature rises, according to coolant temperature and engine running time:

l Coolant temperature < 60°C:

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 82 · Applies to: 451 · AR: GF54.30-P-6000MCU, GF83.57-P-4000MCC, GF07.61-P-6000MCU, GF54.21-P-4157MCU, GF26.19-P-1010MCU

The current outside temperature value is always displayed when the instrument cluster is activated. l Coolant temperature > 60°C: When the instrument cluster is activated rising outside temperature values are displayed with a delay. l Coolant temperature > 60°C and circuit 15 OFF: The last measured temperature value is stored for a period of t = 60 min. When the instrument cluster is activated, the stored temperature value is shown in the outside temperature display. If the coolant temperature sensor (B11/4) is defective or if it provides implausible coolant temperature value, the ME-SFI [ME] control unit sends a corresponding message over CAN to the instrument cluster. A coolant temperature of > or = 60°C is assumed. Set the time After pressing the left button on the instrument cluster for > 5 s the colon in the time display starts to flash on and off. Now the left button or the right button can be used to set the time. If one of the two buttons is not pressed again within the next 5 s, the set value is stored and the colon stops flashing. INSTRUMENT CLUSTER, COMPONENT DESCRIPTION - GF54.30-P-6000MCU MODEL 451.3/4 Shown on code (K07) Speedometer (miles) Instrument cluster, component description A1 GF54.30-P-6000MCU Outside air temperature sender component description B14 GF83.57-P-4000MCC ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MCU SAM control unit, component description N10/10 GF54.21-P-4157MCU Automated manual transmission control unit, component description N15/6 Transmission 717.482 GF26.19-P-1010MCU

Fig. 66: Identifying Instrument Cluster Components

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 83 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Location The instrument cluster is located in the dashboard on the driver-side. Task The instrument cluster has the following tasks: l Gateway between Controller Area Network (data bus/CAN bus) (CAN) and Controller Area Network bus Class B (interior) (CAN-B) l Receive the input signals from the CAN and CAN-B for the various displays and warning messages l Reading in of the paddle shift for steering wheel gearshift (SAL) (S112) over the fanfare horns and airbag clock spring contact (A45) (with code (I75) Leather sport steering wheel with steering wheel rocker switch system) l Reading in the outside temperature display temperature sensor (B14) l Determining and displaying the vehicle speed l Illumination of the multifunction display, the dial face, the pointers and displays depending on the dimmer stage l Display of dimmer stage over circuit 58d l Actuation of warning and indicator lamps l Output of acoustic signals Acoustic signals

The acoustic warning and information signals and the turn signal indicator clicking are generated by means

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 84 · Applies to: 451 · AR: GF54.30-P-6000MCU, GF83.57-P-4000MCC, GF91.60-P-4048MCU, GF07.61-P-6000MCU, GF54.21-P-4157MCU (+5 more)

of an audio signal generator: l Turn signal ON (turn signal knocking sound) l Light warning (warning tone) l Door warning (warning tone) l Daytime running lights activated or deactivated (signal tone) (with code (K06) Daytime running lights) l Seat belt reminder warning Actuation of stepper motors The electronic speedometer is driven by a stepper motor. Variable displays in the multifunction display The following displays are shown in the multifunction display: l Fuel level and reserve indicator l Transmission mode display in automatic mode l Gear indicator or gearshift recommendation in manual mode l Main odometer l Multifunction display for remaining fuel, trip odometer and maintenance interval display l Time display l Ambient temperature display l Transmission mode display l Display of gear engaged or gearshift recommendation in manual mode Instrument cluster, component description A1 GF54.30-P-6000MCU Outside air temperature sender component description B14 GF83.57-P-4000MCC 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 Automated manual transmission control unit, component description N15/6 GF26.19-P-1010MCU ESP control unit, component description N47-5 GF42.45-P-5118MCU Electric steering control unit, component description N68 For vehicles with code (V26) Power steering, EPS (FFO) GF46.35-P-7100MCU Tire pressure monitor control unit, component description N88 GF40.15-P-5124MCU Table of contents for function description of GF54.30-P-0997MCU

OVERVIEW OF SYSTEM COMPONENTS, INSTRUMENT CLUSTER (IC) COMPONENT

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 85 · Applies to: 451 · AR: GF54.30-P-9996MCU, GF54.30-P-6000MCU, GF83.57-P-4000MCC, GF91.60-P-4048MCU, GF07.61-P-6000MCU (+5 more)

DESCRIPTION - GF54.30-P-9996MCU MODEL 451.3/4 WIRING DIAGRAM FOR DATA LINK CONNECTOR/DIAGNOSTIC SOCKET - PE54.22-P-2000- 97MCU instrument cluster (IC) Instrument cluster, component description A1 GF54.30-P-6000MCU Outside air temperature sender component description B14 GF83.57-P-4000MCC 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 Automated manual transmission control unit, component description N15/6 GF26.19-P-1010MCU ESP control unit, component description N47-5 GF42.45-P-5118MCU Electric steering control unit, component description N68 For vehicles with code (V26) Power steering, EPS (FFO) GF46.35-P-7100MCU Tire pressure monitor control unit, component description N88 GF40.15-P-5124MCU Table of contents for function description of instrument cluster (IC) GF54.30-P-0997MCU Code: Designation: Position: A1 Instrument cluster 9L N10/10 SAM control unit 4L N10/10f12 Fuse 12 2L N10/10f19 Fuse 19 6L W26 Ground (transmission tunnel) 6E X11/4 Data link connector 11A X11/4 Data link connector 4A Z3/24 Circuit 15 (fused) connector sleeve, function 5E Z37/2 CAN engine bus (low) connector sleeve 9E Z37/3 CAN engine bus (high) connector sleeve 8E Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 2E

Fig. 67: Data Link Connector/Diagnostic Socket - Wiring Diagram

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 86 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000-97MCV Code: Designation: Position: A2/1 smart radio 9 24L A2/2 smart radio 10 25L A2/3 smart Entry radio 24L A2/4 smart Premium radio 25L E1 Left front lamp unit 54L E15/4 Front interior lamp 32L E1e1 Left high beam E1e2 Left low beam E2 Right front lamp unit 57L E2e1 Right high beam E2e2 Right low beam E3 Left taillamp 53L E3e2 Left taillamp E6/13 Left standing lamp 51L E6/14 Right standing lamp 50L K116 Relay for shutoff-capable interior lamp 29L K52/11 Left turn signal/stop lamp relay 60L K52/12 Right turn signal/stop lamp relay 61L K61 Blower motor relay 1 18L K62 Blower motor relay 2 20L

K66/1

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 87 · Applies to: 451

Open soft top relay 37L K66/2 Close soft top relay 39L K87/1 Rear fog lamp relay 79L M2 Blower motor 16L M4/2 Coolant fan motor 48L N10/10 SAM control unit 76A N10/10 SAM control unit 19A N10/10 SAM control unit 61A N10/10 SAM control unit 52A N10/10 SAM control unit 44A N10/10 SAM control unit 11A N10/10 SAM control unit 68A N10/10 SAM control unit 4A N10/10 SAM control unit 28A N10/10 SAM control unit 37A N10/10f11 Fuse 11 70A N10/10f15 Fuse 15 24A N10/10f20 Fuse 20 12A N10/10f22 Fuse 22 N10/10f23 Fuse 23 N10/10f24 Fuse 24 75A N10/10f25 Fuse 25 N10/10f26 Fuse 26 54A N10/10f28 Fuse 28 46A N10/10f29 Fuse 29 40A N10/10f3 Fuse 3 13A N10/10f34 Fuse 34 67A N10/10f35 Fuse 35 64A N10/10f37 Fuse 37 (slot R2) 59A N10/10f4 Fuse 4 N10/10f42 Fuse 42 (slot R7) 31A N10/10f6 Fuse 6 N10/10f7 Fuse 7 51A N10/10k1 Heated rear window relay N10/10k11 Heater blower relay N10/10k12 Standing lamps relay N10/10k2 Soft top "open" and soft top "closed" relay N10/10k2 Soft top "open" and soft top "closed" relay N10/10k6 High beam relay N10/10k8 Low beam headlamp relay N15/5 Electronic selector lever module control unit 71L N15/5 Electronic selector lever module control unit 75L N23 Heater/AC operating unit 6L N47-5 ESP control unit 68L N57/2 Power window convenience feature control unit 13L N68 Steering assist control unit 64L R1 Heated rear window 47L

Heated rear window

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 88 · Applies to: 451

45L S4 Combination switch 2L S4/4 Right wiper switch 10L S84 Power soft top switch 43L S84/37 Soft top microswitch 40L S84/38 Left roof cassette microswitch 41L S84/39 Right rear soft top microswitch 44L S9/1 Stop lamp switch 59L S9/1 Stop lamp switch 78L U1000 Valid for model 451.391/491 17E U1000 Valid for model 451.391/491 73F U1001 Not valid for model 451.391/491 15E U1001 Not valid for model 451.391/491 77F U1001 Not valid for model 451.391/491 70F U101 Valid up to 02/2009 36E U101 Valid up to 02/2009 34E U1010 Valid for radio with Premium sound system 22K U1012 Valid up to 30/08/2010 35E U1012 Valid up to 30/08/2010 32E U1012 Valid up to 30/08/2010 23K U1013 Valid as of 31/08/2010 36E U1013 Valid as of 31/08/2010 31E U1013 Valid as of 31/08/2010 23K U102 Valid as of 03/2009 35E U102 Valid as of 03/2009 32E U102 Valid as of 03/2009 26C U14 Valid for rain/light sensor 79G U23 Valid for convertibles 35D U492 Valid for power steering 62A U606 Valid for all except convertibles 46D U606 Valid for all except convertibles 8E U656 Valid for interior lights package 27L U861 Valid for versions without interior light package 27K U865 Valid for Entry radio 22K W43 Ground (outside left fire wall) 48G W43 Ground (outside left fire wall) 52G W43 Ground (outside left fire wall) 50G W9 Ground (left front, at lamp unit) 48F X18/19 Trunk lid connector 46G X23/7 Soft top connector 43G X23/7 Soft top connector 40G X85/10 Heating or air conditioning connector 16H Z29/4 Circuit 58R (fused) connector sleeve 49G Z29/4 Circuit 58R (fused) connector sleeve 18G Z3/44 Instrument cluster - radio circuit 15 (fused) connector sleeve 11G Z7/59 Tml. 30 connector sleeve 33F

Fig. 68: Electrical Center - Wiring Diagram (1 Of 5)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 89 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig. 69: Electrical Center - Wiring Diagram (2 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Z7/59 Tml. 30 connector sleeve 35F Z7/59 Tml. 30 connector sleeve 31F

Fig. 70: Electrical Center - Wiring Diagram (3 Of 5)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 90 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig. 71: Electrical Center - Wiring Diagram (4 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig. 72: Electrical Center - Wiring Diagram (5 Of 5)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 91 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. MISCELLANEOUS NOTES DISPOSE OF BATTERY - OS54.10-P-0001-01Z

All models

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 92 · Applies to: 451 · AR: PE54.00-P-1100MCU, PE54.10-P-2003MEV, PE54.10-P-2011MEV, PE54.10-P-2104MEV, PE54.21-P-2132MEV

Information on recycling and disposing of lead-acid batteries and lead-gel batteries l Old lead batteries up to 31.12.1998 are not classed as recyclable waste requiring special monitoring and control. They bear the ISO symbol for return and recycling. l The electrolyte, diluted sulfuric acid or acid gel should never be emptied in a careless manner. This procedure must be carried out by specialist companies. Picture shows ISO symbol for return and recycling Fig. 73: View Of ISO Symbol For Return And Recycling Courtesy of MERCEDES-BENZ OF NORTH AMERICA. l Old lead-acid batteries and lead-gel batteries should not be mixed together as this would make recycling more difficult. Always store lead-acid batteries horizontally and do not tilt during transport. l Lead batteries can be taken back to the respective manufacturer, to sales outlets and to scrap metal dealers and are recycled at lead recycling plants. Recycled lead is fed back into the production process. The disposal of batteries as domestic waste is not permitted and is forbidden by law. WIRING DIAGRAMS OVERVIEW OF WIRING DIAGRAMS FOR ELECTRICAL SYSTEM, EQUIPMENT AND INSTRUMENTS - PE54.00-P-1100MCU MODEL 451 Wiring diagram for battery charger control unit for high-voltage battery MODEL 451.391/ 491 PE54.10-P-2003MEV Wiring diagram, socket for charger feed MODEL 451.391/ 491 PE54.10-P-2011MEV Wiring diagram for battery management control unit MODEL 451.391/ 491 PE54.10-P-2104MEV Wiring diagram for Communications control unit for external socket MODEL 451.391/ 491 PE54.21-P-2132MEV

WIRING DIAGRAM FOR DATA LINK CONNECTOR/DIAGNOSTIC SOCKET - PE54.22-P-

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 93 · Applies to: 451 · AR: PE54.21-P-2133MEV, PE54.22-P-2000MCU, PE54.22-P-2000MEV, PE54.25-P-2000MCU, PE54.25-P-2000MCV (+5 more)

2000MCU MODEL 451 / (except 451.391 /491) WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000-97MCU Wiring diagram for high-voltage distributor control unit MODEL 451.391/ 491 PE54.21-P-2133MEV Wiring diagram for data link connector/diagnostic socket MODEL 451 except 451.391/491 PE54.22-P-2000MCU Wiring diagram for data link connector/diagnostic socket MODEL 451.391/ 491 PE54.22-P-2000MEV Wiring diagram electrical center MODEL 451 Sheet 1 PE54.25-P-2000MCU Wiring diagram electrical center MODEL 451 Sheet 2 PE54.25-P-2000MCV Wiring diagram electrical center MODEL 451 Sheet 3 PE54.25-P-2000MCW Electrical function schematic for electrical center MODEL 451 PE54.25-P-2050MCU Wiring diagram large instrument (instrument cluster) MODEL 451 except 451.391/491 PE54.30-P-2001MCU Wiring diagram large instrument (instrument cluster) MODEL 451.391/ 491 PE54.30-P-2001MEV Wiring diagram of auxiliary instruments MODEL 451 / (except 451.391 /491) up to 30.8.10 PE54.30-P-2003MCU Electrical function diagram for instrument cluster (KI) MODEL 451 PE54.30-P-2051MCU Wiring diagram for signaling system MODEL 451 PE54.35-P-2000MCU Wiring diagram for data link connector/diagnostic socket PE54.22-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 Code: Designation: Position: A1 Instrument cluster 46L A15 Additional instruments 28L A15x1 Additional instruments connector A6/1 STH radio remote control receiver 32L

Blower motor relay 1

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 94 · Applies to: 451

K61 Blower motor relay 1 66L M3/3 Fuel pump with fuel level sensor 69L M4/9 Battery cooling fan motor 22L M6/1 Wiper motor 14L M6/4 Tailgate wiper motor 17L N10/10 SAM control unit 45A N10/10 SAM control unit 36A N10/10 SAM control unit 68A N10/10 SAM control unit 53A N10/10 SAM control unit 28A N10/10 SAM control unit 61A N10/10 SAM control unit 76A N10/10 SAM control unit 12A N10/10 SAM control unit 20A N10/10 SAM control unit 5A N10/10f1 Fuse 1 4A N10/10f10 Fuse 10 8A N10/10f12 Fuse 12 34A N10/10f16 Fuse 16 73A N10/10f17 Fuse 17 17A N10/10f18 Fuse 18 42A N10/10f19 Fuse 19 1A N10/10f2 Fuse 2 14A N10/10f27 Fuse 27 2A N10/10f30 Fuse 30 21A N10/10f44 Fuse 44 (slot R9) 60A N10/10f8 Fuse 8 7A N10/10f9 Fuse 9 N10/10k10 Front wiper relay N10/10k13 Rear wiper relay N10/10k3 Starter relay N10/10k4 Electric fuel pump relay N10/10k7 Main relay N10/10k9 Automated manual transmission relay N15/6 Automated manual transmission control unit 20L N3 EVCM electric vehicle control unit 37L N3 EVCM electric vehicle control unit 75L N3 EVCM electric vehicle control unit 24L N3/10 ME-SFI [ME] control unit 72L N47/5 ESP control unit 42L N65/3 Brake booster vacuum pump control unit 63L S6/1 Cockpit switch group 53L S6/1s1 Hazard warning flasher switch S6/1s10 Tow-away protection/interior protection switch S6/1s11 Inside unlock CL [ZV] switch S6/1s12 Inside lock CL [ZV] switch S6/1s3 Left seat heater switch

Right seat heater switch

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 95 · Applies to: 451

S6/1s8 Front fog lamps switch S6/1s9 TPM [RDK] switch U1000 Valid for model 451.391/491 6G U1000 Valid for model 451.391/491 30G U1000 Valid for model 451.391/491 44F U1000 Valid for model 451.391/491 61D U1000 Valid for model 451.391/491 65G U1000 Valid for model 451.391/491 74G U1000 Valid for model 451.391/491 45L U1000 Valid for model 451.391/491 21F U1001 Not valid for model 451.391/491 1G U1001 Not valid for model 451.391/491 46F U1001 Not valid for model 451.391/491 68G U1001 Not valid for model 451.391/491 55E U1001 Not valid for model 451.391/491 45K U1001 Not valid for model 451.391/491 44F U1012 Valid up to 30/08/2010 26H U1012 Valid up to 30/08/2010 43G U1013 Valid as of 31/08/2010 41G U114 Valid for front fog lamps 50F U21 Valid for heated seats 55D U30 Valid for diesel engines 18F U492 Valid for power steering 44E U493 Not valid for power steering 46E U606 Valid for all except convertibles 15D U75 Valid for gasoline engines 70G U75 Valid for gasoline engines 26H U75 Valid for gasoline engines 18G W10 Ground (battery) 50G W10 Ground (battery) 22G X11/4 Data link connector 39L X18/19 Trunk lid connector 16H X99/3 Vehicle wiring harness connector 62H Y19/1 Interior air conditioning expansion valve 34L Y19/3 Battery air conditioning expansion valve 35L Z3/17 Circuit 15 (fused) connector sleeve 42E Z37/4 Power steering CAN bus connector sleeve (low) 45G Z37/5 Power steering CAN bus connector sleeve (high) 46G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 34G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 20G Z7/24 Circuit 87/1 connector sleeve 18G Z78 Cockpit LIN connector sleeve 27G Z81 Circuit 58d connector sleeve 48G

Fig. 74: Electrical Center - Wiring Diagram (1 Of 5)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 96 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig. 75: Electrical Center - Wiring Diagram (2 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig. 76: Electrical Center - Wiring Diagram (3 Of 5)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 97 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig. 77: Electrical Center - Wiring Diagram (4 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig. 78: Electrical Center - Wiring Diagram (5 Of 5)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 98 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000-97MCW Code: Designation: Position: A45 Fanfare horns and airbag clock spring contact 26L A9 Refrigerant compressor 15L B32 Microwave sensor 73L E34 Charger feed socket indicator LED 47H E5/1 Left front fog lamp 65L E5/2 Right fog lamp 66L F90 12 V charge line prefuse 3H F91 SAM prefuse 8H G1 Battery 7L G1 Battery 5L

Battery

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 99 · Applies to: 451

G1 Battery 9L H2 Horn 17L H3/2 Alarm siren with inclination sensor 71L K97 Mirror heater relay 61L L11 Transponder coil 76L M14/10 Fuel filler flap CL [ZV] motor 18L M14/6 Left door CL [ZV] motor 20L M21/1 Left electrically adjustable and heated outside mirror 57L M21/1x1 Left electrically adjustable and heated exterior mirror connector M21/2 Right electrically adjustable and heated outside mirror 58L M21/2x1 Right electrically adjustable and heated exterior mirror connector M44 Charge air fan motor 14L M57/4 Trunk lid opening assist motor 1 (cabriolet) 23L M57/5 Trunk lid opening assist motor 2 (cabriolet) 24L M57/6 Trunk lid opening assist motor (cabriolet) 21L M6/1 Wiper motor 52L M6/4 Tailgate wiper motor 55L N10/10 SAM control unit 20A N10/10 SAM control unit 27A N10/10 SAM control unit 36A N10/10 SAM control unit 44A N10/10 SAM control unit 52A N10/10 SAM control unit 62A N10/10 SAM control unit 69A N10/10 SAM control unit 12A N10/10 SAM control unit 76A N10/10 SAM control unit 4A N10/10f14 Fuse 14 13A N10/10f17 Fuse 17 55A N10/10f2 Fuse 2 53A N10/10f21 Fuse 21 51A N10/10f31 Fuse 31 22A N10/10f33 Fuse 33 8A N10/10f36 Fuse 36 (slot R1) 61A N10/10f39 Fuse 39 (slot R4) 78A N10/10f39 Fuse 39 (slot R4) 60A N10/10f40 Fuse 40 (slot R5) 40A N10/10f41 Fuse 41 (slot R6) 68A N10/10f42 Fuse 42 (slot R7) 33A N10/10f43 Fuse 43 (slot R8) 30A N10/10f5 Fuse 5 65A N10/10k10 Front wiper relay N10/10k13 Rear wiper relay

N10/10k14

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 100 · Applies to: 451

Front fog lamp relay N10/10k820 Charge air fan motor and horn relay N10/10k820 Charge air fan motor and horn relay N10/10k830 CL [ZV] "open" and CL [ZV] "locked" relay N10/10k830 CL [ZV] "open" and CL [ZV] "locked" relay N10/10k840 Rear-end door/trunk lid CL [ZV] relay N116/5 High-voltage distributor control unit 30L N116/5 High-voltage distributor control unit 79L N145 Electric motor control unit 33L N145 Electric motor control unit 3L N24/3 High-voltage AC/DC battery charger control unit 41L N24/4 Smart battery charger control unit 44L N3 EVCM electric vehicle control unit 47L N3 EVCM electric vehicle control unit 68L N82/2 Battery management system control unit 37L S2/1 Ignition/starter switch 11L U100 Valid as of 12/2008 59F U1000 Valid for model 451.391/491 28A U1000 Valid for model 451.391/491 66E U1000 Valid for model 451.391/491 1C U1001 Not valid for model 451.391/491 6C U1001 Not valid for model 451.391/491 8C U1012 Valid up to 30/08/2010 73E U1012 Valid up to 30/08/2010 6C U1012 Valid up to 30/08/2010 60C U1013 Valid as of 31/08/2010 74E U1013 Valid as of 31/08/2010 8C U1013 Valid as of 31/08/2010 61C U114 Valid for front fog lamps 64A U180 Valid for ATA [EDW] with siren 70D U23 Valid for convertibles 20G U606 Valid for all except convertibles 54D U606 Valid for all except convertibles 22G U75 Valid for gasoline engines 13G U99 Valid up to 12/2008 57C W10 Ground (battery) 6G W10 Ground (battery) 71G W10 Ground (battery) 51G W10 Ground (battery) 5G W10 Ground (battery) 73F W10 Ground (battery) 75E W10 Ground (battery) 9G W12 Ground (center console) 12F W43 Ground (outside left fire wall) 17G W43 Ground (outside left fire wall) 53G W6 Ground (left wheelhouse in luggage compartment) 14G

Ground (left wheelhouse in luggage

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 101 · Applies to: 451

W6 Ground (left wheelhouse in luggage compartment) 23G W6 Ground (left wheelhouse in luggage compartment) 24G W6 Ground (left wheelhouse in luggage compartment) 21G W9 Ground (left front, at lamp unit) 17F W9 Ground (left front, at lamp unit) 27D X18/19 Trunk lid connector 54H X26 Interior/engine connector 13F X35/1 Left door separation point 57H X35/1 Left door separation point 19G X35/2 Right door separation point 58H X58/1 Interior socket 50L X99/3 Vehicle wiring harness connector 29H Z17 Connector sleeve 9 74G Z19/1 CL [ZV] "open" connector sleeve 18G Z19/2 CL [ZV] "closed" connector sleeve 17G Z212 Circuit 30 supply connector sleeve 68G Z4/3 Tml. 30 connector sleeve 40E Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 60G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 73H Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 71G Z78/1 ATA [EDW] LIN connector sleeve 72G

Fig. 79: Electrical Center - Wiring Diagram (1 Of 5)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 102 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig. 80: Electrical Center - Wiring Diagram (2 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig. 81: Electrical Center - Wiring Diagram (3 Of 5)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 103 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig. 82: Electrical Center - Wiring Diagram (4 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig. 83: Electrical Center - Wiring Diagram (5 Of 5)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 104 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000-99MCV Code: Designation: Position: A2/1 smart radio 9 24 L A2/2 smart radio 10 25 L E1 Left front headlamp unit 52 L E15/4 Front interior lamp 27 L E1e1 Left high beam 51 L E1e2 Left low beam 52 L E2 Right front headlamp unit 54 L E2e1 Right high beam 54 L E2e2 Right low beam 55 L

Left taillamp

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 105 · Applies to: 451

E3 Left taillamp 50 L E3e2 Left tail light 49 L E6/13 Left standing lamp 48 L E6/14 Right standing lamp 46 L K52/11 Left turn signal/stop lamp relay 58 L K52/12 Right turn signal/stop lamp relay 60 L K66/1 Open soft top relay 30 L K66/2 Close soft top relay 32 L M2 Blower motor 22 L M21/1 Left electrically adjustable and heated exterior mirror 15 L M21/1x1 Left electrically adjustable and heated exterior mirror connector 15 K M21/2 Right electrically adjustable and heated exterior mirror 16 L M21/2x1 Right electrically adjustable and heated exterior mirror connector 16 K M4/2 Coolant fan motor 44 L N10/10 SAM control unit 4 A N10/10 SAM control unit 12 A N10/10 SAM control unit 20 A N10/10 SAM control unit 28 A N10/10 SAM control unit 36 A N10/10 SAM control unit 44 A N10/10 SAM control unit 52 A N10/10 SAM control unit 61 A N10/10 SAM control unit 68 A N10/10 SAM control unit 75 A N10/10f11 Fuse 11 70 A N10/10f15 Fuse 15 24 A N10/10f20 Fuse 20 14 A N10/10f22 Fuse 22 52 A N10/10f23 Fuse 23 55 A N10/10f24 Fuse 24 72 A N10/10f25 Fuse 25 54 A N10/10f26 Fuse 26 50 A N10/10f28 Fuse 28 40 A N10/10f29 Fuse 29 32 A N10/10f3 Fuse 3 18 A N10/10f34 Fuse 34 67 A N10/10f35 Fuse 35 64 A N10/10f37 Fuse 37 16 A N10/10f38 Fuse 38 57 A N10/10f4 Fuse 4 21 A N10/10f6 Fuse 6 46 A N10/10f7 Fuse 7 49 A

N10/10k1

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 106 · Applies to: 451

Rear window defroster relay module 41 C N10/10k11 Heater blower relay 19 C N10/10k12 Standing lamps relay 46 B N10/10k2 Soft top "open" and soft top "closed" relay 30 C N10/10k2 Soft top "open" and soft top "closed" relay 32 C N10/10k6 High beam relay 50 C N10/10k8 Low beam headlamp relay 52 B N15/5 Electronic selector lever module control module 72 L N23 Heater/AC operating unit 7 L N47-5 ESP control module 68 L N57/2 Power window convenience feature control unit 19 L N68 Steering assist control module 64 L R1 Heated rear window 40 L R1 Heated rear window 42 L S4 Combination switch 3 L S4/4 Right wiper switch 12 L S84 Power soft top switch 37 L S84/37 Soft top microswitch 33 L S84/38 Roof cassette microswitch 35 L S84/39 Rear soft top microswitch 38 L S9/1 Stop lamp switch (4-pin) 57 L U23 Valid for cabriolet 29 D U492 Valid for power steering 62 A U606 Valid for all except convertibles 11 F U606 Valid for all except convertibles 41 D W43 Ground (outside left fire wall) 44 G W9 Ground (at left headlamp unit) 43 G X18/19 Trunk lid connector 41 H X23/7 Soft top connector 33 H X23/7 Soft top connector 38 H X35/1 Left door separation point 15 H X35/2 Right door separation point 16 H X85/10 Heating or air conditioning connector 21 H Z29/4 Circuit 58R (fused) connector sleeve 45 H Z3/44 Instrument cluster - radio circuit 15 connector sleeve (fused) 13 H

Fig. 84: Electrical Center - Wiring Diagram (1 Of 5)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 107 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig. 85: Electrical Center - Wiring Diagram (2 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig. 86: Electrical Center - Wiring Diagram (3 Of 5)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 108 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig. 87: Electrical Center - Wiring Diagram (4 Of 5) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig. 88: Electrical Center - Wiring Diagram (5 Of 5)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 109 · Applies to: 451 · AR: PE54.25-P-2000MCU, OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000MCU MODEL 451 Sheet 1 Wiring diagram electrical center PE54.25-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 plug connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU

WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000MCV

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 110 · Applies to: 451 · AR: PE54.25-P-2000MCV, GF00.19-P-3000MCU, PE07.00-P-1100MCU, PE08.00-P-1100MCC, PE26.00-P-1100MCU (+5 more)

MODEL 451 Sheet 2 Location and assignment of Z connector sleeves (line connectors in wiring harness) GF00.19-P-3000MCU Engine 132 Further wiring diagrams PE07.00-P-1100MCU Engine 780.009 Further wiring diagrams PE08.00-P-1100MCC Transmission 717 (except model 451.391/491) Further wiring diagrams PE26.00-P-1100MCU Model 451.391 / 491 Further wiring diagrams PE27.00-P-1100MCC Further wiring diagrams PE42.00-P-1100MCU Model 451.391 / 491 Further wiring diagrams PE43.00-P-1100MCC Further wiring diagrams PE46.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU Further wiring diagrams PE72.00-P-1100MCU Further wiring diagrams PE80.00-P-1100MCU Further wiring diagrams PE82.00-P-1100MCU Further wiring diagrams PE83.00-P-1100MCU Further wiring diagrams PE91.00-P-1100MCU Wiring diagram electrical center PE54.25-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 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 Engine 132 Further wiring diagrams PE07.00-P-1100MCU Engine 780.009 Further wiring diagrams PE08.00-P-1100MCC Transmission 717 (except model 451.391/491) Further wiring diagrams PE26.00-P-1100MCU Model 451.391 / 491 Further wiring diagrams PE27.00-P-1100MCC Further wiring diagrams PE42.00-P-1100MCU Model 451.391 / 491 Further wiring diagrams PE43.00-P-1100MCC

WIRING DIAGRAM ELECTRICAL CENTER - PE54.25-P-2000MCW

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 111 · Applies to: 451 · AR: PE54.25-P-2000MCW, PE54.25-P-2050MCU, PE46.00-P-1100MCU, PE54.00-P-1100MCU, PE72.00-P-1100MCU (+5 more)

MODEL 451 Sheet 3 ELECTRICAL FUNCTION DIAGRAM FOR ELECTRICAL CENTER - PE54.25-P-2050MCU MODEL 451 Further wiring diagrams PE46.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU Further wiring diagrams PE72.00-P-1100MCU Further wiring diagrams PE80.00-P-1100MCU Further wiring diagrams PE82.00-P-1100MCU Further wiring diagrams PE83.00-P-1100MCU Further wiring diagrams PE91.00-P-1100MCU Wiring diagram electrical center PE54.25-P-2000-97MCW 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 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 Engine 132 Further wiring diagrams PE07.00-P-1100MCU Engine 780.009 Further wiring diagrams PE08.00-P-1100MCC Transmission 717 (except model 451.391/491) Further wiring diagrams PE26.00-P-1100MCU Model 451.391 / 491 Further wiring diagrams PE27.00-P-1100MCC Further wiring diagrams PE42.00-P-1100MCU Model 451.391 / 491 Further wiring diagrams PE43.00-P-1100MCC Further wiring diagrams PE46.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU Further wiring diagrams PE72.00-P-1100MCU Further wiring diagrams PE80.00-P-1100MCU Further wiring diagrams PE82.00-P-1100MCU Further wiring diagrams PE83.00-P-1100MCU Further wiring diagrams PE91.00-P-1100MCU

WIRING DIAGRAM LARGE INSTRUMENT (INSTRUMENT CLUSTER) - PE54.30-P-2001-

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 112 · Applies to: 451 · AR: OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU, PE07.00-P-1100MCU (+4 more)

97MCU Electrical function diagram for electrical center PE54.25-P-2050-99MCU Legend of electrical function diagram for electrical center PE54.25-P-2050-60MCU 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 PE07.00-P-1100MCU Further wiring diagrams PE26.00-P-1100MCU Further wiring diagrams PE42.00-P-1100MCU Further wiring diagrams PE46.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU Code: Designation: Position: A1 Instrument cluster 25A A1 Instrument cluster 5A A1 Instrument cluster 43A A1 Instrument cluster 12A A1 Instrument cluster 36A A1e1 Left tern signal indicator lamp 29A A1e15 Airbag indicator and warning lamp 21A A1e17 ABS indicator lamp 15A A1e18 Electric steering indicator lamp 45A A1e2 Right turn signal indicator lamp 30A A1e26 "CHECK ENGINE" MIL 31A A1e3 High beam indicator lamp 12A A1e30 Oil pressure warning lamp 20A A1e41 ESP warning lamp 22A A1e5 Alternator charge monitoring and warning lamp 24A A1e54 Coolant temperature warning lamp 32A A1e66 Tire pressure monitor warning lamp 26A A1e67 Low beam indicator lamp 10A A1e7 Brake fluid and parking brake warning lamp 14A A1e8 Instrument illumination 3A A1e9 Seat belt warning lamp 23A A1p13 Multifunction display 18A A1p8 Electronic speedometer 19A A2/1 smart radio 9 21L A2/2 smart radio 10 22L A2/3 smart Entry radio 25L

A2/4

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 113 · Applies to: 451

smart Premium radio 26L A45 Fanfare horns and airbag clock spring contact 32L A45 Fanfare horns and airbag clock spring contact 44L B14 Outside temperature display temperature sensor 18L N10/10 SAM control unit 9L N10/10f12 Fuse 12 7L N10/10f18 Fuse 18 6L N23 Heater/AC operating unit 36L S111/2 Right steering wheel pitman arm 3L S6/1 Cockpit switch group 30L U1010 Valid for radio with Premium sound system 25K U1011 Valid for radio without Premium sound system 25L U1012 Valid up to 30/08/2010 4E U1012 Valid up to 30/08/2010 20G U1012 Valid up to 30/08/2010 38K U1013 Valid as of 31/08/2010 2E U1013 Valid as of 31/08/2010 24G U1013 Valid as of 31/08/2010 31G U1013 Valid as of 31/08/2010 38K U492 Valid for power steering 10E U493 Not valid for power steering 12E U494 Valid for SAL 42E U865 Valid for Entry radio 25K W9 Ground (left front, at lamp unit) 9G Z3/17 Circuit 15 (fused) connector sleeve 5G Z37/4 Power steering CAN bus connector sleeve (low) 11G Z37/5 Power steering CAN bus connector sleeve (high) 11G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 7G Z81 Circuit 58d connector sleeve 29E

Fig. 89: Large Instrument (Instrument Cluster) - Wiring Diagram (1 Of 3)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 114 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig. 90: Large Instrument (Instrument Cluster) - Wiring Diagram (2 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fig. 91: Large Instrument (Instrument Cluster) - Wiring Diagram (3 Of 3)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 115 · Applies to: 451 · AR: PE54.30-P-2001MCU, OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU (+1 more)

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. WIRING DIAGRAM LARGE INSTRUMENT (INSTRUMENT CLUSTER) - PE54.30-P-2001MCU MODEL 451 / (except 451.391 /391) WIRING DIAGRAM OF AUXILIARY INSTRUMENTS - PE54.30-P-2003-97MCU Wiring diagram large instrument (instrument cluster) PE54.30-P-2001-97MCU 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 plug 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

Fig. 92: Auxiliary Instruments - Wiring Diagram

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 116 · Applies to: 451 · AR: PE54.30-P-2003MCU

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. WIRING DIAGRAM OF AUXILIARY INSTRUMENTS - PE54.30-P-2003MCU MODEL 451 / (except 451.391 /491) up to 30.8.10 Code: Designation: Position: A15 Additional instruments 11A A15 Additional instruments 6A A15 Additional instruments 3A A15p3 Clock A15p4 Tachometer A15p5 Display A15x1 Additional instruments connector 1D A15x2 Additional instruments connector 10D A34/7 Bluetooth module 11L N10/10 SAM control unit 5L N10/10f12 Fuse 12 2L U31 Valid on vehicles with Bluetooth with display 9A U32 Not valid on vehicles with Bluetooth with display 5A W9 Ground (left front, at lamp unit) 3G Z45 ATA [EDW] sensor supply circuit 30 connector sleeve 2G Z78 Cockpit LIN connector sleeve 4G

ELECTRICAL FUNCTION DIAGRAM FOR INSTRUMENT CLUSTER (KI) - PE54.30-P-2051MCU

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 117 · Applies to: 451 · AR: PE54.30-P-2051MCU, PE54.35-P-2000MCU, OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU (+5 more)

MODEL 451 WIRING DIAGRAM FOR SIGNALING SYSTEM - PE54.35-P-2000MCU MODEL 451 Wiring diagram of auxiliary instruments PE54.30-P-2003-97MCU 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 plug 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 Electrical function diagram for instrument cluster (KI) PE54.30-P-2051-99MCU Legend of function diagram of instrument cluster (KI) electrical system PE54.30-P-2051-60MCU 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 PE07.00-P-1100MCU Further wiring diagrams PE26.00-P-1100MCU Further wiring diagrams PE42.00-P-1100MCU Further wiring diagrams PE54.00-P-1100MCU Further wiring diagrams PE83.00-P-1100MCU Further wiring diagrams PE91.00-P-1100MCU Wiring diagram for signaling system PE54.35-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 plug 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

SPECIAL TOOLS

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 118 · Applies to: 451 · AR: PE54.00-P-1100MCU

129 589 00 21 00 126-PIN SOCKET BOX - WS54.00-P-0008B FG 00/42/54/91 / Set B MODEL all Use: 126-pin socket box for contacting electrical systems in combination with model-specific test cable sets. Fig. 93: Identifying 126-Pin Socket Box (129 589 00 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 220 589 00 99 00 ELECTRICAL CONNECTION KIT - WS54.00-P-0050B FG 00 FG 01/13/15/20/25/42/43/47/54/72/Set B MODEL all MODIFICATION NOTES Further wiring diagrams PE54.00-P-1100MCU 22.11.04 Replacement for 201 589 00 99 00 6.8.07 Replaced by 220 589 05 99 00 WS00.00-P-0279Z Part 220 589 00 99 01 Adapter line WS54.00-P-0050- 01B Part 220 589 00 99 02 Adapter line WS54.00-P-0050- 02B Part 220 589 00 99 03 Adapter line WS54.00-P-0050- 03B

Use:

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 119 · Applies to: 451

Part 220 589 00 99 04 Adapter line WS54.00-P-0050- 04B Part 220 589 00 99 05 Adapter line WS54.00-P-0050- 05B Part 220 589 00 99 06 Adapter line WS54.00-P-0050- 06B Part 220 589 00 99 07 Adapter line FG 25/42/43/54/Set B WS54.00-P-0050- 07B Part 220 589 00 99 08 Adapter line WS54.00-P-0050- 08B Part 220 589 00 99 09 Adapter line WS54.00-P-0050- 09B Part 220 589 00 99 10 Adapter line WS54.00-P-0050- 10B Part 220 589 00 99 11 Adapter line WS54.00-P-0050- 11B Part 220 589 00 99 12 Adapter line WS54.00-P-0050- 12B Part 220 589 00 99 13 Adapter line WS54.00-P-0050- 13B Part 220 589 00 99 20 Test cable FG 25/42/43/54/Set B WS54.00-P-0050- 14B Part 220 589 00 99 21 Alligator clip WS54.00-P-0050- 15B Part 220 589 00 99 22 Safety clamp FG 25/42/43/54/Set B WS54.00-P-0050- 16B Part 220 589 00 99 23 Clamp test probe WS54.00-P-0050- 17B Part 220 589 00 99 24 Connector WS54.00-P-0050- 18B Part 220 589 00 99 25 Empty case FG54/Set B WS54.00-P-0050- 26B Part 220 589 00 99 30 Adapter cable WS54.00-P-0050- 19B Part 220 589 00 99 31 Adapter cable WS54.00-P-0050- 20B Part 220 589 00 99 33 Safety cable WS54.00-P-0050- 22B 140 589 12 21 00 Baseline current draw test adapter 1 WS54.00-P-0015B 140 589 13 21 00 Quiescent current test adapter 2 WS54.00-P-0016B 000 581 06 54 Pliers Further use FG 42/Set B WS42.00-N-3062B Further use FG 43/Set B WS43.00-N-3053B

Electrical connection kit for contacting during voltage/current/resistance measurements and for connection

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 120 · Applies to: 451

of the compression tester. Fig. 94: Identifying Electrical Connection Kit (220 589 00 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 450 589 01 63 00 HOT AIR BLOWER - WS54.00-P-0062B FG 54/Set B MODEL 450, 451, 452, 454 Use: Hot air blower for soldering cable connection at solder connectors. Fig. 95: Identifying Hot Air Blower (450 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 450 589 04 63 01 MEASURING RESISTOR - WS54.00-P-0064-01B NOTE: Hot air blower Smart No. 0005029.

FG54/Set B

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 121 · Applies to: 451

MODEL 450, 451, 452 Use: Precision resistor for fault limitation with e.g faulty lines, control units or triggering components e.g. a simulation of a sidebag. Fig. 96: Identifying Measuring Resistor (450 589 04 63 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 450 589 04 63 02 PROBE - WS54.00-P-0064-02B FG54/Set B MODEL 450, 451, 452 Use: Probe for contacting measuring points. NOTE: Separate part for 450 589 04 63 00 NOTE: Separate part for 450 589 04 63 00

Fig. 97: Identifying Probe (450 589 04 63 02)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 122 · Applies to: 451

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 450 589 04 63 00 CABLE SET WITH DIAGNOSIS CASE - WS54.00-P-0064B FG 54/Set B MODEL 450, 451, 452 Use: Cable set with diagnosis case for contacting measuring instruments and design of measuring circuits, including decade resistor. Fig. 98: Identifying Cable Set With Diagnosis Case (450 589 04 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 450 589 15 21 00 BATTERY TESTER - WS54.00-P-0066A FG 54/Set A Part 450 589 04 63 01 Measuring resistor FG54/Set B WS54.00-P-0064-01B Part 450 589 04 63 02 Probe FG54/Set B WS54.00-P-0064-02B NOTE: Cable set with diagnosis case incl. decade resistor Smart No. 0005111.

MODEL 450, 451, 452, 454

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 123 · Applies to: 451

Use: Battery tester for checking battery voltage. Fig. 99: Identifying Battery Tester (450 589 15 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. 169 589 00 37 00 PLIERS - WS54.00-P-0073B FG 54/Set B MODEL 163, 164, 168, 169, 170, 171, 172, 197, 203, 204, 207, 208, 209, 210, 211, 212, 216, 218, 219, 221, 230, 245, 251, 451 Use: Pliers for removing 12V sockets and cigar lighters with an SAE standard NOTE: Battery tester Smart no. 0006967.

Fig. 100: Identifying Pliers (169 589 00 37 00)

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 124 · Applies to: 451 · AR: WS54.00-Z-9999CZ

Courtesy of MERCEDES-BENZ OF NORTH AMERICA. SPECIAL TOOLS: SMART: ELECTRICAL SYSTEM, EQUIPMENT AND INSTRUMENTS - WS54.00-Z-9999CZ MODEL all 000 589 13 99 00 Wiring harness repair kit, basic FG 00 FG 14/46/47/54/82/83/ Set B WS00.19-P-0007B 000 589 13 99 10 MCP 2.8 ELA crimping set FG00/54/Set B WS00.19-P-0007- 10B 000 589 13 99 30 MCP 2.8 / Fl. blade 2.8 / JPT / SPT FG00/54/83/Set B WS00.19-P-0007- 30B 001 589 01 91 00 Set of protective covers FG 01/08/09/14/15/ 54/83/ Set B WS01.00-P-0111B 110 589 03 59 00 Mounting wedge FG 00/01/05/13/18/ 26/54/67/68/72/77/80/82/83/88/91/ Set K WS00.00-P-0274K 129 589 00 21 00 126-pin socket box FG 00/42/54/91 / Set B WS54.00-P-0008B 156 589 00 31 00 Guide pins FG 54/Set B WS54.00-P-0081B 169 589 00 37 00 Pliers FG 54/Set B WS54.00-P-0073B 220 589 00 99 00 Electrical connection kit FG 00 FG 01/13/15/20/25/42/ 43/47/54/72/ Set B WS54.00-P-0050B 220 589 01 99 05 JPT crimping set FG 00/54/83/Set B WS00.19-P-0001- 05B 220 589 01 99 10 Crimp pliers FG 00/14/54/83/Set B WS00.19-P-0001- 09B 220 589 01 99 20 Unlocking device with RK 1.5 ejector FG00/54/Set B WS00.19-P-0001- 18B 220 589 01 99 30 Unlocking device with RK 2.5 ejector FG00/14/54/Set B WS00.19-P-0001- 20B 220 589 01 99 40 Wire stripper FG 00/54/83/Set B WS00.19-P-0001- 22B 220 589 01 99 41 Reflector FG 00/54/83/Set B WS00.19-P-0001- 23B 220 589 01 99 42 Adapter FG 00/54/83/Set B WS00.19-P-0001- 24B 220 589 01 99 50 Blade holder with clamping pliers FG00/14/54/83/Set B WS00.19-P-0001- 25B 220 589 01 99 60 MQS blade FG00/54/Set B WS00.19-P-0001- 35B 220 589 01 99 82 JPT ELA crimp set FG00/54/Set B WS00.19-P-0002- 08B 220 589 01 99 85 MQS crimping set FG00/54/Set B WS00.19-P-0002- 11B 220 589 01 99 86 MQS ELA crimping set FG00/54/Set B WS00.19-P-0002- 12B 220 589 02 99 00 Wiring harness repair kit FG 00 FG 54/83/Set B WS00.19-P-0002B

220 589 04 99 00 New passenger car wiring

Fortwo_451_2009_Equipment_Instructions_125p.pdf · p. 125 · Applies to: 451

harness repair kit FG 00 FG 46/47/54/82/83/Set B WS00.19-P-0006B 450 589 00 63 00 Press-out pin FG 54/Set B WS54.00-P-0060B 450 589 01 63 00 Hot air blower FG 54/Set B WS54.00-P-0062B 450 589 04 63 00 Cable set with diagnosis case FG 54/Set B WS54.00-P-0064B 450 589 04 63 01 Measuring resistor FG54/Set B WS54.00-P-0064- 01B 450 589 04 63 02 Probe FG54/Set B WS54.00-P-0064- 02B 450 589 04 99 00 Cable repair set FG 54/Set B WS54.00-P-0063B 450 589 05 37 00 Pliers FG 54/Set B WS54.00-P-0061B 450 589 07 21 07 Adapter FG 01/20/54/Set B WS01.00-P-0074- 07B 450 589 12 63 00 Measuring instrument/tester FG 54/Set B WS54.00-P-0065B 450 589 15 21 00 Battery tester FG 54/Set A WS54.00-P-0066A 450 589 19 21 00 Pin socket box 126-pin FG 54/Set B WS54.00-P-0071B 452 589 02 99 00 Wiring harness repair kit FG 00/54/77/83/ Set B WS00.00-P-0243B 452 589 02 99 01 Crimper 0.35 - 1.0 FG00/54/Set B WS00.00-P-0243- 01B 452 589 02 99 02 Crimper 1.5 - 2.5 FG00/54/Set B WS00.00-P-0243- 02B 452 589 02 99 03 Crimper 4.0 - 6.0 FG00/54/Set B WS00.00-P-0243- 03B 452 589 02 99 04 Wire stripper FG00/54/Set B WS00.00-P-0243- 04B 452 589 02 99 05 Box with connectors 0.35 - 1.0 FG00/54/Set B WS00.00-P-0243- 05B 452 589 02 99 06 Box with connectors 1.5 - 2.5 FG00/54/Set B WS00.00-P-0243- 06B 452 589 02 99 07 Box with connectors 4.0 - 6.0 FG00/54/Set B WS00.00-P-0243- 07B 452 589 02 99 08 Small box with heat- shrinkable tubes 5.75 mm FG00/54/Set B WS00.00-P-0243- 08B 930 589 00 99 00 Supplemental truck wiring harness repair kit FG 00/14/54/67 / Set B WS00.19-N-0004B 930 589 00 99 07 MCP 6.3 crimp set FG 00/54/67/Set B WS00.19-N-0004- 13B 930 589 00 99 08 MCP 6.3 crimp set FG 00/54/67/Set B WS00.19-N-0004- 14B 930 589 00 99 25 MCP 6.3 positioner FG00/54/67/Set B WS00.19-N-0004- 15B 930 589 00 99 26 MCP 6.3 positioner FG00/54/67/Set B WS00.19-N-0004- 16B