2014-2024 Smart Fortwo 453 Workshop Manual.pdf

495 excerpts.

Folding roof drive unit

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 124 · Applies to: 453 · AR: PE77.20-P-2200BBA, PE77.39-P-2202BBA, PE27.19-P-2106BBA, PE54.18-P-2300BBA, PE80.20-P-2000BBA (+5 more)

M12 Folding roof drive unit Model 453.0 (except 453.091) up to model PE77.20-P-2200BBA year 2020 M12/7 Left soft top drive Model 453.4 (except 453.491) up to model PE77.39-P-2202BBA year 2020 M12/8 Right soft top drive Model 453.4 (except 453.491) up to model PE77.39-P-2202BBA year 2020 M14 Clutch actuator 1 Transmission 700.4 in model 453.0/3/4 up to PE27.19-P-2106BBA model year 2020 with code 429 (twinamic) M14/10 Fuel filler flap CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBA 453.391), 453.4 (except 453.491) up to model year 2020 Sheet1 M14/10 Fuel filler flap CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE80.20-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Except UK M14/10 Fuel filler flap CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE80.20-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 UK version M14/31 Trunk lid/liftgate locking element Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBB 453.391), 453.4 (except 453.491) up to model year 2020 Sheet2 M14/31 Trunk lid/liftgate locking element Model 453.0 (except 453.091), 453.3 (except PE80.20-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Except UK M14/31 Trunk lid/liftgate locking element Model 453.0 (except 453.091), 453.3 (except PE80.20-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 UK version M14/5 Right door CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBD 453.391), 453.4 (except 453.491) up to model year 2020 W1/5 M14/5 Right door CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBD 453.391), 453.4 (except 453.491) up to model year 2020 Sheet4 M14/5 Right door CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE80.20-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Except UK M14/5 Right door CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE80.20-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 UK version M14/5 Right door CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) M14/6 Left door CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBC 453.391), 453.4 (except 453.491) up to model year 2020 W1/3 M14/6 Left door CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBC 453.391), 453.4 (except 453.491) up to model year 2020 Sheet3 M14/6 Left door CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE80.20-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Except UK M14/6 Left door CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE80.20-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 UK version M14/6 Left door CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) M14/7 Rear-end door CL [ZV] motor Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 M14/8 Left rear central locking actuator Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 M14/8 Left rear central locking actuator Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBD 453.391), 453.4 (except 453.491) up to model year 2020 Sheet4 M14/8 Left rear central locking actuator Model 453.0 (except 453.091), 453.3 (except PE80.20-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Except UK M14/8 Left rear central locking actuator Model 453.0 (except 453.091), 453.3 (except PE80.20-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 UK version M14/8 Left rear central locking actuator Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) Page 14 of 55 © Mercedes-Benz AG, 5/22/18, L/07/20, ov00.01-p-1909bba, Search aid for all electrical components Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020

W1/1

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 183 · Applies to: 453 · AR: PE68.49-P-2000BEA, PE68.49-P-2200BEA, PE80.50-P-2000BEA, PE82.60-P-2102BEA, PE82.85-P-2200BEA (+5 more)

Cockpit frame ground point Model 453.091/391/491 up to model year PE68.49-P-2000BEA 2020 with code V35 (Automatically dimming inside rearview mirror) except code 494 (USA version) W1/1 Cockpit frame ground point Model 453.391/491 up to model year 2020
PE68.49-P-2200BEA with code 494 (USA version) W1/1 Cockpit frame ground point Model 453.091/391/491 up to model year PE80.50-P-2000BEA 2020 except code V19 (Anti-theft alarm system) W1/1 Cockpit frame ground point Model 453.091/391/491 up to model year PE82.60-P-2102BEA 2020 with code 535 (smart media system) W1/1 Cockpit frame ground point Model 453.091/391/491 up to model year PE82.85-P-2200BEA 2020 with code 535 (smart media system) W1/1 Cockpit frame ground point Model 453.091/391/491 up to model year PE83.30-P-2000BEA 2020 with code I01 (Automatic air conditioning) except code I77 (Manual air conditioning) W1/1 Cockpit frame ground point Model 453.091/391/491 up to model year PE83.70-P-2102BEA 2020 W1/3 Left cockpit ground point Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 W1/3 Left cockpit ground point Model 453.091/391/491 up to model year PE82.20-P-2000BEA 2020 W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE54.22-P-2000BEA 2020 W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE72.29-P-2001BEA 2020 with code 583 (Power windows) except code 584 (Power windows with convenience feature and reversing function) except code ICPA (Standard equipment) W1/5 Right cockpit ground point Model 453.391/491 up to model year 2020
PE72.29-P-2001BEB with code 583 (Power windows) with code ICPA (Standard equipment) except code 584 (Power windows with convenience feature and reversing function) except code P74 (Comfort Package) except code V21 (Electrically adjustable and heated outside mirrors (FFO)) W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE72.29-P-2001BEC 2020 with code 584 (Power windows with convenience feature and reversing function) except code 583 (Power windows) W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE82.20-P-2000BEA 2020 W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE83.30-P-2000BEA 2020 with code I01 (Automatic air conditioning) except code I77 (Manual air conditioning) W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE88.79-P-2000BEA 2020 with code V21 (Electrically adjustable and heated outside mirrors (FFO)) W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE91.30-P-2000BEA 2020 with code 873 (Seat heater for driver's seat at left and right) W1/5 Right cockpit ground point Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 W10 Ground (battery) Model 453.091/391/491 up to model year PE15.00-P-2101BEA 2020 W11 Ground (engine) Engine 780.997 in model 453.091/391/491 up PE20.00-P-2001BEA to model year 2020 W11 Ground (engine) Model 453.091/391/491 up to model year PE43.05-P-2000BEA 2020 W11 Ground (engine) Model 453.091/391/491 up to model year PE54.10-P-2104BEA 2020 W11 Ground (engine) Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) W11 Ground (engine) Model 453.091/391/491 up to model year PE54.21-P-2154BEB 2020 with code 908 (22 kW on-board charger) Page 18 of 39 © Mercedes-Benz AG, 5/22/18, L/07/20, ov00.01-p-1909bea, Search aid for all electrical components Model 453.091/391/491 up to model year 2020

Z81z3

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 204 · Applies to: 453 · AR: PE72.29-P-2001BEB, PE72.29-P-2001BEC, PE77.20-P-2200BEA, PE77.39-P-2202BEA, PE82.10-P-2000BEA (+5 more)

Circuit 58d connector sleeve Model 453.391/491 up to model year 2020
PE72.29-P-2001BEB with code 583 (Power windows) with code ICPA (Standard equipment) except code 584 (Power windows with convenience feature and reversing function) except code P74 (Comfort Package) except code V21 (Electrically adjustable and heated outside mirrors (FFO)) Z81z3 Circuit 58d connector sleeve Model 453.091/391/491 up to model year PE72.29-P-2001BEC 2020 with code 584 (Power windows with convenience feature and reversing function) except code 583 (Power windows) Z81z3 Circuit 58d connector sleeve Model 453.091 up to model year 2020 PE77.20-P-2200BEA Z81z3 Circuit 58d connector sleeve Model 453.491 up to model year 2020 PE77.39-P-2202BEA Z81z3 Circuit 58d connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z81z3 Circuit 58d connector sleeve Model 453.091/391/491 up to model year PE82.60-P-2000BED 2020 with code C08 (Pre-installation for radio) except code 535 (smart media system)
except code 537 (smart audio system) Z81z3 Circuit 58d connector sleeve Model 453.091/391/491 up to model year PE91.30-P-2000BEA 2020 with code 873 (Seat heater for driver's seat at left and right) Z81z4 Circuit 58d connector sleeve Model 453.091/391/491 up to model year PE00.19-P-2600BEA 2020 Z81z4 Circuit 58d connector sleeve Engine 780.997 in model 453.091/391/491 up PE08.20-P-2000BEA to model year 2020 Z81z4 Circuit 58d connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z81z4 Circuit 58d connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z81z4 Circuit 58d connector sleeve Model 453.091 up to model year 2020 except PE91.30-P-2000BEB code 873 (Seat heater for driver's seat at left and right) Z99/15 Power electronics control unit power supply Model 453.091/391/491 up to model year PE54.10-P-2003BEA connector sleeve 2020 Z99/15 Power electronics control unit power supply Model 453.091/391/491 up to model year PE54.21-P-2144BEA connector sleeve 2020 Z99/15 Power electronics control unit power supply Model 453.091/391/491 up to model year PE54.21-P-2154BEA connector sleeve 2020 except code 908 (22 kW on-board charger) Z99/15 Power electronics control unit power supply Model 453.091/391/491 up to model year PE54.21-P-2154BEB connector sleeve 2020 with code 908 (22 kW on-board charger) Z99/16 Connector sleeve / LIN bus Model 453.091/391/491 up to model year PE00.19-P-2131BEA 2020 Z99/16 Connector sleeve / LIN bus Model 453.091/391/491 up to model year PE43.05-P-2000BEA 2020 Z99/16 Connector sleeve / LIN bus Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 Z99/16 Connector sleeve / LIN bus Model 453.091/391/491 up to model year PE83.55-P-2000BEA 2020 Z99/16 Connector sleeve / LIN bus Model 453.091/391/491 up to model year PE83.70-P-2102BEA 2020 Z99/2 Wake-up signal connector sleeve Model 453.091/391/491 up to model year PE00.19-P-2131BEA 2020 Z99/2 Wake-up signal connector sleeve Model 453.091/391/491 up to model year PE54.10-P-2109BEA 2020 Z99/2 Wake-up signal connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z99/2 Wake-up signal connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) Z99/2 Wake-up signal connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2154BEB 2020 with code 908 (22 kW on-board charger) Z99/2 Wake-up signal connector sleeve Model 453.091/391/491 up to model year PE82.85-P-2105BEA 2020 with code 535 (smart media system)
with code P02 (car2go) Page 39 of 39 © Mercedes-Benz AG, 5/22/18, L/07/20, ov00.01-p-1909bea, Search aid for all electrical components Model 453.091/391/491 up to model year 2020

Detach lower engine compartment paneling

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 582 · Applies to: 453 · AR: AR61.20-P-1105FF, AR26.00-P-0200FF, AR33.30-P-0620FF, AR14.10-P-3915FI, AR14.10-P-3915FG (+3 more)

10.2 Detach lower engine compartment paneling Only on vehicles without code (I01) Air AR61.20-P-1105FF conditioning Plus or without code (I77) Manual AC 11.1 Remove refrigerant compressor Only for vehicles with code (I01) Air AR83.55-P-5300-04FF conditioning Plus or code (I77) Manual AC *BA83.55-P-1001-01L

*BA83.55-P-1002-01L

12 Lower vehicle with lifting platform 13 Detach engine wiring harness from engine AR01.00-P-2420-01FF and place aside *BA15.30-P-1002-01I

*BA15.40-P-1001-01J

14 Drain transmission oil AR26.00-P-0200FF 15.1 Detach slave cylinder at transmission Only with transmission 717.470/471 AR25.20-P-0150-01FF *BA25.20-P-1002-01D

16 Remove front drive shafts AR33.30-P-0620FF 17 Lower vehicle with lifting platform 18 Remove exhaust manifold Engine 134.9 in model 454.0 with code (RHD) AR14.10-P-3915FI Right-hand drive vehicle Engine 134.9 in model 454.0 with code (LHD) AR14.10-P-3915FG Left-hand drive vehicle Engine 135.9 in model 454.0 with code (LHD) AR14.10-P-3915FF Left-hand drive vehicle 19 Remove lower transmission bearing AR26.10-P-0031FF 20 Drain coolant AR20.00-P-1142FF 21 Lower vehicle with lifting platform 22 Remove coolant hoses (11, 12, 13) on engine Collect the escaping coolant in a suitable container. 23 Install engine bridge AR01.10-P-2400-05FF *BA22.10-P-1003-01Q

*BA22.10-P-1004-01Q

*BA22.10-P-1005-01Q

*454589006100

*454589040900

24 Unscrew bolt (9) and unscrew nuts (10) Install new self-locking bolt (9) and nuts (10). BA26.00-P-1002-01D BA26.00-P-1003-01D 25 Lower engine and transmission (1) using When lowering the transmission (1) engine crossmember and position horizontally loosen the transmission bearing (8) from the transmission (1) using a suitable screwdriver. *454589006100

26 Remove engine with removal fixture AR01.10-P-2400-01FF The base jacks from companies Mazzola and AS Hydraulic can be used according to choice. *454589006100

*454589006200

WH58.30-Z-1011-07A Base jack Co. Mazzola WH58.30-Z-1011-07A Base jack from co. AS Hydraulic 27 Install in the reverse order Starter

Number Designation Engine Engine 134.9 135.9 BA15.30-P-1002-01I Nut, terminal 30 to starter Nm 11 11 Alternator

Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.10-p-2401ff, Remove, install engine with transmission ENGINE 134.9, 135.9 in MODEL 454.0

AR72.10-P-0500FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 783 · Applies to: 453 · AR: AR72.10-P-0500FF, AR68.30-P-4010FF

Remove/install front door 13.8.03 MODEL 454.0 P72.10-2852-09 1 Wiring harness 3 Wiring harness X35/1 Left front door separation point 2 Front door 4 Bolt X35/2 Right front door separation point Removal/installation

Risk of injury Danger! to fingers being jammed or When moving components, ensure that no AS00.00-Z-0011-01A

pinched when Remove/install or aligning body parts or limbs are within the operating hoods, doors, trunk lid/tailgate or sliding roof. range of moving parts. 1 Remove left and right footwell paneling AR68.30-P-4010FF 2 Separate left front door separation point (X35/1) or right front door separation point (X35/2) behind footwell paneling 3 Guide wiring harness (1) or wiring harness (3) Carefully loosen protection hose for wiring through opening in A-pillar toward outside harness (1) and wiring harness (3) from A- pillar 4 Unscrew bolts (4) from left and right front door *BA72.10-P-1001-01K

(2) 5 Remove left and right front door (2) upward Do not handle front door (2) improperly, from door hinges and install in assembly otherwise paintwork may be damaged. device of door or lay down on suitable surface. Helper required *454589005900 Assembly device 6 Install in the reverse order Front door

Number Designation Model 454.0 BA72.10-P-1001-01K Torx bolt for door hinge joint Nm 32 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-0500ff, Remove/install front door MODEL 454.0

Install lower engine compartment paneling.

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1008 · Applies to: 453 · AR: AR61.20-P-1105FF

17 Install lower engine compartment paneling. AR61.20-P-1105FF 18 Close engine hood Belt tensioning device

Number Designation Engines 134.910/911, 135.930/950 BA13.25-P-1001-01O Nut for alternator on tensioning device Nm 20 BA13.25-P-1003-01O Alternator adjustment bolt Nm 5 Alternator

Number Designation Engines 134.910/911 135.930/950 BA15.40-P-1002-01J Nut of alternator to crankcase Nm 42 450 589 00 21 00 Gauge (V-belt tension) Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar13.22-p-1202ff, Remove/install poly-V belt ENGINES 134.9, 135.9 in MODEL 454.0

Position the cover (7) and fasten it in place

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1253 · Applies to: 453 · AR: AR88.00-P-2792FF, AR20.00-P-1142FF, AR20.00-P-1142FG, AR68.10-P-1400FF

14 Position the cover (7) and fasten it in place with the screw (6) 15 Install bracket (5) Make sure that the bracket (5) is properly seated. 16 Remove the clamp pliers from the coolant hoses (1) 17 Install covering on center section in front of AR88.00-P-2792FF windshield 18 Fill in coolant and check the cooling system See: for leaks in the area of the coolant pipes (9) Drain coolant, pour in Engine 134.910/135.930/950 AR20.00-P-1142FF Engine 639.939 AR20.00-P-1142FG 19 Install the trim panel (4) and reposition the floor covering (3) in the vehicle 20 Install glove compartment (2) AR68.10-P-1400FF Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar83.20-p-1100fg, Remove/install heat exchanger MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle

AR25.20-P-0095FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1310 · Applies to: 453 · AR: AR25.20-P-0095FF, AR68.10-P-1500FF

Remove/install clutch pedal switch 8.1.07 MODEL 454.0 with ENGINE 639.9 1 Clutch pedal S40/3 Clutch pedal switch P25.10-2046-06 Removing

The clutch pedal switch (S40/3) must never

come into contact with grease or antifriction agent as otherwise it may malfunction 1 Adjust the driver seat into the rearmost position 2 Remove cover below left of instrument panel On vehicles with code (LHD) Left-hand drive AR68.10-P-1500FF vehicle 3 Detach electrical connector of clutch pedal switch (S40/3) 4 Depress clutch pedal (1) 5 Rotate clutch pedal switch (S40/3) through 90° to the left and remove upwards Install

6 Pull out clutch pedal switch (S40/3) button Pull out clutch pedal switch (S40/3) button as otherwise the clutch pedal switch (S40/3) may be damaged. 7 Press and hold clutch pedal (1) 8 Insert clutch pedal switch (S40/3) on clutch pedal's bearing bracket (1) and rotate through 90° to the right 9 Slowly release clutch pedal (1) 10 Connect STAR DIAGNOSIS and check signal from clutch pedal switch (S40/3) Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory 11 Install cover below instrument panel on left On vehicles with code (LHD) Left-hand drive AR68.10-P-1500FF side vehicle Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar25.20-p-0095ff, Remove/install clutch pedal switch MODEL 454.0 with ENGINE 639.9

Remove paneling on center piece in front of

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1349 · Applies to: 453 · AR: AR88.00-P-2792FF, AR54.00-P-0002FF, AR49.10-P-5500FG, AR49.10-P-5501FF

15 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 16 Remove battery tray AR54.00-P-0002FF 17.1 Detach shift cables from transmission. With TRANSMISSION 717.473 AR26.60-P-6627-01FG 18 Detach wiring harness (11) at bracket (10). 19 Detach bracket (8, 9, 10) at transmission (1). 20 Detach wiring harness (11) at bracket (12). 21.1 Remove catalytic converter On vehicles without code (K13) Diesel AR49.10-P-5500FG particulate filter 21.2 Remove catalytic converter diesel particulate On vehicles with code (K13) Diesel particulate AR49.10-P-5501FF filter unit filter 22 Remove bolts (13) 23 Unscrew bolts of the transmission (1) from the The transmission (1) is secured at the top engine at the top. by three bolts. *BA26.00-P-1006-01D

24 Install engine bridge AR01.10-P-2400-05FG *454589006100

25 Unscrew bolt (15) and unscrew nuts (14) Installation:

Replace self-locking bolt (15) and nuts (14). *BA26.00-P-1002-01D

*BA26.00-P-1003-01D

*454589040900

26 Lower the transmission (1) carefully using When lowering transmission (1), loosen engine bridge until the transmission (1) can be transmission bearing (16) from transmission taken out (1) using a suitable screwdriver, if necessary align transmission (1) using a suitable vehicle jack to prevent the guide bolts from jamming in the transmission bearing (16). *454589006100

27 Raise vehicle 28 Position removal fixture (17) under the The main lifters from the companies transmission (1) Mazzola and AS Hydraulic can be used according to choice. *450589026200

WH58.30-Z-1011-07A Main lifter Co. Mazzola WH58.30-Z-1011-07A Main lifter Fa. AS Hydraulic 29 Unscrew bolts of the transmission (1) on The transmission (1) is secured at the engine at bottom. bottom by four bolts. *BA26.00-P-1006-01D

30 Detach transmission (1) from engine and put *450589026200

onto the removal fixture (17). WH58.30-Z-1011-07A Main lifter Co. Mazzola WH58.30-Z-1011-07A Main lifter Fa. AS Hydraulic Installation:

Grease transmission shaft slightly using suitable grease. 31 Install in the reverse order 32.1 Teach in gear position, clutch motor with drag With TRANSMISSION 717.475 point and shift actuator Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Clutch mechanism

Number Designation Model 454.0 BA25.20-P-1002-01D Torx bolt, clutch slave cylinder Nm 18 to transmission Complete manual transmission

Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar26.10-p-0020fg, Remove/install transmission Transmission 717.473 /475 in MODEL 454.0

AZ31.10-P-8080FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1498 · Applies to: 453 · AR: AZ31.10-P-8080FF, AR88.20-P-1900FF, AR49.10-P-4951FF, AR82.10-P-4905FF, AR68.30-P-4785FF (+5 more)

Retrofit trailer hitch 17.1.06 MODEL 454.0 (except 454.034) 1 Trailer hitch P31.10-2798-11 Disassemble

1 Remove CBS rear end Remove/install CBS rear end AR88.20-P-1900FF

2 Remove rear muffler Replace rear muffler AR49.10-P-4951FF

3 Remove left and right taillamps Remove/install taillamp AR82.10-P-4905FF

4 Remove rear center section paneling Remove/install rear center section paneling AR68.30-P-4785FF

5 Remove left and right side paneling in trunk Remove/install side paneling in trunk AR68.30-P-4800FF

6 Remove C-pillar paneling at bottom left Remove/install paneling on C-pillar AR68.30-P-4490FF

7 Remove B-pillar paneling at bottom left Remove/install paneling on B-pillar AR68.30-P-4700FF

8 Remove paneling in left footwell Remove/install paneling in footwell AR68.30-P-4010FF

9 Remove left door sill molding Remove/install door sill molding AR68.30-P-4100FF

10 Remove fuse and relay module Remove/install fuse and relay box AR54.15-P-1255FF

Install

11 Retrofit mechanical detachable parts of trailer AZ31.11-P-8080-05FF hitch (1) *BA31.11-P-1001-01D Bolt, trailer hitch to body 12 Retrofit wiring harness of trailer hitch (1) AZ31.19-P-8100-05FF 13 Connect wiring harness of trailer hitch (1) to AZ31.19-P-8100-02FF fuse and relay module 14 Retrofit trailer recognition control unit and rear AZ31.19-P-8080-05FF fog lamp cutout relay of trailer hitch (1) 15 Install trailer hitch socket (13-pin) for trailer AZ31.19-P-8100-04FF hitch (1) Assemble

16 Install fuse and relay module Remove/install fuse and relay box AR54.15-P-1255FF

17 Install left door sill molding Remove/install door sill molding AR68.30-P-4100FF

18 Install paneling in left footwell Remove/install paneling in footwell AR68.30-P-4010FF

19 Install B-pillar paneling at bottom left Remove/install paneling on B-pillar AR68.30-P-4700FF

20 Install C-pillar paneling at bottom left Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az31.10-p-8080ff, Retrofit trailer hitch MODEL 454.0 (except 454.034)

Remove/install paneling on C-pillar

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1499 · Applies to: 453 · AR: AR68.30-P-4490FF, AR68.30-P-4800FF, AR68.30-P-4785FF, AR82.10-P-4905FF, AR49.10-P-4951FF (+1 more)

AR68.30-P-4490FF

21 Install left and right side paneling in trunk Remove/install side paneling in trunk AR68.30-P-4800FF

22 Install rear center section paneling Remove/install rear center section paneling AR68.30-P-4785FF

23 Install left and right taillamps Remove/install taillamp AR82.10-P-4905FF

24 Install rear muffler Replace rear muffler AR49.10-P-4951FF

25 Install CBS rear end Remove/install CBS rear end AR88.20-P-1900FF

26.1 Enter special equipment in the vehicle data If the workshop does not have access to the card and in the vehicle's online data card DMS Autoline 8.0 dealership system. Enter code (E50) Trailer hitch. Check

27 Check signals at trailer hitch socket (13-pin) If a turn signal lamp fails, the flashing using suitable test equipment frequency should be doubled. If the rear fog lamp on the trailer fails, the rear fog lamp on the vehicle should light up. Trailer hitch mechanical system

Number Designation Model 454.0 BA31.11-P-1001-01D Bolt, trailer hitch to Nm 58 body Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az31.10-p-8080ff, Retrofit trailer hitch MODEL 454.0 (except 454.034)

AN42.20-P-0003FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1843 · Applies to: 453 · AR: AN42.20-P-0003FF, AR68.20-P-2350FF

Install Brabus hand brake lever 17.1.06 MODEL 454.0 P42.20-2210-07 1 Rear center console cover 4 Lower part of covering 6 BRABUS hand brake lever 2 Pad 5 Cap 7 Leather boot 3 Upper part of covering Remove

1 Remove rear center console covering (1) Remove/install cover on center console AR68.20-P-2350FF

2.1 Detach cover (2) from upper part cover (3) Only on vehicle with cover (2). and lower part cover (4) of hand brake lever 3 Unclip upper part covering (3) from lower part covering (4) 4 Remove lower part covering (4) of hand brake lever Install

5 Install rear center console covering (1) Remove/install cover on center console AR68.20-P-2350FF

6 Push cap (5) over operating head 7 Push BRABUS hand brake lever (6) on up to the stop on the hand brake lever and align 8 Tighten clamp screws (arrows) under the leather boot (7) 9 Pull leather boot (7) backwards and insert in the rear center console covering (1) 10.1 Enter special equipment in the vehicle data If the workshop does not have access to the card and in the vehicle's online data card DMS Autoline 8.0 dealership system. Enter code (J09) Black leather/anodized matt aluminum hand brake lever, BRABUS. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, an42.20-p-0003ff, Install Brabus hand brake lever MODEL 454.0

AZ42.20-P-0006SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1852 · Applies to: 453 · AR: AZ42.20-P-0006SR, AR68.20-P-2000SR

Retrofit trim piece on parking brake lever 19.04.2016 Model 453.0/3/4 1 Trim piece P42.20-2717-11 Remove

1 Remove center console AR68.20-P-2000SR

2 Remove trim piece (1) fitted at factory to AZ42.20-P-0006-01SR parking brake lever

Do not cut too deeply. Otherwise the components below can be damaged and weakened. Use eccentric saw for cutting.

Install

3 Install new trim piece (1) onto parking brake AZ42.20-P-0006-02SR lever 4 Install center console AR68.20-P-2000SR

Update Vehicle Documentation (VeDoc) 5 Attach "Parking brake lever trim piece retrofitted according to AZ42.20-P-0006SR" note under field organization texts to design group (KG) 42 Parts ordering note Part no. Designation Quantity KG 98 (siehe EPC) Parts kit for parking brake lever trim piece 1 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, az42.20-p-0006sr, Retrofit trim piece on parking brake lever Model 453.0/3/4

AR43.10-P-0355FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1922 · Applies to: 453 · AR: AR43.10-P-0355FH, AR88.00-P-2792FF

Remove/install brake booster vacuum line 29.6.04 MODEL 454.0## 2# with ENGINE 639.939 with CODE (RHD) Right-hand drive vehicle 1 Connector 2 Vacuum line 3 Vacuum hose 4 Bracket 5 Brake booster P43.10-2049-04 Remove/Install

1 Push down brake pedal several times in order to release any vacuum. 2 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 3 Release retainer on plug (1) and detach it 4 Detach vacuum line (3) from vacuum line (2) 5 Use a suitable tool to unclip the vacuum line (2) from the bracket (4) 6 Pull the vacuum line (2) from the brake booster (5) 7 Remove the vacuum line (2) 8 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar43.10-p-0355fh, Remove/install brake booster vacuum line MODEL 454.0## 2# with ENGINE 639.939 with CODE (RHD) Right-hand drive vehicle

AR43.10-P-0355FI

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1923 · Applies to: 453 · AR: AR43.10-P-0355FI, AR88.00-P-2792FF

Remove/install brake booster vacuum line 26.7.04 MODEL 454.0## 2# with ENGINE 134.9, 135.9 with CODE (RHD) Right-hand drive vehicle P43.10-2053-08 1 Top part of air filter housing 3 Brake booster 5 Connector 2 Brake booster vacuum line 4 Bracket Remove/Install

1 Push down brake pedal several times In order to eliminate any vacuum present. 2 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 3 Undo clips on top part of air filter housing (1) Top part of air filter housing (1) is secured and place top part of air filter housing (1) to with two clips. one side 4 Pull brake booster vacuum line (2) out of brake booster (3) 5 Detach brake booster vacuum line (2) from Brake booster vacuum line (2) is secured firewall and bracket (4) to firewall using two nuts. 6 Squeeze together catches (arrows) and disconnect connector (5) 7 Take out vacuum line of brake booster (2) 8 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar43.10-p-0355fi, Remove/install brake booster vacuum line MODEL 454.0## 2# with ENGINE 134.9, 135.9 with CODE (RHD) Right-hand drive vehicle

Insert the jumper cable (7), as shown, at the

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1990 · Applies to: 453 · AR: AR68.10-P-1500FF, AR68.10-P-1400FF

9 Insert the jumper cable (7), as shown, at the Use a suitable jumper cable (7). position of relay 2, fuel pump 10 Switch the ignition on and pump the fuel out of The fuel pump with fuel level sensor must the tank into the safety container not be allowed to dry for more than 3 minutes, otherwise it will be damaged. The delivery rate of the fuel pump with tank level sensor is approx. 1 liter/16.5 s. Install

11 Pull the drain hose (5) out of the safety canister 12 Loosen hose clamp (6) and pull the drain *454589049100

hose (5) out of the adapter (4) 13 Expand the clamp (1) by hand and pull the Catch fuel coming out in suitable vessel adapter (4) out of the fuel line (2) *454589049100

14 Remove plug at connection of fuel distributor Make sure the secondary clamp (1) (3) and plug the fuel line (2) onto the latches correctly into place. connection of the fuel distributor (3) 15 Close engine hood 16 Insert relay 2, fuel pump in the fuse and relay module (K40/1) Fuse and relay box relay assignment GF54.15-P-1255-21FG

17.1 Install cover below instrument panel on left On vehicles with code (LHD) left-hand drive AR68.10-P-1500FF side vehicle 17.2 Install glove compartment On vehicles with code (RHD) right-hand drive AR68.10-P-1400FF vehicle Charging 18 Connect ground line of Saugmaster device to *WE58.40-Z-1001-22A

ground of vehicle 19 Pump fuel out of the safety tank through the *WE58.40-Z-1001-22A

filler opening into the fuel tank 20 Remove ground line of Saugmaster device *WE58.40-Z-1001-22A

from vehicle 21 Screw the cap onto the fuel tank filler neck Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 22 Perform an engine test run and check the fuel line (2) for leaks at the connection of the fuel distributor (3) 454 589 04 91 00 Adapter Workshop equipment WE58.40-Z-1001-22A Tank emptying device Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.10-p-4001ff, Empty, fill fuel tank MODEL 454.0 with ENGINE 134.9, 135.9

Install

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1992 · Applies to: 453 · AR: AR68.10-P-1500FF, AR68.10-P-1400FF

12 Pull the drain hose (5) out of the safety canister 13 Raise vehicle 14 Loosen hose clamp (4) and pull the drain *454589049100

hose (5) out of the adapter (3) 15 Carefully depress release (arrow) and pull the Catch fuel coming out in suitable vessel adapter (3) off the fuel line (1) *454589049100

16 Remove the plugs from the fuel line (2) and Ensure fuel line (2) is fitted correctly to connect fuel line (2) to fuel line (1) fuel line (1). 17 Lower vehicle 18 Insert relay 2, fuel pump in the fuse and relay module (K40/1) Fuse and relay box relay assignment GF54.15-P-1255-21FG

19.1 Install cover below instrument panel on left On vehicles with code (LHD) left-hand drive AR68.10-P-1500FF side vehicle 19.2 Install glove compartment On vehicles with code (RHD) right-hand drive AR68.10-P-1400FF vehicle Charging 20 Connect ground line of Saugmaster device to *WE58.40-Z-1001-22A

ground of vehicle 21 Pump fuel out of the safety tank through the *WE58.40-Z-1001-22A

filler opening into the fuel tank 22 Remove ground line of Saugmaster device *WE58.40-Z-1001-22A

from vehicle 23 Screw the cap onto the fuel tank filler neck Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 24 Perform an engine test run and check the fuel line (1) for leaks at the connection of the fuel line (2) 454 589 04 91 00 Adapter Workshop equipment WE58.40-Z-1001-22A Tank emptying device Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.10-p-4001fg, Empty, fill fuel tank MODEL 454.0 with ENGINE 639.9

AZ49.10-P-0003SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2052 · Applies to: 453 · AR: AZ49.10-P-0003SR, AR88.20-P-2200SRA, AR49.10-P-4823SR, AZ88.20-P-0006SR

Retrofit sport exhaust system 12.04.2016 Engine 281.9 in model 453.3/4 Shown: sport exhaust system (1) with 2 exhaust tailpipes 1 Sport exhaust system P49.10-3148-11 Shown: sport exhaust system (1) with 2 exhaust tailpipes 1 Sport exhaust system 2 Bracket 3 Screw/bolt 4 Elastomer bearing P49.10-3153-06 Remove

1 Remove rear bumper For retrofitting of the sport exhaust system (1) with 2 exhaust tailpipes. AR88.20-P-2200SRA

2 Remove rear muffler AR49.10-P-4823SR

Install

3 Position bracket (2) and tighten screw/bolts (3) For retrofitting of the sport exhaust system (1) with 2 exhaust tailpipes. 4 Install sport exhaust system (1) AR49.10-P-4823SR

5 Install elastomer bearing (4) For retrofitting of the sport exhaust system (1) with 2 exhaust tailpipes. 6 Retrofit rear apron For retrofitting of the sport exhaust system (1) with 2 exhaust tailpipes. AZ88.20-P-0006SR 7 Install rear bumper For retrofitting of the sport exhaust system (1) with 2 exhaust tailpipes. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az49.10-p-0003sr, Retrofit sport exhaust system Engine 281.9 in model 453.3/4

AR88.20-P-2200SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2053 · Applies to: 453 · AR: AR88.20-P-2200SRA, AZ49.10-P-0003SR

Update Vehicle Documentation (VeDoc) 8 Attach note Sport exhaust system as per AZ49.10-P-0003SR retrofitted under field organization texts on the DG 49 9 Attach note Sport exhaust system as per For retrofitting of the sport exhaust system (1) AZ49.10-P-0003SR retrofitted under field with 2 exhaust tailpipes. organization texts on the DG 88 Parts ordering note Part no. Designation Quantity KG 98 (siehe EPC) Parts kit for sport exhaust system 1 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az49.10-p-0003sr, Retrofit sport exhaust system Engine 281.9 in model 453.3/4

Install

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2361 · Applies to: 453 · AR: AR68.10-P-1520FF, AR54.10-P-0003FF

3 Expose plug (3) and contact the central gateway control unit (N93) 4 Insert central gateway control unit (N93) in the The central gateway control unit (N93) lower area in the bracket (4) and into the must latch audibly in the retainer tabs (arrows retainer tabs (arrows B) B). 5.1 Insert trim (2) in the guide (arrow A) and On vehicles with code (Left-hand drive install clips (1) vehicle) Left-hand steering 5.2 Install cover below instrument panel on right On vehicles with code (RHD) right-hand drive vehicle Remove/install cover below instrument panel AR68.10-P-1520FF

(right) 6 Connect ground cable to battery Disconnect/connect battery's ground cable AR54.10-P-0003FF

7 Read fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az54.21-p-0001ff, Retrofit central gateway control unit (central gateway) MODELS 454.0

Release screws (2) gradually in steps and

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2458 · Applies to: 453 · AR: AR68.30-P-2000SR

check the manual reset functions again. Install

10 Position upper steering column trim (1) and AR68.30-P-2000SR install lower steering column trim. Switches Number Designation Model 453 BA54.25-P-1001-01A Screw, combination switch to steering column Stage 1 Nm 0,75 tube module ° Stage 2 180 001 589 81 21 00 Torque screwdriver Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar54.25-p-2809sr, Remove/install left combination switch Model 453

AZ54.30-P-0001FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2495 · Applies to: 453 · AR: AZ54.30-P-0001FF, AR68.10-P-1020FF

Retrofit additional instruments 17.1.06 MODEL 454.0 (except 454.034) 1 Instrument panel top section 2 Covers 3 Bolts 4 Plug 5 Plug connector 6 Electrical line A15p2 Coolant temperature indicator A15p3 Clock P54.30-8261-06 1 Instrument panel top section 6 Electrical line 7 Plug 8 Strut A15x1 Additional instruments connector P54.30-8262-06 Remove

1 Remove instrument panel top section (1) Remove/install instrument panel top section AR68.10-P-1020FF

2 Unclip covers (2) from instrument panel top Unclip the covers (2) carefully otherwise section (1) using a suitable tool the instrument panel top section (1) may be damaged. Install

3 Insert coolant temperature indicator (A15p2) and clock (A15p3) into instrument panel top section (1) and latch in place 4 Secure coolant temperature indicator (A15p2) and clock (A15p3) with bolts (3) 5 Connect plug (4) of clock (A15p3) with plug Ensure that the plug (4) is properly connector (5) of coolant temperature indicator engaged in the plug connector (5). (A15p2) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az54.30-p-0001ff, Retrofit additional instruments MODEL 454.0 (except 454.034)

Unclip additional instruments connector

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2496 · Applies to: 453 · AR: AR68.10-P-1020FF

6 Unclip additional instruments connector (A15x1) from strut (8) and route it upwards into radio recess 7 Insert instrument panel top section (1) Helper required 8 Connect plug (7) with additional instruments Ensure that the plug (7) is properly connector (A15x1) engaged in the additional instruments connector (A15x1). 9 Clip additional instruments connector (A15x1) Ensure that the electrical line (6) is routed onto strut (8) correctly. 10 Install instrument panel top section (1) Remove/install instrument panel top section AR68.10-P-1020FF

11 Set clock (A15p3) 12 Perform road test and check coolant temperature indicator (A15p2) for proper operation 13.1 Enter special equipment in the vehicle data If the workshop does not have access to the card and in the vehicle's online data card DMS Autoline 8.0 dealership system. Enter code (V56) Additional instruments and coolant gauge. Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az54.30-p-0001ff, Retrofit additional instruments MODEL 454.0 (except 454.034)

Clip remover

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2519 · Applies to: 453 · AR: AR88.20-P-1925SRA

*452589016300 Clip remover 3 Remove heat shield (5) in the area of center Model 453.3 (except 453.391), 453.4 (except AR88.20-P-1925SRA rear parking system distance sensor (B8/10) 453.491) with code 220 (Rear parking assist) Model 453.3 (except 453.391), 453.4 (except 453.491) with code V52 (Combination code for rear parking aid and reversing camera) 4 Separate electrical connections (1) 5 Unclip parking system distance sensors (B8/8, Installation: Check parking system

B8/9, B8/10) from retaining clip (3) and distance sensors (B8/8, B8/9, B8/10) are remove correctly seated into retaining clips (3). 6 Install in the reverse order Check

7 Read out fault memory using diagnostic unit and delete AD00.00-P-2000-06SR

452 589 01 63 00 Clip remover Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar54.65-p-0002sr, Remove/install Parktronic system (PTS) sensors in rear bumper Model 453 with code 220 (Rear parking assist) Model 453 with code V52 (Combination code for rear parking aid and reversing camera)

AR60.00-P-0032SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2612 · Applies to: 453 · AR: AR60.00-P-0032SR, AR54.10-P-1160SRE, AR54.10-P-0003SR

Replace ground point 03.12.2019 Model 453 Risk of death Danger when working on component Do not touch damaged or defective live AS00.00-Z-0035-01A

parts and systems with U >= 30 V alternating component parts and lines or non-insulated voltage (AC) or U >= 60 V direct voltage (DC) electrical connections and lines. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Risk of injury. Skin or eye injuries may result Wear protective gloves, protective clothing AS00.00-Z-0002-01A Warning

when handling hot or glowing objects. and safety glasses, if necessary. Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on handling vehicles with AH00.00-Z-0300-01A high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system Topical note General information on body repair AH60.00-N-0001-01A Remove

1.1 Enable high voltage on-board electrical Model 453.091/391/491 system AR54.10-P-1160SRE 1.2 Disconnect battery ground line Model 453 (except 453.091/391/491) AR54.10-P-0003SR 2 Remove detachable parts in area to be repaired 3 Remove ground line from the weld stud of the ground point 4 Cover all detachable parts remaining on vehicle with spark protection blankets 5 Cut off old weld stud of the ground point as close as possible to the body Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6 Check repair point for crack formation In the event of crack formation Weld cracks. 000 588 02 84 00 Welder WS60.00-P-0022K

7 Surface grind repair point and grind down to bare metal 8 Weld on new weld stud Commercially available devices/tools

Stud welder 9 Clean weld joint 10 Remove spark protection blankets 11 Clean repair area 12 Mask off thread of the weld stud with tape 13 Prime repair area with primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: https://xentryportal.i.daimler.com/wps/portal 14 Paint repair area Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

https://xentryportal.i.daimler.com/wps/portal 15 Remove tape from the weld stud 16 Attach ground line to the weld stud of the ground point Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar60.00-p-0032sr, Replace ground point Model 453

BE60.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2615 · Applies to: 453 · AR: BE60.00-Z-9999CZ

Test and adjustment values: Smart: Body - general 18.09.2019 MODEL all Gap dimensions Model 453.0/3/4 BE60.00-P-1000-01CA Gap dimensions MODEL 450.3/4 BE60.00-P-1000-01H Gap dimensions MODEL 452.3/4 BE60.00-P-1000-01J Gap dimensions MODEL 454.0 BE60.00-P-1000-01M Gap dimensions MODEL 451.3/4 BE60.00-P-1000-01V Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be60.00-z-9999cz, Test and adjustment values: Smart: Body - general MODEL all

AR60.10-P-0100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2616 · Applies to: 453 · AR: AR60.10-P-0100FF

Position body on straightening bench, check and align if necessary 08.03.2019 Model 454.0 CAR-BENCH straightening systems P60.10-2170-09 1 Straightening bench 2 Crossmember high 3 Crossmember flat 1 Straightening bench 4 Straightening boom 5 Uni-anchorings 6 Support arm of the uni-anchoring P60.10-2171-06 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar60.10-p-0100ff, Position body on straightening bench, check and align if necessary Model 454.0 CAR-BENCH straightening systems

AR60.10-P-0100FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2619 · Applies to: 453 · AR: AR60.10-P-0100FG

Position body on straightening bench, check and align if necessary 08.03.2019 Model 454.0 Celette straightening systems 1 Straightening bench 2 Module longitudinal member left 3 Module longitudinal member right 4 Module member 5 Assembly strip P60.10-2176-06 1 Straightening bench 6 Straightening equipment 7 Anchoring attachments P60.10-2172-05 Upgrading and downgrading Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Install straightening bench (1) The assembly instructions can be found in

the Celette assembly plan. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar60.10-p-0100fg, Position body on straightening bench, check and align if necessary Model 454.0 Celette straightening systems

AR60.10-P-0100FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2621 · Applies to: 453 · AR: AR60.10-P-0100FH

Position body on straightening bench, check and align if necessary 08.03.2019 Model 454.0 BLACKHAWK straightening systems 1 Straightening bench 2 Anchoring attachments P60.10-2174-05 1 Straightening bench 2 Anchoring attachments 3 Universal longitudinal member right 4 Universal longitudinal member left 5 Universal members P60.10-2173-05 Upgrading and downgrading Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Install straightening bench (1) The assembly instructions can be found in

the BLACKHAWK assembly plan. 2 Attach universal longitudinal member left (4), The number and position of the universal

universal longitudinal member right (3) and members (5) and the position of the universal universal members (5) left and right to the longitudinal member left (4) and the universal straightening bench (1) longitudinal member right (3) depends on the BLACKHAWK assembly plan. The straightening bench (1) is divided into index fields (arrow) in the longitudinal direction. The index fields (arrow) are marked with numbers on the lateral straightening bench flange. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar60.10-p-0100fh, Position body on straightening bench, check and align if necessary Model 454.0 BLACKHAWK straightening systems

AR60.10-P-0100FJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2623 · Applies to: 453 · AR: AR60.10-P-0100FJ

Position body on straightening bench, check and align if necessary 08.03.2019 Model 454.0 CAR-O-Liner straightening systems Shown on the straightening bench 1 Straightening bench 2 Anchoring attachments P60.10-2175-06 Upgrading and downgrading Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Install straightening bench (1) The assembly instructions can be found in

the CAR-O-Liner assembly plan. 2 Attach two anchoring attachments (2) to the The anchoring attachments (2) are

left and right on the straightening bench (1) mounted on the straightening bench (1) in such a way that they float. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. 3 Lift the body with the vehicle lift and align the straightening bench (1) beneath it 4 Align the anchoring attachments (2) with the Use either the "Classic" or "Vision"

lift support points on the longitudinal member measurement system. outer shell of the body The position of the anchoring attachments (2) is specified by the measurement system. 5 Lower the body with the vehicle lift, position it

in the anchoring attachments (2) and place the Ensure that the body has been firmly clamped steel clamping jaws of the anchoring in the steel clamping jaws of the anchoring attachments (2) in position attachments (2). Otherwise, it may be torn out during straightening procedures. 6 Assemble and set up the measurement The assembly and set-up instructions are

system in accordance with the manufacturer's given in the measurement system's screen instructions. menu. Check

7 Approach the measuring points on the body The test process is specified by the

and compare the positions of the measuring measurement system, the instructions and tips with the drive points on the body. evaluations are given via the measurement system's screen menu. Straightening Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar60.10-p-0100fj, Position body on straightening bench, check and align if necessary Model 454.0 CAR-O-Liner straightening systems

AR61.10-P-5139SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2627 · Applies to: 453 · AR: AR61.10-P-5139SRC, AR61.10-P-5138SRC

Remove/install cross strut 04.08.2016 Model 453.44/45/46 1 Front cross strut 2 Rear cross strut 3 Diagonal strut 4 Screw 5 Screw 6 Bolts 7 Bolts 8 Bolts P61.10-2279-06 Remove/install

1 Remove diagonal strut (3) AR61.10-P-5138SRC 2 Unscrew bolts (4, 5) 3 Unscrew bolts (7) and remove front cross Helper required.

strut (1) 4 Remove bolts (6) 5 Unscrew bolts (8) and remove rear cross Helper required.

strut (2) 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar61.10-p-5139src, Remove/install cross strut Model 453.44/45/46

AR61.10-P-5138SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2628 · Applies to: 453 · AR: AR61.10-P-5138SRC

Remove/install diagonal strut 04.08.2016 Model 453.44/45/46 1 Diagonal strut 2 Bolts P61.10-2278-06 Remove/install

Risk of death Danger ! caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. 1 Raise vehicle with vehicle lift 2 Remove underfloor panels 3 Remove bolts (2) and remove diagonal strut Installation: Screw in all bolts (2) to stop

(1) and then tighten. Helper required.

4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar61.10-p-5138src, Remove/install diagonal strut Model 453.44/45/46

AR61.10-P-0020SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2629 · Applies to: 453 · AR: AR61.10-P-0020SRC

Remove/install mounting bracket for front cross strut 03.04.2019 Model 453.4 1 Fastening console 2 Fastening console P61.10-2283-11 Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A General information on MB materials AH98.00-P-9409-03A General information on repair of vehicles with AH60.00-P-0024-01N ultra-strength steels. Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove mounting consoles (1, 2) AR61.10-P-0020-01SRC Commercially available devices/tools

Round wire brush Spot weld milling machine Wet/dry vacuum cleaner 4 Prepare mounting consoles (1, 2) for AR61.10-P-0020-02SRC installation Commercially available devices/tools

Round wire brush Wet/dry vacuum cleaner Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 5 Install mounting consoles (1, 2) AR61.10-P-0020-03SRC 000 588 02 84 00 Welder WS60.00-P-0022K

Commercially available devices/tools

Round wire brush Wet/dry vacuum cleaner 6 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 7 Remove spark protection blankets Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar61.10-p-0020src, Remove/install mounting bracket for front cross strut Model 453.4

AR61.20-P-1105FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2631 · Applies to: 453 · AR: AR61.20-P-1105FF

Remove/install bottom engine compartment paneling 9.6.06 MODEL 454.0 Shown on vehicle with code (I60) Stationary heater, gasoline 1 Engine compartment lining 2 Profile rubber element (on vehicles with code (I58) Stationary heater, diesel or code (I60) Stationary heater, gasoline ) 3 Exhaust line (on vehicles with code (I58) Stationary heater, diesel or code (I60) Stationary heater, gasoline ) P61.20-2056-11 Remove/install

Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A toppling off of the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 1 Raise vehicle 2.1 Press profile rubber element (2) with exhaust Only on vehicles with code (I58) Stationary line (3) upward through hole into engine heater, diesel or code (I60) Stationary heater, compartment paneling (1) gasoline Installation:

Ensure that profile rubber element (2) is seated correctly in engine compartment paneling (1). 3 Remove clips from engine compartment paneling (1). 4 Pull out engine compartment paneling (1) toward rear 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar61.20-p-1105ff, Remove/install bottom engine compartment paneling MODEL 454.0

BE62.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2634 · Applies to: 453 · AR: BE62.00-Z-9999CZ

Test and adjustment values: Smart: Front end and fire wall 18.09.2019 MODEL all Body shell - Front end MODEL 452 BE62.10-P-1000-01A Crossmember MODEL 451.3/4 BE62.30-P-1000-01A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be62.00-z-9999cz, Test and adjustment values: Smart: Front end and fire wall MODEL all

AR62.10-P-1020SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2636 · Applies to: 453 · AR: AR62.10-P-1020SR

Remove/install CMS front 15.07.2016 Model 453 Modification notes 06.07.2016 Step 4 added 453.062/362/462 Shown on model 453.0 with removed lamp units 1 Front CMS 2 CMS front foam pad 3 Bolts 6 Screw 7 Bracket P62.10-2235-06 Shows on model 453.3 1 Front CMS 2 CMS front foam pad 3 Bolts P62.10-2233-06 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.10-p-1020sr, Remove/install CMS front Model 453

Front CMS

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2637 · Applies to: 453 · AR: AR88.20-P-2000SR, AR88.20-P-2000SRA

1 Front CMS 4 Radiator shutters 5 Electrical connector P62.10-2234-01 Remove/install

1 Remove front bumper Model 453.0 AR88.20-P-2000SR Model 453.3/4 AR88.20-P-2000SRA 2 Remove CMS front foam pad (2) Installation: Check CMS front foam pad

(2) for damage. If CMS front foam pad (2) is damaged Replace CMS front foam pad (2) 3 Disconnect electrical connector (5) from radiator shutters (4) 4 Disconnect electrical connector from horn, Model 453.062/362/462 unscrew bolt and remove horn 5 Unscrew bolts (3) and remove CMS front (1) *BA62.30-P-1001-02L Screw/bolt, crossmember to longitudinal member 6 Unscrew bolt (6) and remove brackets (7) When replacing CMS front (1). 7 Remove radiator shutters (4) from CMS front When replacing CMS front (1). (1) 8 Install in the reverse order Front end with front reinforcement Number Designation Model 453.0/3/4 BA62.30-P-1001-02L Screw/bolt, crossmember to longitudinal member Nm 21 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.10-p-1020sr, Remove/install CMS front Model 453

AR62.20-P-1300FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2638 · Applies to: 453 · AR: AR62.20-P-1300FF, AR82.10-P-4730FF

Remove/install headlamp support 21.10.03 MODEL 454.0 Removal with lamp unit removed P62.20-2984-07 1 Spreading clip 3 Headlamp support E1 Left front headlamp unit 2 Retaining clamp 4 Control cable E2 Right front headlamp unit Shown on right headlamp support 3 Headlamp support 5 Guide bolts 6 Bolts P62.20-2985-06 Remove/install

1 Remove left front lamp unit (E1) and right AR82.10-P-4730FF front lamp unit (E2) 2.1 Unclip refrigerant line from holder on Only when removing right headlamp support headlamp support (3) (3) on vehicles with code (I01) Air conditioning system Plus (with outside temperature indicator) (FFO). 3.1 Remove spreading clip (1) from headlamp Only when removing right headlamp support support (3) (3). 3.2 Unclip control cable (4) from retaining clip (2) Only when removing left headlamp support on headlamp support (3) (3). 4 Remove spreading clip from front inner fender Spreading clip is located in outer area of service flap for changing low beam bulbs 5 Unscrew bolts (6) from right and left headlamp support (3) 6 Remove right and left headlamp support (3) Installation:

Ensure that headlamp upward support (3) is seated properly in guide bolts (5). 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1300ff, Remove/install headlamp support MODEL 454.0 Removal with lamp unit removed

AR62.20-P-1300FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2639 · Applies to: 453 · AR: AR62.20-P-1300FG, AR88.00-P-1010FF

Remove/install headlamp support 24.11.03 MODEL 454.0 Removal with installed headlamp P62.20-2984-07 1 Expanding clip 3 Headlamp support E1 Left front lamp unit 2 Retaining clamp 4 Bowden cable E2 Right front lamp unit P62.20-3040-07 Shown on right headlamp support 3 Headlamp support 6 Guide bolts E1 Left front lamp unit 5 Bolts 7 Electrical connector E2 Right front lamp unit 8 Expanding clip P62.20-3045-01 Removal/installation

1 Remove front CBS AR88.00-P-1010FF 2.1 Unclip refrigerant line from holder on Only when removing right headlamp support headlamp support (3) (3), on vehicles with code (I01) air conditioning Plus (with outside temperature indicator) (FFO). 3.1 Remove expanding clip (1) from headlamp Only when removing right headlamp support support (3) (3). 4.1 Unclip Bowden cable (4) from retaining Only when removing left headlamp support clamps (2) on headlamp support (3) (3). 5 Disconnect electrical connectors (7) from left front headlamp (E1) or right front headlamp (E2) and from headlamp support (3) 6 Unscrew bolts (5) from right or left headlamp support (3) 7 Remove expanding clip (8) in front inner Expanding clip (8) is located in outer area fender of service flap for replacing low beams 8 Remove left or right headlamp support (3) Installation:

Ensure that headlamp upward support (3) is seated properly in guide bolt (6) 9 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1300fg, Remove/install headlamp support MODEL 454.0 Removal with installed headlamp

AR62.20-P-1200SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2640 · Applies to: 453 · AR: AR62.20-P-1200SR, AR62.20-P-1286SR

Replace complete wheel well 14.05.2019 Model 453 Shown on model 453.3 1 A-pillar end plate 2 Suspension strut tower 3 Longitudinal member end plate 4 Longitudinal member P62.20-4975-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove top front longitudinal member AR62.20-P-1286SR 4 Remove wheel well AR62.20-P-1200-21SR The wheel well consists of the A-pillar end

plate (1), suspension strut tower (2), longitudinal member end plate (3) and longitudinal member (4). Commercially available tools

-Round wire brush - Body jig saw - Weld-spot milling machine - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 5 Prepare wheel well for installation AR62.20-P-1200-19SR Commercially available tools

-Round wire brush - Body jig saw - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar62.20-p-1200sr, Replace complete wheel well Model 453

Topical note

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2641 · Applies to: 453 · AR: AR62.20-P-1286SR, AR97.10-P-4000SR, AR97.20-P-1500SR

Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work General information on riveting AH60.00-P-0003-01N 6 Install and weld in wheel well AR62.20-P-1200-17SR Commercially available tools

-Round wire brush - Spot welder MIG-MAG inert gas welder Blind rivet 6.5 12.5 (clamping *BR00.45-Z-1012-13A range 2 mm to 5 mm, draw-off strength min. 19 kN) 7 Clean weld joints and sheet metal flange with Commercially available tools

round wire brush -Round wire brush 8 Install upper front longitudinal member AR62.20-P-1286SR 9 Remove spark protection blankets 10 Clean repair area Commercially available tools

• Wet/dry vacuum cleaner Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 11 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://aftersales.mercedes-benz.com 12 Seal seam following repairs AR97.10-P-4000SR Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 13 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://aftersales.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install detachable parts in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off BR00.45-Z-1012-13A A 004 990 16 97 strength min. 19 kN) Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar62.20-p-1200sr, Replace complete wheel well Model 453

AR62.20-P-1265FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2642 · Applies to: 453 · AR: AR62.20-P-1265FF

Replace consoles on front longitudinal member 08.03.2019 Model 454.0 P62.20-3003-09 1 Mounting console 2 Longitudinal member 1 Mounting console 2 Longitudinal member P62.20-3004-12 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1265ff, Replace consoles on front longitudinal member Model 454.0

AR62.20-P-1267FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2645 · Applies to: 453 · AR: AR62.20-P-1267FF

Replace longitudinal member closing section 08.03.2019 Model 454.0 P62.20-3014-09 1 End plate 2 Mounting console 3 Longitudinal member P62.20-3015-09 1 End plate 2 Mounting console 3 Longitudinal member Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1267ff, Replace longitudinal member closing section Model 454.0

AR62.20-P-1260FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2648 · Applies to: 453 · AR: AR62.20-P-1260FF

Replace longitudinal member front section 08.03.2019 Model 454.0 1 Longitudinal member inner section LH 2 Longitudinal member outer section LH A1 Cut point at longitudinal member inner section FRT A2 Cut point at longitudinal member inner section RR B1 Start of cut point area at longitudinal member outer section FRT B2 End of cut point area at longitudinal member outer section RR Pfeil Laser weld seam P62.20-3007-06 3 Longitudinal member inner section RH 4 Longitudinal member outer section RH A1 Cut point at longitudinal member inner section FRT A2 Cut point at longitudinal member inner section RR B1 Start of cut point area at longitudinal member outer section FRT B2 End of cut point area at longitudinal member outer section RR Pfeil Laser weld seam P62.20-3008-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1260ff, Replace longitudinal member front section Model 454.0

AR62.20-P-1232FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2650 · Applies to: 453 · AR: AR62.20-P-1232FG, AR97.10-P-4000FF

Replace suspension strut tower 19.03.2019 Model 454.0 1 Suspension strut tower P62.20-3561-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarps, To prevent damage as a result of flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4 Remove suspension strut tower (1) AR62.20-P-1232-01FG 5 Prepare suspension strut tower (1) for AR62.20-P-1232-03FG installation Notes on replacing body parts AH60.00-P-0027-01FF 6 Prepare mating surfaces on vehicle for AR62.20-P-1232-02FG suspension strut tower (1) Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 7 Install suspension strut tower (1) AR62.20-P-1232-04FG Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 8 Take vehicle of the straightening bench and remove straightening bench 9 Clean weld joints and metal flanges with a wire brush and clean repair areas 10 Prime repair area using primer filler 11 Supply standard seam seals with body sealant AR97.10-P-4000FF Seam sealing following repair

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1232fg, Replace suspension strut tower Model 454.0

AR62.20-P-1286SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2652 · Applies to: 453 · AR: AR62.20-P-1286SR

Replace upper front longitudinal member 14.05.2019 Model 453 Shown on model 453.3 1 Upper front longitudinal member P62.20-4937-06 Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Separate upper front longitudinal member (1) AR62.20-P-1286-01SR Commercially available tools

-Round wire brush - Weld-spot milling machine - Wet/dry vacuum cleaner 4 Prepare upper front longitudinal member (1) AR62.20-P-1286-02SR Commercially available tools

-Round wire brush Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work General information on riveting AH60.00-P-0003-01N 5 Install upper front longitudinal member (1) and AR62.20-P-1286-03SR weld in Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1286sr, Replace upper front longitudinal member Model 453

AR62.20-P-1856FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2654 · Applies to: 453 · AR: AR62.20-P-1856FF, AR63.20-P-1110FF, AR63.20-P-1112FF

Replace wheel well with front longitudinal member 08.03.2019 Model 454.0 1 Longitudinal member inner shell 2 Outer longitudinal member shell 3 Suspension strut tower 4 Connecting panel of A-pillar P62.20-3508-06 Remove

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Notes on replacing body parts AH60.00-P-0027-01FF 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use a fireproof tarp to avoid damage caused by flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

tool set and place the vehicle on it 4 Remove A-pillar reinforcement AR63.20-P-1110FF 5 Remove connecting panel of A-pillar (4) Only when removing the complete connecting AR63.20-P-1112FF panel of A-pillar (4). Only when replacing parts of the A-pillar AR63.20-P-1112-01FG connecting panel (4). 6 Remove the suspension strut tower (3) with AR62.20-P-1856-01FF longitudinal member inner shell (1) and longitudinal member outer shell (2) at the front 7 Prepare the body for welding in the AR62.20-P-1240-05FF longitudinal member inner shell (1) and the longitudinal member outer shell (2) 8 Prepare the body for welding in the AR62.20-P-1232-02FF suspension strut tower (3) 9 Prepare the longitudinal member inner shell AR62.20-P-1240-04FF (1) and longitudinal member outer shell (2) for welding in Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1856ff, Replace wheel well with front longitudinal member Model 454.0

Prepare suspension strut tower (3) for

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2655 · Applies to: 453 · AR: AR63.20-P-1112FF, AR97.10-P-4000FF, AR97.20-P-1500FF, AR63.20-P-1110FF

10 Prepare suspension strut tower (3) for AR62.20-P-1232-03FF installation 11 Prepare A-pillar connecting panel (4) for Only when replacing parts of the A-pillar AR63.20-P-1112-02FG installation connecting panel (4). Zinc dust paint suitable for spot welding, *BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint Install

12 Install longitudinal member inner shell (1) AR62.20-P-1242-03FF 13 Install longitudinal member outer shell (2) AR62.20-P-1242-03FG 14 Install suspension strut tower (3) AR62.20-P-1232-04FF 15 Prepare the body for welding in the A-pillar Only when replacing parts of the A-pillar AR63.20-P-1112-03FG connecting panel (4) connecting panel (4). 16 Install A-pillar connecting panel (4) Only when installing the complete A-pillar AR63.20-P-1112FF connecting panel (4). Only when replacing parts of the A-pillar AR63.20-P-1112-04FG connecting panel (4). 17 Clean the weld joints and metal flanges with wire brush and clean the repair areas 18 Prime repair area using primer filler 19 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 20 Supplement the standard underfloor protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underbody sealant 21 Paint repair area adjacent surfaces 22 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 23 Install reinforcement on the A-pillar AR63.20-P-1110FF 24 Take the vehicle off the straightening bench and dismantle the straightening bench 25 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding, replaced by A 000 986 A 000 986 34 42 28 00 1K zinc dust paint BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1856ff, Replace wheel well with front longitudinal member Model 454.0

AR62.25-P-1100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2656 · Applies to: 453 · AR: AR62.25-P-1100FF, AR63.30-P-0815FF

Partially remove/install lower firewall 19.03.2019 Model 454.0 1 Outer firewall lower section P62.25-2368-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarps, To prevent damage as a result of flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4 Remove side front longitudinal member AR63.30-P-0815FF 5 Remove outer firewall lower section (1) and AR62.25-P-1100-01FF prepare mating surfaces on the body for installation Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint 6 Prepare outer firewall lower section (1) for AR62.25-P-1100-02FF installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 7 Install outer firewall lower section (1) AR62.25-P-1100-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.25-p-1100ff, Partially remove/install lower firewall Model 454.0

AR62.25-P-1200FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2658 · Applies to: 453 · AR: AR62.25-P-1200FF, AR62.25-P-1100FF, AR63.20-P-1112FF, AR62.20-P-1232FG

Partially remove/install upper firewall 19.03.2019 Model 454.0 P62.25-2569-09 1 Top firewall upper section 2 Top firewall lower section 3 Inner reinforcement Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Notes on replacing body parts AH60.00-P-0027-01FF 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarps, To prevent damage as a result of flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4 Partially remove bottom firewall AR62.25-P-1100FF 5 Remove A-pillar connecting panel AR63.20-P-1112FF 6 Remove suspension strut tower AR62.20-P-1232FG 7 Remove top firewall upper section (1) with top AR62.25-P-1200-01FF firewall lower section (2) and remove inner reinforcement (3) 8 Prepare top firewall upper section (1) with top AR62.25-P-1200-02FF firewall lower section (2) and prepare inner reinforcement (3) for installation Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint 9 Prepare suspension strut tower for installation AR62.20-P-1232-03FG 10 Prepare A-pillar connecting panel for AR63.20-P-1112-02FF installation Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.25-p-1200ff, Partially remove/install upper firewall Model 454.0

Prepare outer firewall lower section for

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2659 · Applies to: 453 · AR: AR62.20-P-1232FG, AR63.20-P-1112FF, AR62.25-P-1100FF, AR97.10-P-4000FF, AR97.20-P-1500FF

11 Prepare outer firewall lower section for AR62.25-P-1100-02FF installation Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint 12 Prepare mating surfaces on the vehicle for the AR62.25-P-1200-04FF top firewall upper section (1) with top firewall lower section (2) and inner reinforcement (3) 13 Prepare mating surfaces on the vehicle for the AR62.20-P-1232-02FH suspension strut tower 14 Prepare mating surfaces on the vehicle for the AR62.25-P-1100-04FF bottom firewall Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 15 Install top firewall upper section (1) with top AR62.25-P-1200-03FF firewall lower section (2) and inner reinforcement (3) Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 16 Install suspension strut tower AR62.20-P-1232FG 17 Install A-pillar connecting panel AR63.20-P-1112FF 18 Partially install bottom firewall AR62.25-P-1100FF 19 Take vehicle of the straightening bench and remove straightening bench 20 Clean weld joints and metal flanges with a wire brush and clean repair areas 21 Prime repair area using primer filler 22 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 23 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 24 Paint repair area adjacent surfaces 25 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 26 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding, replaced by A 000 986 A 000 986 34 42 28 00 1K zinc dust paint BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.25-p-1200ff, Partially remove/install upper firewall Model 454.0

AR62.25-P-5753FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2660 · Applies to: 453 · AR: AR62.25-P-5753FF

Remove/install firewall 27.2.12 MODEL 454.0 1 Firewall center section P62.25-2564-06 Remove

Risk of injury Danger! caused by scraping or cutting Always wear protective gloves when working AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of injury Danger! caused by cutting wire tearing Wear protective gloves and safety glasses. AS65.00-Z-0001-01A

or heating up while using it to cut out components that are glued into place. Notes on removal/installation of firewall AH62.25-P-1000-01MCC

The following workshop equipment and tools are required for repair: "Veritrac" window removal tool gotis://K_67.0_01.0 Cup suction tool gotis://K_67.0_03.0 Wet/dry vacuum cleaner gotis://P_00.12_06.0 Cartridge preheater gotis://K_67.0_02.0 Cartridge gun gotis://K_67.0_02.0 1 Remove detachable parts in the repair area 2 Remove firewall center section (1) AR62.25-P-5753-01FF Aid of helper required. Adhesive parts kit (with isopropanol cleaner) *BR00.45-Z-1141-02A Install

3 Prepare firewall center section (1) for gluing When installing removed firewall center AR62.25-P-5753-06FF in. section (1) Adhesive parts kit (with isopropanol cleaner) BR00.45-Z-1141-02A When installing new firewall center section (1) AR62.25-P-5753-06FG Adhesive parts kit (with isopropanol cleaner) BR00.45-Z-1141-02A 4 Prepare body flange on firewall center section AR62.25-P-5753-08FF (1) for gluing in. Adhesive parts kit (with isopropanol cleaner) *BR00.45-Z-1141-02A 5 Apply adhesive material AR62.25-P-5753-07FF Install firewall center section (1) on body flange within 2 minutes after applying adhesive material, to prevent adhesion problems of the adhesive material. The curing time is approx. 2 h measured from the time the firewall center section (1) is installed. The rated accident strength is achieved only after approx. 8 h. Uniformly apply adhesive bead at a height of approx. 12 mm. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.25-p-5753ff, Remove/install firewall MODEL 454.0

AR62.25-P-5752FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2662 · Applies to: 453 · AR: AR62.25-P-5752FF, AR60.10-P-0100FF, AR62.25-P-1100FF, AR62.30-P-1352FF

Remove/install firewall bottom section 19.03.2019 Model 454.0 1 Center firewall lower section P62.25-2369-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarps To prevent damage as a result of flying sparks. 3 Position body on the straightening bench, AR60.10-P-0100FF check, and straighten if necessary 4 Partially remove bottom left and right firewall AR62.25-P-1100FF 5 Remove cross member AR62.30-P-1352FF 6 Remove center firewall lower section (1) AR62.25-P-1100-01FG 7 Prepare center firewall lower section (1) for AR62.25-P-1100-02FG installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint 8 Prepare connecting points on the body for the AR62.10-P-1000-03FF installation of the center firewall lower section (1) Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint 9 Set up Car-O-Flex holding system for the Determine positioning of the Car-O-Flex

installation of the center firewall lower section holding system with the Car-O-Tronic (1) measuring system. Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 10 Install center firewall lower section (1) AR62.25-P-1100-03FG Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.25-p-5752ff, Remove/install firewall bottom section Model 454.0

AR62.30-P-1575FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2664 · Applies to: 453 · AR: AR62.30-P-1575FF

Remove/install front module 17.1.06 MODEL 454.0 with ENGINE 122.9, 134.9, 135.9, 639.9 1 Front module E1 Left front headlamp unit E2 Right front headlamp unit P62.30-2494-04 P62.30-2895-07 Shown on vehicle with engine 135.9 1 Front module 4 Expansion clip 7 Engine hood cable 2 Expansion clip 5 Air intake connection 8 Engine hood catch 3 Refrigerant line (with code (I01) Air 6 Bracket conditioning Plus (with outside temperature indicator) (FFO)) P62.30-2894-09 Shown on vehicle with engine 135.9 1 Front module 12 Bracket 17 Retaining clamp 7 Engine hood cable 13 Expansion clip 18 Guide 9 Bolt 14 Horn wiring harness 10 Radiator unit 15 Bolt E1 Left front headlamp unit 11 Electrical connector 16 Electrical connectors E2 Right front headlamp unit H2 Horn Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.30-p-1575ff, Remove/install front module MODEL 454.0 with ENGINE 122.9, 134.9, 135.9, 639.9

P62.30-2893-09

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2665 · Applies to: 453 · AR: AR62.30-P-1300FF

Shown on vehicle with engine 639.9 1 Front module 23 Bolt (with engine 122.9 or 639.9) B14 outside temperature display

temperature sensor (with code 3 Refrigerant line (with code (I01) Air 24 Charge air cooler (with engine 122.9

(I01) Air conditioning plus (with conditioning Plus (with outside or 639.9) outside temperature indicator) temperature indicator) (FFO)) 25 Wiring harness (with code (I01) Air (FFO)) 19 Bracket (with code (I01) Air conditioning plus (with outside H3/1 Alarm signal horn with conditioning plus (with outside temperature indicator) (FFO)) additional battery (with code temperature indicator) (FFO)) 26 Bolts (with code (I60) Stationary (V40) Alarm system) 20 Bracket (with code (I01) Air heater, gasoline or code (I58) H3/1x1 Connector for alarm signal horn conditioning plus (with outside Stationary heater, diesel) with additional battery (with temperature indicator) (FFO) and 27 Exhaust muffler (with code (I60) code (V40) Alarm system) with code (V40) Alarm system) Stationary heater, gasoline or code 21 Electrical connector (with code (V40) (I58) Stationary heater, diesel) Alarm system) 22 Bolt (with engine 122.9, 639.9 or

with code (I60) Stationary heater, gasoline) Shown on vehicle with engine 639.9 1 Front module 28 STH wiring harness (with code (I60) Stationary heater, gasoline or code (I58) Stationary heater, diesel) 29 ATA wiring harness (with code (V40) Alarm system) P62.30-2892-05 Remove/install

1 Remove front crossmember AR62.30-P-1300FF 2 Loosen left frontal acceleration sensor and See: right frontal acceleration sensor, lay down to side with lines connected and fasten with adhesive tape. Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.30-p-1575ff, Remove/install front module MODEL 454.0 with ENGINE 122.9, 134.9, 135.9, 639.9

AR62.30-P-0005SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2667 · Applies to: 453 · AR: AR62.30-P-0005SRC

Remove/install lower front crossmember 18.02.2016 Model 453.4 Shown on body shell on model 453.3 1 Crossmember 2 Bolts P62.30-3115-06 Remove/install

1 Remove all detachable parts in repair area 2 Remove impact absorber from crossmember (1) 3 Unscrew screws/bolts (2) BA62.30-P-1001-02L Screw/bolt, crossmember to longitudinal member 4 Remove crossmember (1) 5 Install in the reverse order 6 Adjust gap dimensions on lamp units and Gap dimension BE60.00-P-1001-01CA bumper Bumper to maintenance flap BE60.00-P-1002-01CA Bumper to lower maintenance flap on side BE60.00-P-1003-01CA Bumper to headlamp BE60.00-P-1004-01CA Bumper to fender BE60.00-P-1005-01CA Headlamp to maintenance flap *BE60.00-P-1006-01CA Test and adjustment values for gap dimensions Number Designation Model 453.4 BE60.00-P-1001-01CA Gap dimension For picture, see AR60.00-P-0700-01 SR Test and adjustment values for gap dimensions Number Designation Model 453.4 3 ( 2) BE60.00-P-1002-01CA Bumper to maintenance flap Dimension "A" mm Test and adjustment values for gap dimensions Number Designation Model 453.4 3 ( 2) BE60.00-P-1003-01CA Bumper to lower maintenance flap on side Dimension "B" mm Test and adjustment values for gap dimensions Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.30-p-0005src, Remove/install lower front crossmember Model 453.4

AR62.30-P-0004SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2669 · Applies to: 453 · AR: AR62.30-P-0004SRC

Remove/install upper front crossmember 18.02.2016 Model 453.4 Shown on body shell 3 Crossmember 4 Bolts P62.30-3116-06 Remove/install

1 Remove all detachable parts in repair area 2 Remove screws (4) BA62.30-P-1002-02L Screw/bolt, reinforcement to carrier 3 Remove crossmember (3) 4 Install in the reverse order 5 Adjust gap dimensions on lamp units and Gap dimension BE60.00-P-1001-01CA bumper Bumper to maintenance flap BE60.00-P-1002-01CA Bumper to lower maintenance flap on side BE60.00-P-1003-01CA Bumper to headlamp BE60.00-P-1004-01CA Bumper to fender BE60.00-P-1005-01CA Headlamp to maintenance flap *BE60.00-P-1006-01CA Test and adjustment values for gap dimensions Number Designation Model 453.4 BE60.00-P-1001-01CA Gap dimension For picture, see AR60.00-P-0700-01 SR Test and adjustment values for gap dimensions Number Designation Model 453.4 3 ( 2) BE60.00-P-1002-01CA Bumper to maintenance flap Dimension "A" mm Test and adjustment values for gap dimensions Number Designation Model 453.4 3 ( 2) BE60.00-P-1003-01CA Bumper to lower maintenance flap on side Dimension "B" mm Test and adjustment values for gap dimensions Number Designation Model 453.4 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.30-p-0004src, Remove/install upper front crossmember Model 453.4

AR62.30-P-1300FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2671 · Applies to: 453 · AR: AR62.30-P-1300FF, AR88.00-P-1010FF

Replace complete front cross member 27.10.03 MODELS 454.0 1 Nuts 2 Crossmember P62.30-2490-10 Remove/install

1 Remove front CBS AR88.00-P-1010FF 2 Unscrew nuts (1) 3 Remove cross member (2) 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.30-p-1300ff, Replace complete front cross member MODELS 454.0

AR62.30-P-1570SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2672 · Applies to: 453 · AR: AR62.30-P-1570SR

Replace complete front end assembly together with reinforcement 25.04.2019 Model 453.0/3 1 Crossmember 2 Bolts 3 Reinforcement 4 Bolts P62.30-3114-05 Shown on model 453.3 1 Crossmember 2 Bolts P62.30-3115-06 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.30-p-1570sr, Replace complete front end assembly together with reinforcement Model 453.0/3

AR62.30-P-1352FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2675 · Applies to: 453 · AR: AR62.30-P-1352FF, AR62.20-P-1856FF, AR97.10-P-4000FF

Replace crossmember 19.03.2019 Model 454.0 1 Front crossmember P62.30-2729-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarps, To prevent damage as a result of flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4 Remove left and right wheel well with front AR62.20-P-1856FF longitudinal member 5 Remove front crossmember (1) AR62.30-P-1300-09FF A new front crossmember (1) can be

installed only if the front longitudinal member is removed. Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint 6 Prepare front crossmember (1) for installation AR62.30-P-1300-10FF Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 7 Install front crossmember (1) AR62.30-P-1300-11FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 8 Clean weld joints and metal flanges with a wire brush and clean repair areas 9 Prime repair area using primer filler 10 Supply standard seam seals with body sealant AR97.10-P-4000FF Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.30-p-1352ff, Replace crossmember Model 454.0

AR62.30-P-1500FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2677 · Applies to: 453 · AR: AR62.30-P-1500FF, AR62.20-P-1300FG, AR62.30-P-1300FF, AR91.60-P-0750FF

Replace radiator support 21.10.03 MODEL 454.0 1 Radiator support 2 Engine hood lock 3 Spreading clip 4 Air intake connection 5 Bracket 6 Engine hood cable P62.30-2495-04 1 Radiator support 7 Headlamp mount 8 Wiring harness for horn 9 Bolt 10 Electrical connections 11 Radiator unit 12 Retaining clamp E1 Left front headlamp unit E2 Right front headlamp unit H2 Horn P62.30-2492-04 1 Radiator support 11 Radiator unit 13 Bolt 14 Bolt H2 Horn P62.30-2491-11 Remove/install

1 Remove headlamp support (7) together with AR62.20-P-1300FG installed left front lamp unit (E1) and right front lamp unit (E2) 2 Remove front cross member AR62.30-P-1300FF 3 Remove front acceleration sensors, lay down AR91.60-P-0750FF to side with electric leads connected and fasten with adhesive tape 4 Separate electrical connections (10) 5 Unclip retaining clamp (12) 6 Unthread horn wiring harness (8) from radiator support (1) and lay down to side 7 Unscrew bolt (14) from horn (H2) 8 Remove horn (H2) together with bracket 9 Remove spreading clip (3) from air intake connection (4) on radiator support (1) 10 Remove air intake connection (4) Installation:

Ensure that air intake connection (4) is seated properly on air cleaner Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.30-p-1500ff, Replace radiator support MODEL 454.0

Unhook engine control cable (6) from bracket

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2678 · Applies to: 453 · AR: AR88.40-P-3200FF

11 Unhook engine control cable (6) from bracket (5) 12 Remove engine hood lock (2) AR88.40-P-3200FF 13 Unclip temperature sensor from radiator Temperature sensor is located in front support (1) area on bottom left 14 Unscrew bolt (9) from left and right upper bracket of radiator (11) 15 Slide back radiator (11), remove left and right upper bracket from radiator (11) 16 Unscrew bolts (13) from radiator support (1) 17 Move radiator support (1) toward front until radiator (11) can be lifted out upward 18 Lift radiator (11) upward out of brackets and Helper required secure Relieve load on cooling water hoses and coolant lines with suitable support and secure radiator (11) against falling down. 19 Take off radiator support (1) Helper required 20 Install in the reverse order 21 Check horn (H2) for proper function Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.30-p-1500ff, Replace radiator support MODEL 454.0

AR63.10-P-0700FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2682 · Applies to: 453 · AR: AR63.10-P-0700FF, AR63.20-P-0098FF, AR63.10-P-0110FF, AR64.20-P-1000FF

Completely replace inner C-pillar side wall 14.05.2019 Model 454.0 P63.10-3815-09 1 Inner C-pillar side wall panel 2 Entire rear wheel well Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4.1 Remove C-pillar paneling If sidewall paneling in area of C-pillar must be removed due to damage history. AR63.20-P-0098FF 4.2 Remove side wall paneling If entire sidewall paneling must be removed due to damage history. AR63.10-P-0110FF 5 Remove lower rear center section AR64.20-P-1000FF 6 Remove inner C-pillar side wall (1) with entire AR63.10-P-0700-01FF rear wheel well (2) 7 Prepare mating surfaces at vehicle for inner C- AR63.10-P-0700-05FF pillar side wall (1) and entire rear wheel well (2) Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 8 Prepare entire rear wheel well (2) for AR63.10-P-0661-02FF installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 9 Prepare inner C-pillar side wall (1) AR63.10-P-0700-02FF Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-0700ff, Completely replace inner C-pillar side wall Model 454.0

AR63.10-P-0662FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2684 · Applies to: 453 · AR: AR63.10-P-0662FF, AR64.20-P-5731FF, AR64.20-P-1000FF, AR64.20-P-1240FF

Partially replace rear wheel well 21.03.2019 Model 454.0 1 Rear wheel well section P63.10-3746-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove end plate AR64.20-P-5731FF 4 Fully remove lower rear-end center section AR64.20-P-1000FF 5 Remove end section at rear longitudinal AR64.20-P-1240FF member 6 Remove rear wheel well section (1) and AR63.10-P-0662-01FF prepare mating surfaces on body for installation Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint 7 Prepare rear wheel well section (1) for AR63.10-P-0662-02FF installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 8 Install rear wheel well section (1) AR63.10-P-0662-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-0662ff, Partially replace rear wheel well Model 454.0

AR63.10-P-0745FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2686 · Applies to: 453 · AR: AR63.10-P-0745FF

Remove/install lower side wall paneling 21.03.2019 Model 454.0 1 Side wall paneling bottom member P63.10-3812-06 1 Side wall paneling bottom member P63.10-3813-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove sidewall paneling lower section (1) AR63.10-P-0745-01FF 4 Prepare connecting points for sidewall AR63.10-P-0745-04FF paneling lower section (1) on body 5 Prepare side wall paneling bottom member (1) AR63.10-P-0745-02FF for installation Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-0745ff, Remove/install lower side wall paneling Model 454.0

AR63.10-P-0665SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2688 · Applies to: 453 · AR: AR63.10-P-0665SR, AR65.20-P-1200SR, AR63.10-P-0110SRC

Remove/install outer rear wheel well 14.05.2019 Model 453.3/4 1 Outer rear wheel well P63.10-5260-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3.1 Remove side roof frame Model 453.3 AR65.20-P-1200SR 3.2 Remove side wall paneling Model 453.4 AR63.10-P-0110SRC 4 Separate outer rear wheel well (1) AR63.10-P-0660-01SR Commercially available devices/tools

Round wire brush Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 5 Prepare outer rear wheel well (1) for AR63.10-P-0670-05SR installation Commercially available devices/tools

Round wire brush Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-0665sr, Remove/install outer rear wheel well Model 453.3/4

Topical note

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2689 · Applies to: 453 · AR: AR65.20-P-1200SR, AR63.10-P-0110SRC, AR97.10-P-4000SR, AR97.20-P-1500SR

Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6 Install rear outer wheel well (1) AR63.10-P-0670-06SR 000 588 01 84 00 Welder WS60.00-P-0021K

000 588 02 84 00 Welder WS60.00-P-0022K

Commercially available devices/tools

Round wire brush Blind rivet tool Blind rivet 6.5 12.5 (clamping BR00.45-Z-1012-13A range 2 mm to 5 mm, draw-off strength min. 19 kN) Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 7.1 Install side roof frame Model 453.3 AR65.20-P-1200SR 7.2 Install side wall paneling Model 453.4 AR63.10-P-0110SRC 8 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 9 Remove spark protection blankets 10 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 11 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://xentryportal.mercedes-benz.com 12 Seal seam following repairs AR97.10-P-4000SR Supplement standard seals with sealant.

Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 13 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://xentryportal.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off BR00.45-Z-1012-13A A 004 990 16 97 strength min. 19 kN) Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-0665sr, Remove/install outer rear wheel well Model 453.3/4

AR63.10-P-0110FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2690 · Applies to: 453 · AR: AR63.10-P-0110FF

Remove/install side wall paneling 21.03.2019 Model 454.0 1 Side wall paneling P63.10-3404-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove side wall paneling (1) AR63.10-P-0110-05FF 4 Prepare connecting points of sidewall paneling AR63.10-P-0110-03FF (1) on body Window adhesive, 310 ml TEROSTAT MS 930BR00.45-Z-1007-02A Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint 5 Prepare side wall paneling (1) for installation AR63.10-P-0110-01FF Notes on replacing body parts AH60.00-P-0027-01FF This area must be treated separately when

replacing body panels under sidewall paneling (1). Zinc dust paint suitable for spot welding, *BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6.1 Install side wall paneling (1) Only when replacing sidewall paneling (1) without additional reinforcements or body panels located underneath. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-0110ff, Remove/install side wall paneling Model 454.0

AR63.10-P-0110SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2692 · Applies to: 453 · AR: AR63.10-P-0110SR

Remove/install side wall paneling 14.05.2019 Model 453.0/3 Shown on model 453.3 1 Side wall paneling P63.10-5234-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on repair of vehicles with AH60.00-P-0024-01N ultra-strength steels. General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove side wall paneling (1) AR63.10-P-0110-05SR Commercially available devices/tools

Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 4 Prepare side wall paneling (1) AR63.10-P-0110-01SR Commercially available devices/tools

Round wire brush Body power jigsaw Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-0110sr, Remove/install side wall paneling Model 453.0/3

AR63.10-P-0110SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2694 · Applies to: 453 · AR: AR63.10-P-0110SRC

Remove/install side wall paneling 14.05.2019 Model 453.4 1 Side wall paneling P63.10-5434-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on repair of vehicles with AH60.00-P-0024-01N ultra-strength steels. General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove side wall paneling (1) AR63.10-P-0110-05SRC Commercially available devices/tools

Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 4 Prepare side wall paneling (1) AR63.10-P-0110-01SRC Commercially available devices/tools

Round wire brush Body power jigsaw Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar63.10-p-0110src, Remove/install side wall paneling Model 453.4

AR63.10-P-9151FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2696 · Applies to: 453 · AR: AR63.10-P-9151FF, AR97.10-P-4000FF

Replace tank filler fitting reinforcement 21.03.2019 Model 454.0 1 Tank filler neck reinforcement P63.10-3619-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove tank filler neck reinforcement (1) and AR63.10-P-9151-01FF prepare connecting points on body Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint 4 Prepare tank filler neck reinforcement (1) for AR63.10-P-9151-02FF installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 5 Install and weld in tank filler neck AR63.10-P-9151-03FF reinforcement (1) Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 7 Prime repair area using primer filler 8 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 Window adhesive, 310 ml TEROSTAT MS 930BR00.45-Z-1007-02A 9 Supplement standard underbody protection Underfloor protection 800 ml *BR00.45-Z-1001-05A with permanent underfloor protection 10 Paint repair area adjacent surfaces Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-9151ff, Replace tank filler fitting reinforcement Model 454.0

AR63.20-P-1352FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2698 · Applies to: 453 · AR: AR63.20-P-1352FF, AR60.10-P-0100FF, AR60.10-P-0100FG, AR60.10-P-0100FH, AR60.10-P-0100FJ (+3 more)

Partially replace B-pillar reinforcement 08.04.2019 Model 454.0 1 B-pillar reinforcement 1.1 Top B-pillar reinforcement 1.2 Center B-pillar reinforcement 1.3 Bottom B-pillar reinforcement P63.20-5082-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Notes on replacing body parts AH60.00-P-0027-01FF 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Position body on the straightening bench, Only when installing a new center B-pillar check, and straighten if necessary reinforcement (1.2). CAR-BENCH straightening systems AR60.10-P-0100FF Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 4.1 Remove side wall paneling When removing the entire sidewall paneling. AR63.10-P-0110FF 4.2 Remove complete side roof paneling When removing the sidewall paneling in the area of the outer roof frame. AR65.10-P-1020FF Adapt cuts to the size of the damage.

4.3 Remove outer section of B-pillar When removing the sidewall paneling in the area of the B-pillar. AR63.20-P-1121FF Adapt cuts to the size of the damage.

Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1352ff, Partially replace B-pillar reinforcement Model 454.0

Remove sidewall paneling lower section

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2699 · Applies to: 453 · AR: AR63.10-P-0745FF, AR97.10-P-4000FF, AR63.20-P-1121FF, AR65.10-P-1020FF, AR63.10-P-0110FF

4.4 Remove sidewall paneling lower section When removing the sidewall paneling in the area of the longitudinal member. AR63.10-P-0745FF Adapt cuts to the size of the damage.

5.1 Remove B-pillar reinforcement (1) in the top When removing the top B-pillar reinforcement area (1.1). AR63.20-P-1352-01FF 5.2 Remove B-pillar (1) reinforcement in the When removing the center B-pillar center area reinforcement (1.2). AR63.20-P-1352-01FG 5.3 Remove B-pillar reinforcement (1) in the When removing the bottom B-pillar bottom area reinforcement (1.3). AR63.20-P-1352-01FH 6.1 Prepare connecting points of the B-pillar When preparing the connecting points of the reinforcement (1) in the top area on the body top B-pillar reinforcement (1.1). AR63.20-P-1352-02FF 6.2 Prepare connecting points of the B-pillar When preparing the connecting points of the reinforcement (1) in the center area on the center B-pillar reinforcement (1.2). body AR63.20-P-1352-02FG 6.3 Prepare connecting points of the B-pillar When preparing the connecting points of the reinforcement (1) in the bottom area on the bottom B-pillar reinforcement (1.3). body AR63.20-P-1352-02FH 7.1 Prepare B-pillar reinforcement (1) in the top When preparing the top B-pillar reinforcement area for installation (1.1). AR63.20-P-1352-03FF 7.2 Prepare B-pillar reinforcement (1) in the center When preparing the center B-pillar area for installation reinforcement (1.2). AR63.20-P-1352-03FG 7.3 Prepare B-pillar reinforcement (1) in the When preparing the bottom B-pillar bottom area for installation reinforcement (1.3). AR63.20-P-1352-03FH 8 Set up Car-O-Flex holding system for When installing a new center B-pillar installation of the B-pillar reinforcement (1) in reinforcement (1.2) with CAR-O-Liner the center area straightening system. Determine positioning of the Car-O-Flex

holding system with the Car-O-Tronic measuring system. CAR-O-Liner "Car-O-Flex", universal holding system for inserting new body panels. CAR-O-Liner adapter for "Car-O-Flex" CAR-O-Liner Car-O-Tronic "Classic" measuring system CAR-O-Liner Car-O-Tronic "Vision" measuring system Install

9.1 Install B-pillar reinforcement (1) in the top area When installing the top B-pillar reinforcement (1.1). AR63.20-P-1352-04FF 9.2 Install B-pillar reinforcement (1) in the center When installing the center B-pillar area reinforcement (1.2). AR63.20-P-1352-04FG 9.3 Install B-pillar reinforcement (1) in the bottom When installing the bottom B-pillar area reinforcement (1.3). AR63.20-P-1352-04FH 10 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 11 Prime repair area using primer filler 12 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL *BR00.45-Z-1003-01A 6069.20 13.1 Install sidewall paneling lower section When installing the sidewall paneling in the area of the longitudinal member. AR63.10-P-0745FF 13.2 Install outer section of B-pillar When installing the sidewall paneling in the area of the B-pillar. AR63.20-P-1121FF 13.3 Completely install side roof paneling When installing the sidewall paneling in the area of the outer roof frame. AR65.10-P-1020FF 13.4 Install side wall paneling When installing the entire sidewall paneling. AR63.10-P-0110FF Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1352ff, Partially replace B-pillar reinforcement Model 454.0

Remove Car-O-Flex holding system

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2700 · Applies to: 453 · AR: AR60.10-P-0100FF, AR60.10-P-0100FG, AR60.10-P-0100FH, AR60.10-P-0100FJ

14 Remove Car-O-Flex holding system When installing a new center B-pillar reinforcement (1.2) with CAR-O-Liner straightening system. CAR-O-Liner "Car-O-Flex", universal

holding system for inserting new body panels. CAR-O-Liner adapter for "Car-O-Flex". CAR-O-Liner Car-O-Tronic "Classic" measuring system. CAR-O-Liner Car-O-Tronic "Vision" measuring system. 15 Take body off the straightening bench and When installing new center B-pillar remove straightening bench reinforcement (1.2). CAR-BENCH straightening systems AR60.10-P-0100FF Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 16 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1352ff, Partially replace B-pillar reinforcement Model 454.0

AR63.20-P-0862FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2701 · Applies to: 453 · AR: AR63.20-P-0862FF, AR60.10-P-0100FF, AR60.10-P-0100FG, AR60.10-P-0100FH, AR60.10-P-0100FJ (+3 more)

Partially replace side wall reinforcement 08.04.2019 Model 454.0 Lower side wall reinforcement 1 Lower side wall reinforcement P63.20-5103-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarps to prevent damage due to flying sparks. 3 Position body on the straightening bench, CAR-BENCH straightening systems AR60.10-P-0100FF check, and straighten if necessary Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 4.1 Remove side wall paneling When removing the entire sidewall paneling. AR63.10-P-0110FF 4.2 Remove C-pillar paneling When removing the sidewall paneling in the area of the C-pillar. AR63.20-P-0098FF 4.3 Remove sidewall paneling lower section When removing the sidewall paneling in the bottom area. AR63.10-P-0745FF 5 Partially cut off bottom side wall reinforcement AR63.20-P-0861-01FF (1) 6 Prepare connecting points of the bottom side Partially prepare connection points on side AR63.20-P-0861-02FF wall reinforcement (1) on the body wall reinforcement on body 7 Prepare bottom side wall reinforcement (1) for AR63.20-P-0861-03FF installation Notes on replacing body parts AH60.00-P-0027-01FF 8 Set up Car-O-Flex holding system for Only for CAR-O-Liner straightening system. installation of the bottom side wall reinforcement (1) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-0862ff, Partially replace side wall reinforcement Model 454.0 Lower side wall reinforcement

AR63.20-P-1102FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2703 · Applies to: 453 · AR: AR63.20-P-1102FF

Remove/install A-pillar outer section 08.04.2019 Model 454.0 1 A-pillar outer section P63.20-6178-06 1 A-pillar outer section P63.20-6174-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove A-pillar outer section (1) AR63.20-P-1102-01FF 4 Prepare connecting points of the A-pillar outer AR63.20-P-1102-06FF section (1) on the body 5 Prepare A-pillar outer section (1) for AR63.20-P-1102-02FF installation Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1102ff, Remove/install A-pillar outer section Model 454.0

AR63.20-P-1102SRB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2705 · Applies to: 453 · AR: AR63.20-P-1102SRB, AR63.10-P-0110SR

Remove/install A-pillar outer section 14.05.2019 Model 453.3 1 A-pillar outer section 3 Longitudinal member outer shell on entry 4 A-pillar reinforcement outer section 5 A-pillar inner section P63.20-8602-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on repair of vehicles with AH60.00-P-0024-01N ultra-strength steels. General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove side wall paneling AR63.10-P-0110SR 4 Separate A-pillar outer section (complete) AR63.20-P-1102-01SR The A-pillar outer section (complete) consists of the A-pillar outer section (1), longitudinal member outer shell on entry (3), A-pillar outer section reinforcement (4) and A- pillar inner section (5). Commercially available tools

-Round wire brush - Body jig saw - Weld-spot milling machine - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 5 Prepare A-pillar outer section (complete) for AR63.20-P-1102-02SR installation Commercially available tools

-Round wire brush - Body jig saw Blind rivet tool - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1102srb, Remove/install A-pillar outer section Model 453.3

The high voltage used for electric welding

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2706 · Applies to: 453 · AR: AR63.10-P-0110SR, AR97.10-P-4000SR, AR97.20-P-1500SR

Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6 Install A-pillar outer section (entire) AR63.20-P-1102-03SR Commercially available tools

-Round wire brush - Spot welder Blind rivet tool MIG-MAG inert gas welder Blind rivet 6.5 12.5 (clamping *BR00.45-Z-1012-13A range 2 mm to 5 mm, draw-off strength min. 19 kN) 7 Install side wall paneling AR63.10-P-0110SR 8 Clean weld joints and sheet metal flange with Commercially available tools

round wire brush -Round wire brush 9 Remove spark protection blankets 10 Clean repair area Commercially available tools

• Wet/dry vacuum cleaner Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 11 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://aftersales.mercedes-benz.com 12 Seal seam following repairs AR97.10-P-4000SR Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 13 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://aftersales.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off BR00.45-Z-1012-13A A 004 990 16 97 strength min. 19 kN) Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1102srb, Remove/install A-pillar outer section Model 453.3

AR63.20-P-1102SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2707 · Applies to: 453 · AR: AR63.20-P-1102SRC, AR62.20-P-1286SR

Remove/install A-pillar outer section 14.05.2019 Model 453.4 P63.20-8858-09 1 A-pillar paneling 3 A-pillar upper outer section 4 Upper front longitudinal member 2 A-pillar outer section Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on repair of vehicles with AH60.00-P-0024-01N ultra-strength steels. General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Set up straightening bench with straightening bench crossmembers and straightening tool set 000 588 01 23 00 Body straightening system WS60.00-P-0023K

4 Place vehicle on straightening bench and fasten 5 Remove upper front longitudinal member (4) AR62.20-P-1286SR 6 Remove A-pillar paneling (1), A-pillar outer AR63.20-P-1102-01SRC section (2) and A-pillar upper outer section (3) 000 588 00 84 00 Heat gun WS54.00-P-0049B

Commercially available devices/tools

Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 7 Prepare A-pillar paneling (1), A-pillar outer AR63.20-P-1102-02SRC section (2) and A-pillar upper outer section (3) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1102src, Remove/install A-pillar outer section Model 453.4

Commercially available devices/tools

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2708 · Applies to: 453 · AR: AR62.20-P-1286SR, AR97.10-P-4000SR, AR97.20-P-1500SR

Round wire brush Body power jigsaw Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work General information on riveting AH60.00-P-0003-01N 8 Install A-pillar paneling (1), A-pillar outer AR63.20-P-1102-03SRC section (2) and A-pillar upper outer section (3) 000 588 01 84 00 Welder WS60.00-P-0021K

000 588 02 84 00 Welder WS60.00-P-0022K

Some riveted joints in the A-pillar paneling

(1) are produced during installation of the upper front longitudinal member (4). Commercially available devices/tools

Round wire brush Body power jigsaw Wet/dry vacuum cleaner Blind rivet tool Blind rivet with countersunk head 6.4 14.0 BR00.45-Z-1043-13A (clamping range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) Parts kit for 2-component adhesive for body BR00.45-Z-1162-02A 9 Install upper front longitudinal member (4) AR62.20-P-1286SR 10 Release vehicle from straightening bench, lift vehicle and remove straightening bench 11 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 12 Remove spark protection blankets 13 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner 14 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://xentryportal.mercedes-benz.com 15 Seal seam following repairs AR97.10-P-4000SR Supplement standard seals with sealant.

16 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://xentryportal.mercedes-benz.com 17 Add cavity preserving agent AR97.20-P-1500SR 18 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet with countersunk head 6.4 14.0 (clamping BR00.45-Z-1043-13A A 000 991 82 32 range 1.5 mm to 3 mm, draw-off strength min. 15.5 kN) BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1102src, Remove/install A-pillar outer section Model 453.4

AR63.20-P-1355FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2709 · Applies to: 453 · AR: AR63.20-P-1355FF, AR60.10-P-0100FF, AR60.10-P-0100FG, AR60.10-P-0100FH, AR60.10-P-0100FJ (+4 more)

Remove/install B-pillar inner section 14.05.2019 Model 454.0 1 B-pillar inner section P63.20-5225-11 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Position body on the straightening bench, CAR-BENCH straightening systems AR60.10-P-0100FF check, and straighten if necessary Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 4.1 Remove B-pillar reinforcement When removing entire B-pillar reinforcement. AR63.20-P-1351FF 4.2 Remove lower and center B-pillar When removing B-pillar reinforcement in lower reinforcement and center area. AR63.20-P-1352FF 5.1 Remove longitudinal member outer shell on When removing entire longitudinal member entrance outer shell. AR63.30-P-1102FF 5.2 Remove center longitudinal member outer When removing longitudinal member outer shell at entrance shell in center area. AR63.30-P-1110FF 6 Remove B-pillar inner section (1) and prepare AR63.20-P-1350-01FF mating surfaces at body for installation Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 7 Prepare B-pillar inner section (1) for AR63.20-P-1350-02FF installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 8 Mount Car-O-Flex holding fixture for Only in case of CAR-O-Liner straightening installation of B-pillar inner section (1) system. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1355ff, Remove/install B-pillar inner section Model 454.0

AR63.20-P-1121FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2711 · Applies to: 453 · AR: AR63.20-P-1121FF

Remove/install B-pillar outer section 08.04.2019 Model 454.0 1 B-pillar outer section P63.20-6192-06 1 B-pillar outer section P63.20-6191-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area B-pillar outer section (1) can be cut in the

areas A to F. Replacement of B-pillar outer section (1) is shown by way of example at cuts A to D. Cuts must be adapted to repair process. 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove B-pillar outer section (1) AR63.20-P-1121-01FF Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1121ff, Remove/install B-pillar outer section Model 454.0

AR63.20-P-2011FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2713 · Applies to: 453 · AR: AR63.20-P-2011FF, AR63.10-P-0110FF, AR63.20-P-0098FF, AR97.10-P-4000FF

Remove/install taillamp reinforcement 14.05.2019 Model 454.0 1 Rear lamp reinforcement P63.20-5053-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3.1 Remove side wall paneling Only when removing the entire sidewall paneling. AR63.10-P-0110FF 3.2 Remove C-pillar paneling Only when removing the sidewall paneling in the area of the C-pillar. AR63.20-P-0098FF 4 Cut off rear lamp reinforcement (1) and AR63.20-P-2011-01FF prepare mating surfaces on the body for installation Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 5 Prepare rear lamp reinforcement (1) AR63.20-P-2011-02FF Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6 Install rear lamp reinforcement (1) AR63.20-P-2011-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 11 Paint repair area adjacent surfaces Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-2011ff, Remove/install taillamp reinforcement Model 454.0

AR63.20-P-0098FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2715 · Applies to: 453 · AR: AR63.20-P-0098FF

Removing, installing paneling of C-pillar 08.04.2019 Model 454.0 1 C-pillar paneling P63.20-6133-06 1 C-pillar paneling P63.20-6134-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove C-pillar paneling (1) AR63.20-P-0098-02FF Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-0098ff, Removing, installing paneling of C-pillar Model 454.0

AR63.20-P-1112FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2717 · Applies to: 453 · AR: AR63.20-P-1112FF, AR63.20-P-1100FF, AR97.10-P-4000FF

Replace A-pillar connecting panel 14.05.2019 Model 454.0 1 Connecting panel of A-pillar P63.20-5488-11 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Topical note General information on body repair AH60.00-N-0001-01A Remove

1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarps to prevent damage due to flying sparks. 3 Completely remove A-pillar with inner section AR63.20-P-1100FF 4 Remove A-pillar connecting panel (1) AR63.20-P-1112-01FF 5 Prepare A-pillar connecting panel (1) for AR63.20-P-1112-02FF installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 6 Prepare connecting points to the body in the Prepare connection points on body in area of AR63.20-P-1112-03FF area of the A-pillar connecting panel (1) A-pillar connecting panel Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 7 Install A-pillar connecting panel (1) AR63.20-P-1112-04FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 8 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 9 Prime repair area using primer filler 10 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 11 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 12 Paint repair area adjacent surfaces 13 Completely install A-pillar with inner section AR63.20-P-1100FF 14 Reinstall all removed assembly parts Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1112ff, Replace A-pillar connecting panel Model 454.0

AR63.20-P-1104SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2719 · Applies to: 453 · AR: AR63.20-P-1104SR, AR63.20-P-1102SRB

Replace A-pillar inner section 14.05.2019 Model 453.3 1 Inner longitudinal member reinforcement 2 Inner longitudinal member 3 Bottom A-pillar 4 Upper A-pillar P63.20-8559-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining in vehicle with spark protection blanket 3 Remove A-pillar outer section AR63.20-P-1102SRB 4 Separate inner A-pillar AR63.20-P-1104-01SR A-pillar inner section consisting of inner longitudinal member reinforcement (1), inner longitudinal member (2), bottom A-pillar (3) and top A-pillar (4). Commercially available tools

-Round wire brush - Body jig saw - Weld-spot milling machine - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 5 Prepare A-pillar inner section for installation AR63.20-P-1104-03SR Commercially available tools

-Round wire brush - Body jig saw - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1104sr, Replace A-pillar inner section Model 453.3

Topical note

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2720 · Applies to: 453 · AR: AR63.20-P-1102SRB, AR97.10-P-4000SR, AR97.20-P-1500SR

Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6 Install A-pillar inner section AR63.20-P-1104-04SR Commercially available tools

-Round wire brush - Manual temporary fastener, 6.35 mm - Spot welder MIG-MAG inert gas welder Blind rivet tool Adhesive kit, body, 2-component adhesive BR00.45-Z-1092-02A Blind rivet 6.5 12.5 (clamping BR00.45-Z-1012-13A range 2 mm to 5 mm, draw-off strength min. 19 kN) 7 Install A-pillar outer section AR63.20-P-1102SRB 8 Clean weld joints and sheet metal flange with Commercially available tools

round wire brush -Round wire brush 9 Remove spark protection blankets 10 Clean repair area Commercially available tools

• Wet/dry vacuum cleaner Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 11 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://aftersales.mercedes-benz.com 12 Seal seam following repairs AR97.10-P-4000SR Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 13 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://aftersales.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install detachable parts in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off BR00.45-Z-1012-13A A 004 990 16 97 strength min. 19 kN) BR00.45-Z-1092-02A Adhesive kit, body, 2-component adhesive A 012 989 17 71 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1104sr, Replace A-pillar inner section Model 453.3

AR63.20-P-1110FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2721 · Applies to: 453 · AR: AR63.20-P-1110FF, AR63.10-P-0110FF, AR63.20-P-1102FF

Replace A-pillar reinforcement 14.05.2019 Model 454.0 1 A-pillar reinforcement P63.20-4908-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Topical note General information on body repair AH60.00-N-0001-01A Remove

1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3.1 Remove side wall paneling When removing entire sidewall paneling. AR63.10-P-0110FF 3.2 Remove A-pillar outer section When removing sidewall paneling in area of A- pillar. AR63.20-P-1102FF 4 Remove A-pillar reinforcement (1) AR63.20-P-1110-01FF 5 Prepare connecting points of A-pillar AR63.20-P-1110-02FF reinforcement (1) at body Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 6 Prepare A-pillar reinforcement (1) for AR63.20-P-1110-03FF installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 7 Install and weld in A-pillar reinforcement (1) AR63.20-P-1110-04FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 8 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 9 Prime repair area using primer filler Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1110ff, Replace A-pillar reinforcement Model 454.0

AR63.20-P-1351FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2723 · Applies to: 453 · AR: AR63.20-P-1351FF, AR60.10-P-0100FF, AR60.10-P-0100FG, AR60.10-P-0100FH, AR60.10-P-0100FJ (+2 more)

Replace B-pillar reinforcement 08.04.2019 Model 454.0 1 B-pillar reinforcement P63.20-5044-11 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarps to prevent damage due to flying sparks. 3 Position body on the straightening bench, CAR-BENCH straightening systems AR60.10-P-0100FF check, and straighten if necessary Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 4.1 Remove side wall paneling When removing entire sidewall paneling. AR63.10-P-0110FF 4.2 Remove outer section of B-pillar When removing sidewall paneling in area of B- pillar. AR63.20-P-1121FF 5 Remove B-pillar reinforcement (1) AR63.20-P-1351-01FF 6 Prepare connecting points of B-pillar AR63.20-P-1351-02FF reinforcement (1) at body 7 Prepare B-pillar reinforcement (1) for AR63.20-P-1351-03FF installation Notes on replacing body parts AH60.00-P-0027-01FF 8 Mount Car-O-Flex holding fixture for Only in case of CAR-O-Liner straightening installation of B-pillar reinforcement (1) system. Determine positioning of the Car-O-Flex

holding system with the Car-O-Tronic measuring system. CAR-O-Liner "Car-O-Flex", universal holding fixture for insertion of new body panels. CAR-O-Liner adapter for "Car-O-Flex" CAR-O-Liner measuring system Car-O-Tronic "Classic" CAR-O-Liner measuring system Car-O-Tronic "Vision" Install

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1351ff, Replace B-pillar reinforcement Model 454.0

AR63.20-P-1351SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2725 · Applies to: 453 · AR: AR63.20-P-1351SRC, AR63.10-P-0110SRC

Replace B-pillar reinforcement 14.05.2019 Model 453.4 1 B-pillar reinforcement P63.20-8788-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on repair of vehicles with AH60.00-P-0024-01N ultra-strength steels. General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove side wall paneling AR63.10-P-0110SRC 4 Remove B-pillar reinforcement (1) AR63.20-P-1351-01SRC Commercially available devices/tools

Round wire brush Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 5 Prepare B-pillar reinforcement (1) AR63.20-P-1351-03SRC Commercially available devices/tools

Round wire brush Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6 Install B-pillar reinforcement (1) AR63.20-P-1351-04SRC Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar63.20-p-1351src, Replace B-pillar reinforcement Model 453.4

AR63.20-P-1100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2727 · Applies to: 453 · AR: AR63.20-P-1100FF, AR63.20-P-1110FF

Replace complete A-pillar 14.05.2019 Model 454.0 Complete A-pillar with inner section 1 Outer A-pillar 2 Inner A-pillar center section P63.20-5235-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4 Remove reinforcement at A-pillar AR63.20-P-1110FF 5 Remove outer A-pillar (1) and inner A-pillar AR63.20-P-1100-01FF center section (2) 6 Prepare connecting points of outer A-pillar (1) AR63.20-P-1100-02FF and inner A-pillar center section (2) at body Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 7 Prepare outer A-pillar (1) and inner A-pillar AR63.20-P-1100-09FF center section (2) for installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 8 Fully install outer A-pillar (1) and inner A-pillar AR63.20-P-1100-10FF center section (2) Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 9 Clean weld joints and sheet metal flanges with wire brush and clean repair areas Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1100ff, Replace complete A-pillar Model 454.0 Complete A-pillar with inner section

AR63.20-P-1100FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2729 · Applies to: 453 · AR: AR63.20-P-1100FG, AR63.20-P-1110FF, AR97.10-P-4000FF

Replace complete A-pillar 14.05.2019 Model 454.0 Outer A-pillar 1 Outer A-pillar P63.20-5055-12 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4 Remove reinforcement from the A-pillar AR63.20-P-1110FF 5 Remove outer A-pillar (1) AR63.20-P-1100-01FG 6 Prepare connecting points of the outer A-pillar AR63.20-P-1100-02FG (1) on the body Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 7 Prepare outer A-pillar (1) for installation AR63.20-P-1100-09FG Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 8 Install outer A-pillar (1) AR63.20-P-1100-10FG Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 9 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 10 Prime repair area using primer filler 11 Supply standard seam seals with body sealant AR97.10-P-4000FF Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1100fg, Replace complete A-pillar Model 454.0 Outer A-pillar

AR63.20-P-1106FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2731 · Applies to: 453 · AR: AR63.20-P-1106FF, AR65.20-P-1200FF, AR97.10-P-4000FF

Replace inner A-pillar 14.05.2019 Model 454.0 1 Inner A-pillar P63.20-5113-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarps to prevent damage due to flying sparks. 3 Remove side roof frame AR65.20-P-1200FF 4 Remove inner A-pillar (1) and prepare mating AR63.20-P-1106-01FF surfaces on the body for installation 5 Prepare inner A-pillar (1) AR63.20-P-1106-02FF Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6 Install inner A-pillar (1) AR63.20-P-1106-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL *BR00.45-Z-1003-01A 6069.20 10 Install side roof frame AR65.20-P-1200FF 11 Reinstall all removed assembly parts Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1106ff, Replace inner A-pillar Model 454.0

AR63.20-P-0860FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2733 · Applies to: 453 · AR: AR63.20-P-0860FF, AR60.10-P-0100FF, AR60.10-P-0100FG, AR60.10-P-0100FH, AR60.10-P-0100FJ (+2 more)

Replace side wall reinforcement 08.04.2019 Model 454.0 1 Side wall reinforcement P63.20-5036-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarps to prevent damage due to flying sparks. 3 Position body on the straightening bench, CAR-BENCH straightening systems AR60.10-P-0100FF check, and straighten if necessary Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 4.1 Remove side wall paneling When removing entire sidewall paneling. AR63.10-P-0110FF 4.2 Remove C-pillar paneling When removing sidewall paneling in area of C- pillar. AR63.20-P-0098FF 5 Remove side wall reinforcement (1) AR63.20-P-0860-01FF 6 Prepare connecting points of side wall AR63.20-P-0860-02FF reinforcement (1) on body 7 Prepare side wall reinforcement (1) for AR63.20-P-0860-03FF installation Notes on replacing body parts AH60.00-P-0027-01FF 8 Mount Car-O-Flex holding fixture for Only in case of CAR-O-Liner straightening installation of side wall reinforcement (1) system. Determine positioning of the Car-O-Flex

holding system with the Car-O-Tronic measuring system. Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 9 Install side wall reinforcement (1) AR63.20-P-0860-04FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-0860ff, Replace side wall reinforcement Model 454.0

AR63.20-P-2012FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2735 · Applies to: 453 · AR: AR63.20-P-2012FF, AR63.10-P-0110FF, AR63.20-P-0098FF, AR97.10-P-4000FF, AR97.20-P-1500FF

Replace weld-on part below rear lamp 08.04.2019 Model 454.0 1 Weld-on part under rear lamp P63.20-5054-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3.1 Remove side wall paneling Only when removing entire sidewall paneling. AR63.10-P-0110FF 3.2 Remove C-pillar paneling Only when removing sidewall paneling in area of C-pillar. AR63.20-P-0098FF 4 Remove weld-on part under rear lamp (1) and AR63.20-P-2012-01FF prepare mating surfaces at body for installation 5 Prepare weld-on part under rear lamp (1) for Prepare weld-on part below rear lamp for AR63.20-P-2012-03FF installation installation. Notes on replacing body parts AH60.00-P-0027-01FF Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6 Install weld-on part under rear lamp (1) AR63.20-P-2012-04FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 11 Paint repair area adjacent surfaces 12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-2012ff, Replace weld-on part below rear lamp Model 454.0

Teroson protective wax, art. no: 122.73Q

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2736 · Applies to: 453 · AR: AR63.20-P-0098FF, AR63.10-P-0110FF

*BR00.45-Z-1008-05A 13.1 Install C-pillar paneling Only when installing sidewall paneling in area of C-pillar. AR63.20-P-0098FF 13.2 Install side wall paneling Only when installing entire sidewall paneling. AR63.10-P-0110FF 14 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-2012ff, Replace weld-on part below rear lamp Model 454.0

AR63.20-P-0013FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2737 · Applies to: 453 · AR: AR63.20-P-0013FF, AR63.20-P-0860FF, AR63.20-P-0862FF, AR63.30-P-1102FF, AR63.30-P-1110FF

Replace wheel well end section 14.05.2019 Model 454.0 1 Wheel arch locking lug P63.20-5112-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3.1 Remove side wall reinforcement When removing entire side wall reinforcement. AR63.20-P-0860FF 3.2 Remove part of the sidewall reinforcement When removing side wall reinforcement in lower area. AR63.20-P-0862FF 4.1 Remove longitudinal member outer shell at When removing entire longitudinal member entrance outer shell. AR63.30-P-1102FF 4.2 Remove longitudinal member outer shell at When removing longitudinal member outer entrance section shell in rear area. AR63.30-P-1110FF 5 Remove wheel arch end section (1) and AR63.20-P-0013-01FF prepare mating surfaces at body for installation Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 6 Prepare wheel arch locking lug (1) for AR63.20-P-0013-02FF installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 7 Install wheel arch end section (1) AR63.20-P-0013-03FF Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-0013ff, Replace wheel well end section Model 454.0

AR63.30-P-1143FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2739 · Applies to: 453 · AR: AR63.30-P-1143FF, AR63.30-P-0815FF

Partially replace longitudinal member inner shell on entrance 14.05.2019 Model 454.0 1 Front longitudinal member inner shell section P63.30-2414-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Set up straightening bench with straightening CAR-O-Liner straightening systems set and position vehicle Observe setup plans.

4 Remove side front longitudinal member AR63.30-P-0815FF 5 Remove front longitudinal member inner shell AR63.30-P-1143-01FF section (1) at entrance and prepare mating surfaces at body for installation Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 6 Prepare front longitudinal member inner shell AR63.30-P-1143-02FF section (1) at entrance Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 7 Install front longitudinal member inner shell AR63.30-P-1143-03FF section (1) at entrance Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 8 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 9 Prime repair area using primer filler Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-1143ff, Partially replace longitudinal member inner shell on entrance Model 454.0

AR63.30-P-1143SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2741 · Applies to: 453 · AR: AR63.30-P-1143SRA, AR63.30-P-1102SRA

Partially replace longitudinal member inner shell on entrance 14.05.2019 Model 453.3/4 Shown on model 453.3 1 Rear wheel well 2 Reinforcement 3 Longitudinal member inner shell on entry P63.30-2942-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on repair of vehicles with AH60.00-P-0024-01N ultra-strength steels. General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove longitudinal member outer shell on AR63.30-P-1102SRA entrance 4 Remove longitudinal member inner shell on AR63.30-P-1143-01SRA entry (3) When replacing longitudinal member inner

shell on entry (3), also replace rear wheel well (1) and reinforcement (2). Commercially available devices/tools

Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 5 Prepare longitudinal member inner shell on AR63.30-P-1143-02SRA entry (3), rear wheel well (1) and reinforcement (2) Commercially available devices/tools

Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar63.30-p-1143sra, Partially replace longitudinal member inner shell on entrance Model 453.3/4

The high voltage used for electric welding

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2742 · Applies to: 453 · AR: AR63.30-P-1102SRA, AR97.10-P-4000SR, AR97.20-P-1500SR

Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6 Install longitudinal member inner shell on entry (3), rear wheel well (1) and reinforcement (2) 000 588 01 84 00 Welder WS60.00-P-0021K

000 588 02 84 00 Welder WS60.00-P-0022K

AR63.30-P-1143-03SRA Commercially available devices/tools

Round wire brush Blind rivet tool Blind rivet 6.5 12.5 (clamping *BR00.45-Z-1012-13A range 2 mm to 5 mm, draw-off strength min. 19 kN) 7 Install longitudinal member outer shell on AR63.30-P-1102SRA entrance 8 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 9 Remove spark protection blankets 10 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner 11 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://xentryportal.mercedes-benz.com 12 Seal seam following repairs AR97.10-P-4000SR Supplement standard seals with sealant.

13 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://xentryportal.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off BR00.45-Z-1012-13A A 004 990 16 97 strength min. 19 kN) Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar63.30-p-1143sra, Partially replace longitudinal member inner shell on entrance Model 453.3/4

AR63.30-P-1110FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2743 · Applies to: 453 · AR: AR63.30-P-1110FF, AR60.10-P-0100FF, AR60.10-P-0100FG, AR60.10-P-0100FH, AR60.10-P-0100FJ (+5 more)

Partially replace outer longitudinal member shell on entry 14.05.2019 Model 454.0 1 Outer longitudinal member shell 1.1 Front outer longitudinal member shell 1.2 Center longitudinal member outer shell 1.3 Rear outer longitudinal member shell P63.30-2251-11 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Position body on the straightening bench, CAR-BENCH straightening systems AR60.10-P-0100FF check, and straighten if necessary Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 4.1 Remove side wall paneling When removing entire sidewall paneling. AR63.10-P-0110FF 4.2 Remove sidewall paneling lower section When removing sidewall paneling in area of longitudinal member outer shell (1). AR63.10-P-0745FF 5.1 Remove B-pillar reinforcement When removing entire B-pillar reinforcement. AR63.20-P-1351FF 5.2 Remove lower B-pillar reinforcement When removing B-pillar reinforcement in lower area. AR63.20-P-1352FF 6.1 Remove entire A-pillar When removing outer A-pillar. AR63.20-P-1100FG 6.2 Remove entire A-pillar When removing entire A-pillar. AR63.20-P-1100FF 7.1 Remove longitudinal member outer shell (1) at When removing front longitudinal member front entrance outer shell (1.1). AR63.30-P-1110-01FF Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-1110ff, Partially replace outer longitudinal member shell on entry Model 454.0

AR63.30-P-1050SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2746 · Applies to: 453 · AR: AR63.30-P-1050SRC

Partially replace outer side longitudinal member 14.05.2019 Model 453.3/4 Shown on model 453.4 1 Outer side longitudinal member P63.30-3076-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on repair of vehicles with AH60.00-P-0024-01N ultra-strength steels. General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove outer side longitudinal member (1) AR63.30-P-1050-01SRC Commercially available devices/tools

Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 4 Prepare outer side longitudinal member (1) AR63.30-P-1050-02SRC Commercially available devices/tools

Round wire brush Body power jigsaw Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-1050src, Partially replace outer side longitudinal member Model 453.3/4

AR63.30-P-0846FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2748 · Applies to: 453 · AR: AR63.30-P-0846FF, AR63.40-P-1180FG, AR62.25-P-1100FF

Remove/install center side longitudinal member 08.04.2019 Model 454.0 1 Center side longitudinal member reinforcement 2 Center side longitudinal member P63.30-2424-12 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4 Remove entire side of main floor AR63.40-P-1180FG 5 Remove left or right lower firewall section AR62.25-P-1100FF 6 Remove center side longitudinal member (2) AR63.30-P-0846-01FF together with center side longitudinal member reinforcement (1) and prepare mating surfaces at body for installation of center side longitudinal member (2) 7 Prepare center side longitudinal member (2) AR63.30-P-0846-02FF together with center side longitudinal member reinforcement (1) for installation Notes on replacing body parts AH60.00-P-0027-01FF Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 8 Install center side longitudinal member (2) AR63.30-P-0846-03FF together with center side longitudinal member reinforcement (1) Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 9 Clean weld joints and sheet metal flanges with wire brush and clean repair areas Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-0846ff, Remove/install center side longitudinal member Model 454.0

AR63.30-P-0815FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2750 · Applies to: 453 · AR: AR63.30-P-0815FF, AR63.20-P-1100FF, AR63.30-P-1110FF, AR63.30-P-1102FF, AR97.10-P-4000FF

Remove/install front side longitudinal member 14.05.2019 Model 454.0 1 Front side longitudinal member P63.30-2273-11 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4 Completely remove A-pillar AR63.20-P-1100FF 5.1 Partially remove outer shell of the longitudinal During removal of the outer longitudinal member at the entrance member outer shell in the front area. AR63.30-P-1110FF 5.2 Remove longitudinal member outer shell from During removal of the entire longitudinal the entrance member outer shell. AR63.30-P-1102FF 6 Remove front side longitudinal member (1) AR63.30-P-0815-01FF and prepare mating surfaces on the body for installation Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 7 Prepare front side longitudinal member (1) for AR63.30-P-0815-02FF installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 8 Install front side longitudinal member (1) AR63.30-P-0815-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 9 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 10 Prime repair area using primer filler 11 Supply standard seam seals with body sealant AR97.10-P-4000FF Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-0815ff, Remove/install front side longitudinal member Model 454.0

AR63.30-P-1164FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2752 · Applies to: 453 · AR: AR63.30-P-1164FF, AR63.30-P-1102FF, AR63.30-P-0815FF, AR63.20-P-1355FF

Replace longitudinal member inner shell on entry 14.05.2019 Model 454.0 1 Longitudinal member inner shell P63.30-2274-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Set up straightening bench with straightening CAR-O-Liner straightening systems set and position vehicle Observe setup plans.

4 Remove longitudinal member outer shell on AR63.30-P-1102FF entrance 5 Remove side front longitudinal member AR63.30-P-0815FF 6 Remove B-pillar inner section AR63.20-P-1355FF 7 Remove longitudinal member inner shell (1) on AR63.30-P-1164-01FF entry Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 8 Prepare longitudinal member inner shell (1) on AR63.30-P-1164-02FF entry Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 9 Install longitudinal member inner shell (1) at AR63.30-P-1164-03FF entrance Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-1164ff, Replace longitudinal member inner shell on entry Model 454.0

AR63.30-P-1102FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2754 · Applies to: 453 · AR: AR63.30-P-1102FF, AR60.10-P-0100FF, AR60.10-P-0100FG, AR60.10-P-0100FH, AR60.10-P-0100FJ (+3 more)

Replace longitudinal member outer shell on entrance 14.05.2019 Model 454.0 1 Longitudinal member outer shell P63.30-2199-11 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Position body on the straightening bench, CAR-BENCH straightening systems AR60.10-P-0100FF check, and straighten if necessary Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 4 Remove side wall paneling AR63.10-P-0110FF 5 Remove B-pillar reinforcement AR63.20-P-1351FF 6 Completely remove A-pillar AR63.20-P-1100FF 7 Remove longitudinal member outer shell (1) AR63.30-P-1102-01FF from the entrance 8 Prepare longitudinal member outer shell (1) at AR63.30-P-1102-02FF the entrance and mating surfaces on the body for installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 9 Set up Car-O-Flex holding system for Only for CAR-O-Liner straightening system. installation of the longitudinal member outer shell (1) Determine positioning of the Car-O-Flex

holding system with the Car-O-Tronic measuring system. Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 10 Install longitudinal member outer shell (1) at AR63.30-P-1102-03FF entrance Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-1102ff, Replace longitudinal member outer shell on entrance Model 454.0

AR63.30-P-1102SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2756 · Applies to: 453 · AR: AR63.30-P-1102SRA, AR63.30-P-1050SRC

Replace longitudinal member outer shell on entrance 14.05.2019 Model 453.3/4 Shown on model 453.3 1 A-pillar outer section 2 Outer rear reinforcement 3 Longitudinal member outer shell on entry 4 A-pillar reinforcement outer section P63.30-2910-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Partially remove outer side longitudinal AR63.30-P-1050SRC member 4 Separate longitudinal member outer shell on AR63.30-P-1102-01SRA entry (complete) The longitudinal member outer shell on

entry (complete) consists of the A-pillar outer section (1), outer rear reinforcement (2), longitudinal member outer shell on entry (3) and A-pillar outer section reinforcement (4). Commercially available devices/tools

Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 5 Prepare A-pillar outer section (1), outer rear AR63.30-P-1102-02SRA reinforcement (2), longitudinal member outer shell on entry (3) and A-pillar outer section reinforcement (4) for installation Commercially available devices/tools

Round wire brush Blind rivet tool Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-1102sra, Replace longitudinal member outer shell on entrance Model 453.3/4

The high voltage used for electric welding

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2757 · Applies to: 453 · AR: AR63.30-P-1050SRC, AR97.10-P-4000SR, AR97.20-P-1500SR

Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6 Install A-pillar outer section (1), outer rear reinforcement (2), longitudinal member outer shell on entry (3) and A-pillar outer section reinforcement (4) 000 588 01 84 00 Welder WS60.00-P-0021K

000 588 02 84 00 Welder WS60.00-P-0022K

AR63.30-P-1102-03SRA Commercially available devices/tools

Round wire brush Blind rivet tool Blind rivet 6.5 12.5 (clamping *BR00.45-Z-1012-13A range 2 mm to 5 mm, draw-off strength min. 19 kN) 7 Partially install outer side longitudinal member AR63.30-P-1050SRC 8 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 9 Remove spark protection blankets 10 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner 11 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://xentryportal.mercedes-benz.com 12 Seal seam following repairs AR97.10-P-4000SR Supplement standard seals with sealant.

13 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://xentryportal.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off BR00.45-Z-1012-13A A 004 990 16 97 strength min. 19 kN) Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-1102sra, Replace longitudinal member outer shell on entrance Model 453.3/4

AR63.40-P-1110FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2758 · Applies to: 453 · AR: AR63.40-P-1110FF, AR97.10-P-4000FF

Replace center main floor panel reinforcement 08.04.2019 Model 454.0 1 Center main floor panel reinforcement P63.40-2714-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove center main floor reinforcement (1) AR63.40-P-1110-01FF 4 Prepare center main floor reinforcement (1) for AR63.40-P-1110-02FF installation Notes on replacing body parts AH60.00-P-0027-01FF 5 Prepare mating surfaces on the vehicle for AR63.40-P-1110-03FF center main floor reinforcement (1) Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6 Install center main floor reinforcement (1) AR63.40-P-1110-04FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 11 Paint repair area adjacent surfaces Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1110ff, Replace center main floor panel reinforcement Model 454.0

AR63.40-P-1192FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2760 · Applies to: 453 · AR: AR63.40-P-1192FF, AR97.10-P-4000FF, AR97.20-P-1500FF

Replace console below front seat 08.04.2019 Model 454.0 1 Mounting console under front seat P63.40-2513-11 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove mounting console under front seat (1) AR63.40-P-1192-01FF 4 Prepare mounting console under front seat (1) AR63.40-P-1192-02FF for installation Notes on replacing body parts AH60.00-P-0027-01FF 5 Prepare connecting points of the mounting AR63.40-P-1192-03FF console under the front seat (1) on the body Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6 Install mounting console under the front seat AR63.40-P-1192-04FF (1) Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 11 Paint repair area adjacent surfaces 12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 13 Reinstall all removed assembly parts Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1192ff, Replace console below front seat Model 454.0

AR63.40-P-1191FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2762 · Applies to: 453 · AR: AR63.40-P-1191FF

Replace crossmember below front seat 14.05.2019 Model 454.0 Crossmember below front seat 1 Crossmember below front seat P63.40-2514-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove crossmember below front seat (1) AR63.40-P-1190-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Notes on replacing body parts AH60.00-P-0027-01FF 4.1 Prepare crossmember under front seat (1) for In case of installed inner longitudinal member. installation AR63.40-P-1190-02FF 4.2 Prepare crossmember under front seat (1) for In case of removed inner longitudinal member. installation AR63.40-P-1190-02FG Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 5.1 Install crossmember below front seat (1) In case of installed inner longitudinal member. AR63.40-P-1190-03FF 5.2 Install crossmember below front seat (1) In case of removed inner longitudinal member. AR63.40-P-1190-03FG Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1191ff, Replace crossmember below front seat Model 454.0 Crossmember below front seat

AR63.40-P-1191FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2764 · Applies to: 453 · AR: AR63.40-P-1191FH, AR63.40-P-1180FG, AR97.10-P-4000FF

Replace crossmember below front seat 14.05.2019 Model 454.0 Rear crossmember 1 Rear crossmember under front seat P63.40-2688-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove left or right main floor AR63.40-P-1180FG 4 Remove rear crossmember under front seat AR63.40-P-1190-01FH (1) and prepare mating surfaces at body Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 5 Prepare rear crossmember under front seat (1) AR63.40-P-1190-02FH for installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6 Install rear crossmember under front seat (1) AR63.40-P-1190-03FH Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL *BR00.45-Z-1003-01A 6069.20 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1191fh, Replace crossmember below front seat Model 454.0 Rear crossmember

AR63.40-P-1191FJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2766 · Applies to: 453 · AR: AR63.40-P-1191FJ, AR63.40-P-1180FG, AR97.10-P-4000FF

Replace crossmember below front seat 08.04.2019 Model 454.0 Front crossmember 1 Front crossmember under front seat P63.40-2683-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove left or right main floor AR63.40-P-1180FG 4 Remove front crossmember under front seat AR63.40-P-1190-01FJ (1) and prepare mating surfaces at body 5 Prepare front crossmember under front seat AR63.40-P-1190-02FJ (1) for installation Notes on replacing body parts AH60.00-P-0027-01FF Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6 Install front crossmember under front seat (1) AR63.40-P-1190-03FJ Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 11 Paint repair area adjacent surfaces Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1191fj, Replace crossmember below front seat Model 454.0 Front crossmember

AR63.40-P-1100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2768 · Applies to: 453 · AR: AR63.40-P-1100FF, AR60.10-P-0100FF, AR60.10-P-0100FG, AR60.10-P-0100FH, AR60.10-P-0100FJ (+1 more)

Replace outer main floor panel reinforcement 08.04.2019 Model 454.0 1 Outer main floor reinforcement P63.30-2372-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Position body on the straightening bench, CAR-BENCH straightening systems AR60.10-P-0100FF check, and straighten if necessary Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 4 Partially remove bottom firewall AR62.25-P-1100FF 5 Remove outer main floor reinforcement (1) AR63.40-P-1100-01FF 6 Prepare outer main floor reinforcement (1) for AR63.40-P-1100-02FF installation Notes on replacing body parts AH60.00-P-0027-01FF 7 Prepare mating surfaces at vehicle for outer AR63.40-P-1100-03FF main floor reinforcement (1) 8 Mount Car-O-Flex holding fixture for Only in case of CAR-O-Liner straightening installation of outer main floor reinforcement system. (1) at entrance Determine positioning of the Car-O-Flex

holding system with the Car-O-Tronic measuring system. Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 9 Install outer main floor reinforcement (1) AR63.40-P-1100-04FF Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1100ff, Replace outer main floor panel reinforcement Model 454.0

AR63.40-P-1180FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2770 · Applies to: 453 · AR: AR63.40-P-1180FF, AR63.40-P-1191FF, AR63.30-P-1143FF, AR63.30-P-1164FF

Replace partial main floor 08.04.2019 Model 454.0 Front footwell 1 Main floor section P63.40-2631-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove crossmember under front seat AR63.40-P-1191FF 4.1 Partially remove outer longitudinal member If only front area of longitudinal member inner inner shell on entrance shell must be removed due to damage history. AR63.30-P-1143FF 4.2 Remove longitudinal member inner shell on If entire longitudinal member inner shell must entry be removed due to damage history. AR63.30-P-1164FF 5 Remove main floor section (1) AR63.40-P-1180-09FF 6 Prepare main floor section (1) for installation AR63.40-P-1180-10FF Notes on replacing body parts AH60.00-P-0027-01FF 7 Prepare mating surfaces at vehicle for main AR63.40-P-1180-19FF floor section (1) Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 8 Install main floor section (1) AR63.40-P-1180-11FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 9 Clean weld joints and sheet metal flanges with wire brush and clean repair areas Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1180ff, Replace partial main floor Model 454.0 Front footwell

AR63.40-P-1180FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2772 · Applies to: 453 · AR: AR63.40-P-1180FG, AR63.40-P-1110FF, AR63.30-P-1164FF, AR97.10-P-4000FF

Replace partial main floor 14.05.2019 Model 454.0 Complete side 1 Main floor panel P63.40-2654-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove center main floor reinforcement AR63.40-P-1110FF 4 Remove longitudinal member inner shell on AR63.30-P-1164FF entry 5 Remove main floor panel (1) AR63.40-P-1180-09FG 6 Prepare main floor (1) for installation AR63.40-P-1180-10FG Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 7 Prepare mating surfaces on the vehicle for the AR63.40-P-1180-19FG main floor (1) Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 8 Install main floor (1) AR63.40-P-1180-11FG Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 9 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 10 Prime repair area using primer filler 11 Supply standard seam seals with body sealant AR97.10-P-4000FF Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1180fg, Replace partial main floor Model 454.0 Complete side

AR63.40-P-1180SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2774 · Applies to: 453 · AR: AR63.40-P-1180SR, AR63.30-P-1143SRA

Replace partial main floor 14.05.2019 Model 453.3/4 Shown on model 453.3 1 Reinforcement 2 Crossmember 3 Seat console 4 Main floor panel P63.40-3208-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on repair of vehicles with AH60.00-P-0024-01N ultra-strength steels. General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove longitudinal member inner shell on AR63.30-P-1143SRA entry 4 Remove main floor (4) AR63.40-P-1180-09SR When replacing main floor (4), also replace

reinforcement (1), crossmember (2) and seat console (3). Commercially available devices/tools

Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 5 Prepare main floor (4), reinforcement (1), AR63.40-P-1180-23SR crossmember (2) and seat console (3) for installation Commercially available devices/tools

Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar63.40-p-1180sr, Replace partial main floor Model 453.3/4

The high voltage used for electric welding

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2775 · Applies to: 453 · AR: AR63.30-P-1143SRA, AR97.10-P-4000SR, AR97.20-P-1500SR

Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6 Install main floor (4), reinforcement (1), crossmember (2) and seat console (3) 000 588 01 84 00 Welder WS60.00-P-0021K

000 588 02 84 00 Welder WS60.00-P-0022K

AR63.40-P-1180-11SR Commercially available devices/tools

Round wire brush Body power jigsaw Blind rivet tool Wet/dry vacuum cleaner Blind rivet 6.5 12.5 (clamping *BR00.45-Z-1012-13A range 2 mm to 5 mm, draw-off strength min. 19 kN) 7 Install longitudinal member inner shell on entry AR63.30-P-1143SRA 8 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 9 Remove spark protection blankets 10 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner 11 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://xentryportal.mercedes-benz.com 12 Seal seam following repairs AR97.10-P-4000SR Supplement standard seals with sealant.

13 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://xentryportal.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off BR00.45-Z-1012-13A A 004 990 16 97 strength min. 19 kN) Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar63.40-p-1180sr, Replace partial main floor Model 453.3/4

AR63.40-P-1185FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2776 · Applies to: 453 · AR: AR63.40-P-1185FF, AR63.40-P-1180FG, AR97.10-P-4000FF

Replace reinforcement on tunnel 14.05.2019 Model 454.0 1 Brake cable reinforcement P63.40-2693-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove left or right main floor AR63.40-P-1180FG 4 Remove brake cable reinforcement (1) AR63.40-P-1185-01FF 5 Prepare brake cable reinforcement (1) for AR63.40-P-1185-02FF installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 6 Prepare mating surfaces at vehicle for brake AR63.40-P-1185-04FF cable reinforcement (1) Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 7 Install brake cable reinforcement (1) AR63.40-P-1185-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 8 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 9 Prime repair area using primer filler 10 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL *BR00.45-Z-1003-01A 6069.20 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1185ff, Replace reinforcement on tunnel Model 454.0

BE64.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2779 · Applies to: 453 · AR: BE64.00-Z-9999CZ

Test and adjustment values: Smart: Rear wall and rear end 18.09.2019 MODEL all Body shell - Rear MODEL 452 BE64.20-P-1000-02A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be64.00-z-9999cz, Test and adjustment values: Smart: Rear wall and rear end MODEL all

AR64.10-P-2000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2781 · Applies to: 453 · AR: AR64.10-P-2000SR

Replace mounting bracket for engine suspension 14.05.2019 Model 453.0/3/4 Shown on model 453.0 1 Fastening console P64.10-2181-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining in vehicle with spark protection blanket 3 Remove mounting bracket (1) for engine AR64.10-P-2000-01SR suspension Commercially available devices/tools

Round wire brush Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 4 Prepare mounting bracket (1) for engine AR64.10-P-2000-02SR suspension for installation Commercially available devices/tools

Round wire brush Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar64.10-p-2000sr, Replace mounting bracket for engine suspension Model 453.0/3/4

AR64.20-P-1220FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2783 · Applies to: 453 · AR: AR64.20-P-1220FF, AR60.10-P-0100FF, AR60.10-P-0100FG, AR60.10-P-0100FH, AR60.10-P-0100FJ (+2 more)

Completely remove/install rear longitudinal member 14.05.2019 Model 454.0 1 Entire rear longitudinal member 2 Crossmember P64.20-4296-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarps to prevent damage due to flying sparks. 3 Position body on the straightening bench, CAR-BENCH straightening systems AR60.10-P-0100FF check, and straighten if necessary Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 4 Remove entire rear-end floor AR64.20-P-1300FF 5 Remove rear longitudinal member outer shell AR63.30-P-1110FF at entrance 6 Remove entire rear longitudinal member (1) AR64.20-P-1200-22FF 7 Prepare entire rear longitudinal member (1) for AR64.20-P-1200-23FF installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 8 Prepare connecting points at vehicle for AR64.20-P-1200-34FF installation of entire rear longitudinal member (1) Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 9 Mount Car-O-Flex holding fixture for Only in case of CAR-O-Liner straightening installation of entire rear longitudinal member system. (1) Determine positioning of the Car-O-Flex

holding system with the Car-O-Tronic measuring system. Install

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1220ff, Completely remove/install rear longitudinal member Model 454.0

The high voltage used for electric welding

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2784 · Applies to: 453 · AR: AR64.20-P-1145FF, AR97.10-P-4000FF, AR63.30-P-1110FF, AR64.20-P-1300FF, AR60.10-P-0100FF (+3 more)

Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 10 Install entire rear longitudinal member (1) AR64.20-P-1200-24FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 11 Install crossmember (2) under rear-end floor Only if crossmember (2) with entire rear longitudinal member (1) ware removed. Replace crossmember below rear floor AR64.20-P-1145FF 12 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 13 Prime repair area using primer filler 14 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 15 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 16 Paint repair area adjacent surfaces 17 Install rear longitudinal member outer shell at AR63.30-P-1110FF entrance 18 Install entire rear-end floor AR64.20-P-1300FF 19 Remove Car-O-Flex holding system Only in case of CAR-O-Liner straightening system. 20 Take body off the straightening bench and CAR-BENCH straightening systems AR60.10-P-0100FF remove straightening bench Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 21 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1220ff, Completely remove/install rear longitudinal member Model 454.0

AR64.20-P-1220SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2785 · Applies to: 453 · AR: AR64.20-P-1220SR, AR64.20-P-1100SR

Completely remove/install rear longitudinal member 14.05.2019 Model 453 Shown on model 453.3 1 Outer rear longitudinal member 2 Inner rear longitudinal member P64.20-5817-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove rear crossmember AR64.20-P-1100SR 4 Remove rear longitudinal member (1, 2) AR64.20-P-1200-22SRA Commercially available tools

-Round wire brush - Body jig saw - Weld-spot milling machine - Wet/dry vacuum cleaner 5 Prepare rear longitudinal member (1, 2) for AR64.20-P-1200-23SRA installation Commercially available tools

-Round wire brush - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to AH60.00-P-0001-02A components when performing electric welding and soldering work General information on riveting AH60.00-P-0003-01N 6 Install rear longitudinal member (1, 2) AR64.20-P-1200-24SRA Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1220sr, Completely remove/install rear longitudinal member Model 453

Commercially available tools

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2786 · Applies to: 453 · AR: AR64.20-P-1100SR, AR97.10-P-4000SR, AR97.20-P-1500SR

-Round wire brush - Spot welder MIG-MAG inert gas welder Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 7 Install rear crossmember AR64.20-P-1100SR 8 Clean weld joints and sheet metal flange with Commercially available tools

round wire brush -Round wire brush 9 Remove spark protection blankets 10 Clean repair area Commercially available tools

• Wet/dry vacuum cleaner Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 11 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://aftersales.mercedes-benz.com 12 Seal seam following repairs AR97.10-P-4000SR Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 13 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://aftersales.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1220sr, Completely remove/install rear longitudinal member Model 453

AR64.20-P-1300FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2787 · Applies to: 453 · AR: AR64.20-P-1300FF, AR63.10-P-0700FF, AR97.10-P-4000FF

Completely replace rear floor 08.04.2019 Model 454.0 When replacing individual rear-end floor P64.20-4274-08 1 Complete rear-end floor Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove entire inner C-pillar side wall AR63.10-P-0700FF 4 Remove entire rear-end floor (1) AR64.20-P-1300-01FF 5 Prepare entire rear-end floor (1) for installation AR64.20-P-1300-02FF Notes on replacing body parts AH60.00-P-0027-01FF 6 Prepare mating surfaces at vehicle for entire AR64.20-P-1300-10FF rear-end floor (1) Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 7 Install entire rear-end floor (1) AR64.20-P-1300-04FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 8 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 9 Prime repair area using primer filler 10 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 11 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 12 Paint repair area adjacent surfaces Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1300ff, Completely replace rear floor Model 454.0 When replacing individual rear-end floor

AR64.20-P-1310FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2789 · Applies to: 453 · AR: AR64.20-P-1310FF, AR64.20-P-1240FF, AR97.10-P-4000FF

Partially replace rear floor assembly 08.04.2019 Model 454.0 P64.20-3996-08 1 Rear-end floor section Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove end section at left and right rear AR64.20-P-1240FF longitudinal member 4 Remove rear-end floor section (1) AR64.20-P-1310-01FF 5 Prepare mating surfaces at vehicle for rear- AR64.20-P-1310-03FF end floor section (1) 6 Prepare rear-end floor section (1) AR64.20-P-1310-02FF Notes on replacing body parts AH60.00-P-0027-01FF Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 7 Install rear-end floor section (1) AR64.20-P-1310-04FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 8 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 9 Prime repair area using primer filler 10 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 11 Seal mating surfaces between body and new White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A part with body sealant 6069.20 12 Supplement standard underbody protection Underfloor protection 800 ml *BR00.45-Z-1001-05A with permanent underfloor protection 13 Paint repair area adjacent surfaces Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1310ff, Partially replace rear floor assembly Model 454.0

AR64.20-P-1260FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2791 · Applies to: 453 · AR: AR64.20-P-1260FF, AR63.10-P-0662FF, AR63.10-P-0700FF, AR64.20-P-1310FF, AR64.20-P-1300FF

Partially replace rear longitudinal member 08.04.2019 Model 454.0 1 Rear longitudinal member section P64.20-4330-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4.1 Partially remove rear wheel well If, because of the damage history, the rear well wheel well has to be partially removed. AR63.10-P-0662FF 4.2 Completely remove inner C-pillar side wall If, because of the damage history, the C-pillar side wall has to be removed. AR63.10-P-0700FF 5.1 Partially remove rear-end floor If, because of the damage history, the rear- end floor has to be partially removed. AR64.20-P-1310FF 5.2 Completely remove rear-end floor If, because of the damage history, the rear- end floor needs to be completely removed. AR64.20-P-1300FF 6 Remove rear longitudinal member section (1) AR64.20-P-1260-01FF and prepare mating surfaces on the body 7 Prepare rear longitudinal member section (1) AR64.20-P-1260-02FF Notes on replacing body parts AH60.00-P-0027-01FF Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 8 Install rear longitudinal member section (1) AR64.20-P-1260-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 9 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 10 Prime repair area using primer filler Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1260ff, Partially replace rear longitudinal member Model 454.0

AR64.20-P-5731FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2793 · Applies to: 453 · AR: AR64.20-P-5731FF, AR97.10-P-4000FF, AR97.20-P-1500FF

Remove/install end plate 14.05.2019 Model 454.0 1 End panel P64.20-3730-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove end panel (1) and prepare connecting AR64.20-P-5731-01FF points on the body Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 4 Prepare connection panel (1) for installation AR64.20-P-5731-02FF Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 5 Install end panel (1) AR64.20-P-5731-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 7 Prime repair area using primer filler 8 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 9 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 10 Paint repair area adjacent surfaces 11 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 12 Reinstall all removed assembly parts Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-5731ff, Remove/install end plate Model 454.0

AR64.20-P-1100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2795 · Applies to: 453 · AR: AR64.20-P-1100FF, AR88.20-P-1900FF

Remove/install rear cross member 20.11.03 MODEL 454.0 1 CBS rear end 2 Cross member 3 Retaining clip 4 Bolts 5 Plastic nuts P64.20-3656-05 Removal/installation

1 Remove CBS rear end (1) AR88.20-P-1900FF 2 Unclip retaining clips (3) from cross member (2) 3 Unscrew bolts (4) from cross member (2) 4 Remove cross member (2) 5.1 Transfer plastic nuts (5) or replace Only when replacing cross member (2) 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1100ff, Remove/install rear cross member MODEL 454.0

AR64.20-P-1100SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2796 · Applies to: 453 · AR: AR64.20-P-1100SR, AR64.20-P-1063SR

Remove/install rear crossmember 14.05.2019 Model 453 Shown on model 453.3 1 Rear crossmember P64.20-5823-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove taillamp mount AR64.20-P-1063SR 4 Separate rear crossmember (1) AR64.20-P-1100-01SR Commercially available tools

-Round wire brush - Weld-spot milling machine - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 5 Prepare rear crossmember (1) for installation AR64.20-P-1100-02SR Commercially available tools

-Round wire brush - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6 Install rear crossmember (1) AR64.20-P-1100-05SR Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar64.20-p-1100sr, Remove/install rear crossmember Model 453

Commercially available tools

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2797 · Applies to: 453 · AR: AR64.20-P-1063SR, AR97.10-P-4000SR, AR97.20-P-1500SR

-Round wire brush - Spot welder MIG-MAG inert gas welder 7 Install taillamp mount AR64.20-P-1063SR 8 Clean weld joints and sheet metal flange with Commercially available tools

round wire brush -Round wire brush 9 Remove spark protection blankets 10 Clean repair area Commercially available tools

• Wet/dry vacuum cleaner Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 11 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://aftersales.mercedes-benz.com 12 Seal seam following repairs AR97.10-P-4000SR Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 13 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://aftersales.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar64.20-p-1100sr, Remove/install rear crossmember Model 453

AR64.20-P-1000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2798 · Applies to: 453 · AR: AR64.20-P-1000FF, AR97.10-P-4000FF

Replace complete bottom rear center section 14.05.2019 Model 454.0 1 Rear center section P64.20-3652-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4 Remove rear-end center section (1) and AR64.20-P-1000-02FF prepare connecting points at body Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 5 Prepare rear center section (1) for installation AR64.20-P-1000-07FF Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6 Install rear end center assembly (1) AR64.20-P-1000-08FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 7 Take vehicle of the straightening bench and remove straightening bench 8 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 9 Prime repair area using primer filler 10 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL *BR00.45-Z-1003-01A 6069.20 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1000ff, Replace complete bottom rear center section Model 454.0

AR64.20-P-1000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2800 · Applies to: 453 · AR: AR64.20-P-1000SR

Replace complete bottom rear center section 14.05.2019 Model 453 Shown on model 453.3 1 Bottom rear center section P64.20-5793-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Separate bottom rear center section (1) AR64.20-P-1000-02SR Commercially available tools

-Round wire brush - Weld-spot milling machine - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 4 Prepare bottom rear center section (1) for AR64.20-P-1000-07SR installation Commercially available tools

-Round wire brush - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 5 Install bottom rear section (1) AR64.20-P-1000-08SR Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1000sr, Replace complete bottom rear center section Model 453

AR64.20-P-1145FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2802 · Applies to: 453 · AR: AR64.20-P-1145FF, AR64.20-P-1300FF, AR97.10-P-4000FF, AR97.20-P-1500FF

Replace crossmember below rear floor 08.04.2019 Model 454.0 1 Crossmember under rear-end floor P64.20-4308-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4 Remove entire rear-end floor AR64.20-P-1300FF 5 Remove crossmember under rear-end floor (1) AR64.20-P-1145-01FF 6 Prepare crossmember under rear-end floor (1) AR64.20-P-1145-02FF for installation Notes on replacing body parts AH60.00-P-0027-01FF 7 Prepare connecting points for crossmember AR64.20-P-1145-04FF under rear-end floor (1) at body Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 8 Install crossmember under rear-end floor (1) AR64.20-P-1145-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 9 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 10 Prime repair area using primer filler 11 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 12 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 13 Paint repair area adjacent surfaces 14 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1145ff, Replace crossmember below rear floor Model 454.0

Install entire rear-end floor

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2803 · Applies to: 453 · AR: AR64.20-P-1300FF

15 Install entire rear-end floor AR64.20-P-1300FF 16 Take vehicle of the straightening bench and remove straightening bench 17 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1145ff, Replace crossmember below rear floor Model 454.0

AR64.20-P-1140FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2804 · Applies to: 453 · AR: AR64.20-P-1140FF, AR63.10-P-0700FF, AR64.20-P-1300FF, AR64.20-P-1220FF

Replace crossmember on bottom front rear floor assembly 14.05.2019 Model 454.0 1 Entire rear-end floor 2 Lower section of crossmember under rear-end floor 3 Upper section of crossmember under rear-end floor P64.20-4328-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Set up straightening bench with straightening Observe setup plans.

set and position vehicle 4 Remove entire inner C-pillar side wall AR63.10-P-0700FF 5 Remove entire rear-end floor (1) AR64.20-P-1300FF 6 Remove complete rear longitudinal member Only if left and/or right rear longitudinal member must be fully removed due to damage history. AR64.20-P-1220FF 7 Remove upper section of crossmember under AR64.20-P-1140-01FF rear-end floor (3) with lower section of crossmember under rear-end floor (2) Install

8 Completely install rear longitudinal member Only if left and/or right rear longitudinal member was fully removed due to damage history. AR64.20-P-1220FF 9 Prepare connecting points at vehicle for upper AR64.20-P-1140-04FF section of crossmember under rear-end floor (3) and lower section of crossmember under rear-end floor (2) 10 Prepare mating surfaces at vehicle for entire AR64.20-P-1300-10FG rear-end floor (1) 11 Prepare upper section of crossmember under AR64.20-P-1140-02FF rear-end floor (3) and lower section of crossmember under rear-end floor (2) Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1140ff, Replace crossmember on bottom front rear floor assembly Model 454.0

AR64.20-P-1240FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2806 · Applies to: 453 · AR: AR64.20-P-1240FF, AR64.20-P-5731FF, AR64.20-P-1000FF, AR97.10-P-4000FF, AR97.20-P-1500FF

Replace end section on rear longitudinal member 14.05.2019 Model 454.0 1 Rear longitudinal member end section P64.20-3748-05 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove end plate AR64.20-P-5731FF 4 Remove lower rear center section AR64.20-P-1000FF 5 Remove rear longitudinal member end section AR64.20-P-1240-01FF (1) and prepare mating surfaces at body for installation Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 6 Prepare rear longitudinal member end section AR64.20-P-1240-02FF (1) Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 7 Install rear longitudinal member end section AR64.20-P-1240-03FF (1) Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 8 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 9 Prime repair area using primer filler 10 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 11 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 12 Paint repair area adjacent surfaces 13 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1240ff, Replace end section on rear longitudinal member Model 454.0

Teroson protective wax, art. no: 122.73Q

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2807 · Applies to: 453 · AR: AR64.20-P-1000FF, AR64.20-P-5731FF

*BR00.45-Z-1008-05A 14 Remove lower rear center section AR64.20-P-1000FF 15 Install end plate AR64.20-P-5731FF 16 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1240ff, Replace end section on rear longitudinal member Model 454.0

AR64.20-P-1480FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2808 · Applies to: 453 · AR: AR64.20-P-1480FF, AR97.10-P-4000FF, AR97.20-P-1500FF

Replace rear muffler mount 08.04.2019 Model 454.0 1 Rear muffler mount P64.20-4289-11 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove rear muffler bracket (1) and prepare AR64.20-P-1480-01FF mating surfaces at body for installation 4 Prepare rear muffler bracket (1) for installation AR64.20-P-1480-02FF Notes on replacing body parts AH60.00-P-0027-01FF Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 5 Install rear muffler bracket (1) AR64.20-P-1480-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 7 Prime repair area using primer filler 8 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 9 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 10 Paint repair area adjacent surfaces 11 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 12 Reinstall all removed assembly parts Repair materials Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1480ff, Replace rear muffler mount Model 454.0

AR64.20-P-1063SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2810 · Applies to: 453 · AR: AR64.20-P-1063SR, AR63.10-P-0110SR, AR63.10-P-0110SRC, AR65.10-P-1000SRA

Replace taillamp mount 14.05.2019 Model 453 Shown on model 453.3 1 Taillamp mount P64.20-5797-06 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove side wall paneling Model 453.0/3 AR63.10-P-0110SR Model 453.4 AR63.10-P-0110SRC 4 Remove roof paneling Only when removing complete taillamp mount (1) Model 453.0 AR65.10-P-1000SRA with code E23 (solid roof) 5 Separate taillamp mount (1) AR64.20-P-1063-01SR Commercially available devices/tools

Round wire brush Body power jigsaw Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 6 Prepare taillamp mount (1) for installation AR64.20-P-1063-02SR Commercially available devices/tools

Round wire brush Body power jigsaw Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

Risk of poisoning Warning caused by inhaling vapors Wear respiratory protection, protective gloves AS00.00-Z-0016-01A

or swallowing adhesive. Risk of injury caused and safety glasses. Pour adhesive into by adhesive coming into contact with skin and suitable and appropriately marked containers eyes only. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1063sr, Replace taillamp mount Model 453

The high voltage used for electric welding

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2811 · Applies to: 453 · AR: AR63.10-P-0110SR, AR63.10-P-0110SRC, AR65.10-P-1000SRA, AR97.10-P-4000SR, AR97.20-P-1500SR

Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note General information on body repair AH60.00-N-0001-01A Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 7 Install taillamp mount (1) AR64.20-P-1063-03SR 000 588 01 84 00 Welder WS60.00-P-0021K

000 588 02 84 00 Welder WS60.00-P-0022K

Commercially available devices/tools

Round wire brush 8 Install side wall paneling Model 453.0/3 AR63.10-P-0110SR Model 453.4 AR63.10-P-0110SRC 9 Install roof paneling Only when removing complete taillamp mount (1) Model 453.0 AR65.10-P-1000SRA with code E23 (solid roof) 10 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 11 Remove spark protection blankets 12 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 13 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://xentryportal.mercedes-benz.com 14 Seal seam following repairs AR97.10-P-4000SR Supplement standard seals with sealant.

Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 15 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://xentryportal.mercedes-benz.com 16 Add cavity preserving agent AR97.20-P-1500SR 17 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1063sr, Replace taillamp mount Model 453

AR65.10-P-5702FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2814 · Applies to: 453 · AR: AR65.10-P-5702FF, AR68.30-P-4300FF, AR82.10-P-4905FF, AR88.30-P-0500FF, AR82.62-P-8110FF (+2 more)

Remove/install roof paneling 27.2.12 MODEL 454.0 Shown on vehicles with code (V29) Electric glass sliding roof (FFO) 1 Roof paneling 2 Rear spoiler E3 Left taillamp E4 Right taillamp P65.10-2771-05 Removing

Risk of injury Danger! caused by cutting wire tearing Wear protective gloves and safety glasses. AS65.00-Z-0001-01A

or heating up while using it to cut out components that are glued into place. Notes on removing/installing roof AH65.10-P-1000-01MCC

The following workshop equipment and tools are required for repair: "Veritrac" window removal tool gotis://K_67.0_01.0 Cup suction tool gotis://K_67.0_03.0 Wet/dry vacuum cleaner gotis://P_00.12_06.0 Cartridge preheater gotis://K_67.0_02.0 Cartridge gun gotis://K_67.0_02.0 1 Remove headliner AR68.30-P-4300FF 2 Remove left taillamp (E3) and right taillamp AR82.10-P-4905FF (E4) 3 Remove rear spoiler (2) AR88.30-P-0500FF 4 Remove radio/telephone antenna On vehicles with code AR82.62-P-8110FF (C27) Telephone preparation including mount and antenna (DFO/FFO) 5 Remove rod antenna On vehicles with code (C08) Radio AR82.70-P-8951FF preinstallation including rod antenna (FFO) or Code (C25) smart radio six or Code (C26) smart radio multimedia navigator or Code (C28) smart radio five or Code (C29) smart radio navigator 6 Remove GPS antenna On vehicles with code (C26) smart radio AR82.61-P-7474FF multimedia navigator or Code (C29) smart radio navigator 7 Cut out roof paneling (1) with window removal AR65.10-P-5702-01FF Aid of helper is required to cut out and tool (cutting wire). remove roof paneling (1). Adhesive parts kit (with heptane cleaner) *BR00.45-Z-1142-02A Install

8 Prepare body flange for installation AR65.10-P-5702-04FF The bonding area must be absolutely free of dust and grease. Dirt can lead to paint adhesion problems of adhesive material. Adhesive parts kit (with heptane cleaner) BR00.45-Z-1142-02A 9 Align roof paneling (1) in body opening AR65.10-P-5702-06FF Aid of helper required. 452589012100 Feeler gauge 10 Prepare roof paneling (1) for installation When reinstalling removed roof paneling (1). AR65.10-P-5702-02FF Adhesive parts kit (with heptane cleaner) *BR00.45-Z-1142-02A When replacing roof paneling (1). AR65.10-P-5702-02FG Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.10-p-5702ff, Remove/install roof paneling MODEL 454.0

Adhesive parts kit (with heptane cleaner)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2815 · Applies to: 453 · AR: AR88.30-P-0500FF, AR82.10-P-4905FF, AR82.62-P-8110FF, AR82.70-P-8951FF, AR82.61-P-7474FF (+1 more)

BR00.45-Z-1142-02A 11 Open crank window in driver door The crank window in the driver door must be opened during the curing time to prevent the roof paneling (1) from being pressed out by the air when the doors are closed. 12 Apply adhesive material AR65.10-P-5702-05FF Install roof paneling (1) on body flange within 2 minutes after applying adhesive material to prevent paint adhesion problems of the adhesive material when installing. Durability is achieved after approx. 2 h measured from the time the roof paneling (1) is installed. The rated accident strength is achieved only after approx. 8 h. Uniformly apply approx. 12 mm high and 8 mm wide adhesive bead. 000589866300 Intermediate piece Adhesive parts kit (with heptane cleaner) BR00.45-Z-1142-02A 13 Install roof paneling (1) AR65.10-P-5702-03FF Aid of helper required. BA68.70-P-1001-02B

14 Install rear spoiler (2) AR88.30-P-0500FF 15 Install left taillamp (E3) and right taillamp (E4) AR82.10-P-4905FF 16 Install radio/telephone antenna On vehicles with code AR82.62-P-8110FF (C27) Telephone preparation including mount and antenna (DFO/FFO) 17 Install rod antenna On vehicles with code (C08) Radio AR82.70-P-8951FF preinstallation including rod antenna (FFO) or Code (C25) smart radio six or Code (C26) smart radio multimedia navigator or Code (C28) smart radio five or Code (C29) smart radio navigator 18 Install GPS antenna On vehicles with code (C26) smart radio AR82.61-P-7474FF multimedia navigator or Code (C29) smart radio navigator 19 Install headliner AR68.30-P-4300FF Handles

Number Designation Model 454 BA68.70-P-1001-02B Bolt, folding handle bracket to roof frame Nm 8 000 589 86 63 00 452 589 01 21 00 Intermediate piece Feeler gauge Repair materials Number Designation Order number BR00.45-Z-1142-02A TS adhesive (with heptane cleaner) A 451 989 01 71 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.10-p-5702ff, Remove/install roof paneling MODEL 454.0

AR65.10-P-5702SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2816 · Applies to: 453 · AR: AR65.10-P-5702SR, AR68.30-P-4300SRA

Remove/install roof paneling 05.09.2017 Model 453.3 with code E23 (solid roof) Modification notes 05.09.2017 Workshop equipment is linked in EPC with replacement Only use linked workshop equipment. part. 1 Roof paneling A Gap dimension B Gap dimension C Gap dimension P77.21-2469-12 Preparation 1 Workshop equipment is linked in EPC with Only use linked workshop equipment.

replacement part. Remove

2 Remove headliner AR68.30-P-4300SRA 3 Determine gap dimensions (A, B, C) with *129589032100 Feeler gauge feeler gauge and note Risk of injury. Injury may result if the cutting Wear protective gloves and safety glasses. AS65.00-Z-0001-01A Warning

wire tears or heats up while using it to cut out components that are glued into place. 4 Cut out roof paneling (1) with cutting wire AR65.10-P-5702-01SR The roof paneling (1) cannot be removed

without damaging the cast on spacers and must be replaced. Install

5 Open side window in driver door

The side window of the driver door should remain open during the curing time. Otherwise the roof paneling (1) can be pressed toward outside by the air when the doors are closed. 6 Prepare roof paneling (1) for installation AR65.10-P-5702-02SR 7 Prepare roof frame for installation roof AR65.10-P-5702-04SR paneling (1) 8 Apply adhesive material to roof paneling (1) AR65.10-P-5702-05SR 9 Install roof paneling (1) AR65.10-P-5702-03SR Observe manufacturer's specifications for

curing time of adhesive material. Perform following work only after curing time. 10 Install headliner AR68.30-P-4300SRA 11 Close side window on driver door Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.10-p-5702sr, Remove/install roof paneling Model 453.3 with code E23 (solid roof)

AR65.20-P-1200FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2827 · Applies to: 453 · AR: AR65.20-P-1200FF, AR65.20-P-1006FF, AR63.10-P-0110FF, AR65.10-P-1020FF, AR63.20-P-1351FF

Remove/install side roof frame 14.05.2019 Model 454.0 1 Outer roof frame 2 Inner roof frame P65.20-2204-06 Remove

Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units 1 Remove detachable parts in the repair area 2 Cover all detachable parts remaining in vehicle

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove front roof frame AR65.20-P-1006FF 4.1 Remove side wall paneling When removing entire sidewall paneling. AR63.10-P-0110FF 4.2 Remove complete side roof paneling When removing sidewall paneling in area of outer roof frame (1) AR65.10-P-1020FF 5 Remove B-pillar reinforcement When removing entire B-pillar reinforcement. AR63.20-P-1351FF 6 Remove outer roof frame (1) and inner roof AR65.20-P-1200-01FF frame (2) at side 7 Prepare outer roof frame (1) and inner roof AR65.20-P-1200-02FF frame (2) at side for installation Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 8 Prepare connecting points of side roof frame AR65.20-P-1200-04FF at body Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 9 Install and weld in outer roof frame (1) and AR65.20-P-1200-03FF inner roof frame (2) at side Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.20-p-1200ff, Remove/install side roof frame Model 454.0

AR65.20-P-1200SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2829 · Applies to: 453 · AR: AR65.20-P-1200SR, AR63.10-P-0110SR

Remove/install side roof frame 14.05.2019 Model 453.3 P65.20-2748-09 1 Side roof frame Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note General information on body repair AH60.00-N-0001-01A General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove side wall paneling AR63.10-P-0110SR 4 Remove side roof frame (1) AR65.20-P-1200-01SR Commercially available tools

-Round wire brush - Weld-spot milling machine - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 5 Prepare side roof frame (1) for installation AR65.20-P-1200-02SR Commercially available tools

-Round wire brush - Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to AH60.00-P-0001-02A components when performing electric welding and soldering work 6 Install side roof frame (1) AR65.20-P-1200-03SR Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.20-p-1200sr, Remove/install side roof frame Model 453.3

Commercially available tools

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2830 · Applies to: 453 · AR: AR63.10-P-0110SR, AR97.10-P-4000SR, AR97.20-P-1500SR

-Round wire brush Blind rivet tool - Spot welder MIG-MAG inert gas welder Blind rivet with countersunk head 6.4 15.5 BR00.45-Z-1044-13A (clamping range 3 mm to 5 mm, draw-off strength min. 15.5 kN) Blind rivet 6.5 12.5 (clamping BR00.45-Z-1012-13A range 2 mm to 5 mm, draw-off strength min. 19 kN) 7 Install side wall paneling AR63.10-P-0110SR 8 Clean weld joints and sheet metal flange with Commercially available tools

round wire brush -Round wire brush 9 Remove spark protection blankets 10 Clean repair area Commercially available tools

• Wet/dry vacuum cleaner Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 11 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://aftersales.mercedes-benz.com 12 Seal seam following repairs AR97.10-P-4000SR Risk of explosion Danger caused by paint vapors No smoking! No open fire! Use respiratory AS98.00-Z-0002-01A

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 13 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://aftersales.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off BR00.45-Z-1012-13A A 004 990 16 97 strength min. 19 kN) Blind rivet with countersunk head 6.4 15.5 (clamping BR00.45-Z-1044-13A A 000 991 83 32 range 3 mm to 5 mm, draw-off strength min. 15.5 kN) Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.20-p-1200sr, Remove/install side roof frame Model 453.3

AR65.20-P-1200SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2831 · Applies to: 453 · AR: AR65.20-P-1200SRC, AR63.20-P-1102SRC

Remove/install side roof frame 14.05.2019 Model 453.4 1 Upper side roof frame 2 Lower side roof frame P65.20-2834-11 Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note General information on body repair AH60.00-N-0001-01A General information on repair of vehicles with AH60.00-P-0024-01N ultra-strength steels. General information on MB materials AH98.00-P-9409-03A Remove

1 Remove detachable parts in area to be repaired 2 Cover all detachable parts remaining on vehicle with spark protection blankets 3 Remove A-pillar outer section AR63.20-P-1102SRC 4 Remove upper side roof frame (1) and lower AR65.20-P-1200-01SRC side roof frame (2) Commercially available devices/tools

Round wire brush Spot weld milling machine Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 5 Prepare upper side roof frame (1) and lower AR65.20-P-1200-02SRC side roof frame (2) for installation Commercially available devices/tools

Round wire brush Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

presents a lethal hazard. Risk of explosion safety glasses and a protective mask. Remove

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work General information on riveting AH60.00-P-0003-01N 6 Install upper side roof frame (1) and lower side AR65.20-P-1200-03SRC roof frame (2) 000 588 01 84 00 Welder WS60.00-P-0021K

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.20-p-1200src, Remove/install side roof frame Model 453.4

Commercially available devices/tools

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2832 · Applies to: 453 · AR: AR63.20-P-1102SRC, AR97.10-P-4000SR, AR97.20-P-1500SR

Round wire brush Blind rivet tool Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Blind rivet 6.5 12.5 (clamping BR00.45-Z-1012-13A range 2 mm to 5 mm, draw-off strength min. 19 kN) 7 Install A-pillar outer section AR63.20-P-1102SRC 8 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 9 Remove spark protection blankets 10 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner 11 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://xentryportal.mercedes-benz.com 12 Seal seam following repairs AR97.10-P-4000SR Supplement standard seals with sealant.

13 Paint repair areas and adjacent surfaces Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only paints approved by Daimler AG:

http://xentryportal.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off BR00.45-Z-1012-13A A 004 990 16 97 strength min. 19 kN) Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.20-p-1200src, Remove/install side roof frame Model 453.4

AR65.20-P-1056SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2833 · Applies to: 453 · AR: AR65.20-P-1056SRC, AR68.30-P-4700SRC

Replace roll bar 21.12.15 Model 453.4 Shown on right side of vehicle 1 Roll bar 2 Cover 3 Screw 4 Bracket 5 Bolts P65.20-2829-06 Risk of injury Always wear protective gloves when working Danger ! caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Remove/install

1 Detach paneling (2) from right an right B- AR68.30-P-4700SRC pillar and remove from working area Do not remove belt end fittings.

2 Unscrew bolts (3) and remove bracket (4) 3 Unscrew bolts (5) and remove roll bar (1) Installation: Repair paint damage on bolt

head (5). Helper required.

4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.20-p-1056src, Replace roll bar Model 453.4

AR67.10-P-1700SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2842 · Applies to: 453 · AR: AR67.10-P-1700SR

Remove, install windshield 12.09.2018 Model 453 Modification notes 12.09.2018 Operation step 28, adapted If new windshield (1) was installed, a new housing of the rain and light sensor must be installed. 06.04.2017 Frame support under windshield with support 453 589 00 40 00 added. 1 Windshield P67.10-2453-06 P67.10-2512-08 2 Support brace Page 1 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar67.10-p-1700sr, Remove, install windshield Model 453

Model 453.0Windshield to A-pillar

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2844 · Applies to: 453 · AR: AR68.30-P-4050SR, AR83.25-P-1410SR, AR54.21-P-3000SR, AR82.30-P-7800SR, AR68.40-P-0001SR

BE60.00-P-1010-01CA Model 453.0Windshield to roof paneling BE60.00-P-1011-01CA *129589032100 Feeler gauge 19 Remove protective foil from rubber spacers 20 Apply glue to body flange AR67.10-P-1000-08SR

Windshield (1) must be mounted on body flange within time specified by adhesive material manufacturer. Otherwise the adhesive force of the adhesive material starts to decrease. Glazing set BR00.45-Z-1168-02A 000589866300 Adapter 21 Install windshield (1) AR67.10-P-1700-05SR Aid of helper required.

22 Fix windshield (1) in place with suitable adhesive tape 23 Release and remove support (2)

Only initially remove support (2) once adhesive material has achieved endurance strength. Otherwise distortions or noise can arise when driving and a secure bonding is no longer ensured. 24 Remove cover from dashboard 25 Install paneling on left and right A-pillar AR68.30-P-4050SR 26 Install air/water duct AR83.25-P-1410SR 27 Install multifunction camera Model 453 with code 238 (Active lane keeping Assist) AR54.21-P-3000SR 28 Install rain/light sensor Model 453 with code V54 (Rain/light sensor) AR82.30-P-7800SR If new windshield (1) was installed, a new

housing of the rain and light sensor must be installed. 29 Install inside rearview mirror AR68.40-P-0001SR 30 Close side window on driver door Check

31 Read out and erase fault memory using the diagnostic system AD00.00-P-2000-06SR

Clean

32 Remove all attached adhesive tapes 33 Clean area to be repaired Test and adjustment values for gap dimensions Number Designation Model 453.0 3 ( 1,5) BE60.00-P-1010-01CA Windshield to A-pillar Dimension "H2" mm Test and adjustment values for gap dimensions Number Designation Model 453.0 3 ( 1,5) BE60.00-P-1011-01CA Windshield to roof paneling Dimension "H3" mm 129 589 03 21 00 453 589 00 40 00 000 589 86 63 00 Feeler gauge Support brace Adapter Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar67.10-p-1700sr, Remove, install windshield Model 453

AR67.10-P-1000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2846 · Applies to: 453 · AR: AR67.10-P-1000FF, AR68.30-P-4050FF, AR68.40-P-0001FF, AR82.30-P-7800FF, AR82.30-P-6951FF (+1 more)

Remove/install windshield 07.03.2019 Model 454.0 P67.10-2322-08 1 Windshield 4 Bracket 8 Retaining rail 3 Cover 7 Edging 5 Seal strip 6 Instrument panel P67.10-2210-11 Remove

Risk of injury Always interrupt air supply or power supply Warning caused by slipping when AS67.00-Z-0001-01A

inserting blade in the multicutter and byglass before inserting or removing blade. splinters when cutting out bonded windows Wear protective gloves and safety glasses Risk of injury Warning from cutting wire tearing or Wear protective gloves and safety glasses. AS67.00-Z-0004-01A

becoming hot and from splinters of glass when cutting out bonded windows Topical note Notes on removal/installation of windows AH67.10-P-1000-02RT Topical note Notes on removal/installation of windshield AH67.10-P-1000-01MCC 1 Remove paneling on both A-pillars AR68.30-P-4050FF 2 Remove inside rearview mirror AR68.40-P-0001FF 3 Remove rain/light sensor Only in vehicles with code V08 (rain sensor AR82.30-P-7800FF (FFO)) with code V41 (Automatic Driving Lights (FFO)) 4 Remove front wiper arms AR82.30-P-6951FF 5 Remove paneling from center section in front AR88.00-P-2792FF of windshield (1) 6 Lift the cover (3) using the brackets (4) and unclip it from the guide on the windshield (1) Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar67.10-p-1000ff, Remove/install windshield Model 454.0

Install windshield (1) within 2 min of applying

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2848 · Applies to: 453 · AR: AR88.00-P-2792FF, AR82.30-P-6951FF, AR68.30-P-4050FF, AR82.30-P-7800FF, AR68.40-P-0001FF

adhesive material to body flange. Otherwise the adhesive force of the adhesive material can decrease. Durability will have been achieved,

measured from the time the windshield (1) is installed, after approx. 2 h. The rated accident strength will not have been achieved until after approx. 8 h. Uniformly apply adhesive bead at a height of approx. 12 mm. Adhesive parts kit (with isopropanol cleaner) BR00.45-Z-1141-02A 000589866300 Adapter 19 Place the windshield (1) onto the body flange Aid of helper required. Insert the guides

with the cup suction tool (arrows) of the windshield (1) into the guide openings on the front roof frame and thus align the windshield (1). 20 Firmly press the windshield (1) allround until it Durability will have been achieved after

lies on spacers approx. 2 h measured from the time the windshield (1) is installed. The rated accident strength will not have been achieved until after approx. 8 h. 21 Insert the cover (3), clip it into the guide on the After installing the windshield (1), do not

windshield (1) and engage it in the brackets move the vehicle until the adhesive has dried (4) at the very earliest. 22 Remove paneling from center section in front AR88.00-P-2792FF of windshield (1) 23 Install the wiper arms of the windshield (1) AR82.30-P-6951FF 24 Install paneling on both A-pillars AR68.30-P-4050FF 25 Install rain/light sensor Only in vehicles with code V08 (rain sensor (FFO)) with code V41 (Automatic Driving Lights (FFO)) AR82.30-P-7800FF Do not install the rain/light sensor until the

adhesive has completely dried. 26 Install inside rearview mirror AR68.40-P-0001FF Do not install the inside rearview mirror

until the adhesive has dried completely. 454 589 01 63 00 000 589 86 63 00 452 589 01 63 00 Set of cutting blades Clip remover Adapter Repair materials Number Designation Order number BR00.45-Z-1072-01A Pre-compressed seal strip Adolf Würth GmbH & Co. KG Reinhold-Würth-Str. 12-17 74653 Künzelsau-Gaisbach Germany Tel. +49 7940 15-0 Fax +49 7940 15-1000 www.wuerth.de Item no.: 0875 01102 BR00.45-Z-1141-02A Adhesive parts kit (with isopropanol cleaner) A 451 989 00 71 Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar67.10-p-1000ff, Remove/install windshield Model 454.0

AR67.10-P-1600MCC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2849 · Applies to: 453 · AR: AR67.10-P-1600MCC

Repair of windshield 15.11.11 MODEL 451.3 /4, 454.0 1 Windshield wiper field 2 Long-range field of vision P67.10-2157-01 Notes on stone impact repair on laminated AH67.10-P-0002-01MCC

glass windows The following tolls are required for stone Stone impact repair tool

impact repair on windshield gotis://K_67.0_05.0 1 Prepare repair for windshield AR67.10-P-1600-01MCC 2 Repair windshield AR67.10-P-1600-02MCC 3 Finish windshield repair AR67.10-P-1600-03MCC Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar67.10-p-1600mcc, Repair of windshield MODEL 451.3 /4, 454.0

AR67.20-P-2000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2850 · Applies to: 453 · AR: AR67.20-P-2000FF, AR88.30-P-0500FF, AR82.30-P-6900FF, AR72.20-P-2555FF, AR82.10-P-4905FF

Remove/install rear wall window 07.03.2019 Model 454.0 1 Rear window 2 Rear-end door P67.20-2149-06 1 Rear window 2 Rear-end door 4 Rear spoiler E3 Left taillamp E4 Right taillamp S62/35 Rear-end door button P67.20-2295-06 Remove

Risk of injury Always interrupt air supply or power supply Warning caused by slipping when AS67.00-Z-0001-01A

inserting blade in the multicutter and byglass before inserting or removing blade. splinters when cutting out bonded windows Wear protective gloves and safety glasses Topical note Notes on remove/install rear window AH67.20-P-2000-01T Topical note Notes on removal/installation of windows AH67.10-P-1000-02RT 1 Remove rear spoiler (4) AR88.30-P-0500FF 2 Remove tailgate wiper motor AR82.30-P-6900FF 3 Remove button for rear-end door (S62/35) AR72.20-P-2555FF 4 Remove left taillamp (E3) and right taillamp AR82.10-P-4905FF (E4) Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar67.20-p-2000ff, Remove/install rear wall window Model 454.0

Disconnect the connectors of the rear window

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2851 · Applies to: 453 · AR: AR88.30-P-0500FF, AR82.10-P-4905FF, AR72.20-P-2555FF, AR82.30-P-6900FF

5 Disconnect the connectors of the rear window heater from the rear window (1) and attach them to the inside of the rear-end door (2) with adhesive tape 6 Mask of the rear-end door (2) in the bottom area of the rear windows (1) 7 Cut into the rear window (1) in areas C and D Use the straight cutting blade in area C.

with cutting blade from inside In area D, use the bent cutting blade with a blade length of 33 mm. *454589016300 Set of cutting blades 8 Cut out the rear window (1) in areas A, B and In area A, use the bent cutting blade with a

E with cutting blade and grab handle from blade length of 25 mm. outside In areas B and E, use the bent cutting blade with a blade length of 45 mm. *454589016300 Set of cutting blades 9 Lift the rear window (1) with cup suction tools Aid of helper required.

off the rear-end door (2) Install

10 Install rear spoiler (4) Throughout the entire assembly work on the new rear window (1), cotton gloves must be worn. Ensure that no fingerprints are present in the area of the bonding surface. AR88.30-P-0500FF 11 Prepare the body flange of the rear-end door AR67.20-P-5160-01FF (2) for installing the window

The bonding area must be absolutely free of dust and grease in order to prevent paint adhesion problems of the adhesive material during window installation. Adhesive parts kit (with isopropanol cleaner) *BR00.45-Z-1141-02A 12 Prepare rear wall window (1) for installation AR67.20-P-1000-07FF

Bonding area on rear window (1) must be fully free from dust and grease. Otherwise the adhesive force of the adhesive material can decrease. Adhesive parts kit (with isopropanol cleaner) *BR00.45-Z-1141-02A 13 Open the crank window in the driver's door This prevents the rear window (1) from

and front passenger door being pressed outwards by the air pressure when the doors are closed before the bond has completely cured. 14 Apply adhesive material AR67.20-P-2000-08RR

Install rear window (1) within 2 minutes of applying adhesive material to body flange. Otherwise the adhesive force of the adhesive material can decrease. Durability will have been reached after

approx. 2 h, measured from time when the rear window (1) is installed. The rated accident strength will not have been achieved until after approx. 8 h. Uniformly apply adhesive bead at a height of approx. 12 mm. Adhesive parts kit (with isopropanol cleaner) BR00.45-Z-1141-02A 000589866300 Adapter 15 Insert the rear window (1), align it on the right Durability will have been reached after

and left of the bottom area with rear-end door approx. 2 h, measured from time when the (2) and press it firmly in all round. rear window (1) is installed. The rated accident strength will not have been achieved until after approx. 8 h. 16 Check the distance between the rear windows In the bottom area, the rear window (1)

(1) and the rear-end door (2) in the bottom must have a distance of area; adjust it if necessary. approx. 1 mm from the rear-end door (2). *452589012100 Feeler gauge 17 Open the rear-end door (2), lock it in a After installing the rear window (1), do not

horizontal position with a wire and let the move the vehicle until the adhesive has dried adhesive material cure. at the very earliest. 18 Connect the connectors of the rear window heater to the rear window (1). 19 Install left taillamp (E3) and right taillamp (E4) AR82.10-P-4905FF 20 Install button for rear-end door (S62/35) AR72.20-P-2555FF 21 Install tailgate wiper motor AR82.30-P-6900FF Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar67.20-p-2000ff, Remove/install rear wall window Model 454.0

PE67.29-P-2000BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2855 · Applies to: 453 · AR: PE67.29-P-2000BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Electric wiring diagram for heated rear window 11.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Electric wiring diagram for heated rear window PE67.29-P-2000-97BBA Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe67.29-p-2000bba, Electric wiring diagram for heated rear window Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020

PE67.29-P-2000ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2856 · Applies to: 453 · AR: PE67.29-P-2000ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Electric wiring diagram for heated rear window 8.3.06 MODEL 454 as of 3.4.06 PE67.29-P-2000-99ZB Electric wiring diagram for heated rear PE67.29-P-2000-99ZB window PE67.29-P-2000-60ZB Legend of wiring diagram for heated rear PE67.29-P-2000-60ZB window OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Location and assignment of line and plug GF00.19-P-1000ZA connectors GF00.19-P-2000ZA Location and assignment of ground points GF00.19-P-2000ZA GF00.19-P-3000ZA Location and assignment of Z connector GF00.19-P-3000ZA sleeves (line connectors in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE83.00-P-1100ZA Further wiring diagrams PE83.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe67.29-p-2000zb, Electric wiring diagram for heated rear window MODEL 454 as of 3.4.06

PE67.29-P-2051BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2857 · Applies to: 453 · AR: PE67.29-P-2051BBA

Function schematic for electrical rear window heater 18.11.15 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) except code I01 (Automatic air conditioning) Function schematic for electrical rear window PE67.29-P-2051-97BBA heater Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe67.29-p-2051bba, Function schematic for electrical rear window heater Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) except code I01 (Automatic air conditioning)

PE67.29-P-2051BBB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2858 · Applies to: 453 · AR: PE67.29-P-2051BBB

Function schematic for electrical rear window heater 18.11.15 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) with code I01 (Automatic air conditioning) Function schematic for electrical rear window PE67.29-P-2051-97BBB heater Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe67.29-p-2051bbb, Function schematic for electrical rear window heater Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) with code I01 (Automatic air conditioning)

PE67.29-P-2000ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2859 · Applies to: 453 · AR: PE67.29-P-2000ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram of heated rear window 16.12.03 MODEL 454 up to 2.4.06 PE67.29-P-2000-99ZA Wiring diagram of heated rear window PE67.29-P-2000-99ZA PE67.29-P-2000-60ZA Legend of wiring diagram for heated rear PE67.29-P-2000-60ZA window OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Arrangement and assignment of the wiring GF00.19-P-1000ZA and plug connectors GF00.19-P-2000ZA Arrangement and assignment of ground GF00.19-P-2000ZA points GF00.19-P-3000ZA Arrangement and assignment of Z connector GF00.19-P-3000ZA sleeves (wiring connections in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE83.00-P-1100ZA Further wiring diagrams PE83.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe67.29-p-2000za, Wiring diagram of heated rear window MODEL 454 up to 2.4.06

AR67.39-P-4175FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2860 · Applies to: 453 · AR: AR67.39-P-4175FF, AR68.10-P-1400FF

Remove/install power window control unit 7.9.04 MODEL 454.0## 1# with CODE (V34) Power windows in rear (FFO) with CODE (LHD) Left-hand drive vehicle P67.39-2085-07 1 Bolts 3 Connector N69 Power windows control unit 2 Housing 4 Bolt Remove/Install

Notes on avoiding damage to electronic AH54.00-P-0001-01A

components due to electrostatic discharge 1 Remove glove compartment AR68.10-P-1400FF 2 Unscrew bolts (1) and carefully pull housing (2) downward 3 Unlock connector (3) and disconnect 4 Remove bolts (4) 5 Remove power window control unit (N69) 6 Install in the reverse order 7 Completely open all windows and close again Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar67.39-p-4175ff, Remove/install power window control unit MODEL 454.0## 1# with CODE (V34) Power windows in rear (FFO) with CODE (LHD) Left-hand drive vehicle

AR67.39-P-4175FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2861 · Applies to: 453 · AR: AR67.39-P-4175FG, AR68.10-P-1520FF

Remove/install power window control unit 8.9.04 MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle with CODE (V34) Power windows in rear (FFO) P67.39-2086-09 1 Bolts 4 Connector N69 Power windows control unit 2 Housing 5 Bolt 3 Connector Remove/Install

Notes on avoiding damage to electronic AH54.00-P-0001-01A

components due to electrostatic discharge 1 Remove cover below right instrument panel AR68.10-P-1520FF 2 Unscrew bolts (1) and carefully pull housing (2) downward 3 Unlock connector (3, 4) and disconnect 4 Unscrew bolts (5) 5 Remove power window control unit (N69) 6 Install in the reverse order 7 Completely open all windows and close again Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar67.39-p-4175fg, Remove/install power window control unit MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle with CODE (V34) Power windows in rear (FFO)

AR68.10-P-1750FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2870 · Applies to: 453 · AR: AR68.10-P-1750FF

Remove bottle holder 18.12.03 MODEL 454.0 With retrofitted bottle holder P68.10-3118-08 1 Bottle holder 3 Bolts 4 Rail 2 Slide 5 Floor mat Removal/installation

1 Move front passenger seat to end position See Operating Instructions toward rear 2 Push back slide (2) until bolts (3) are accessible 3 Unscrew bolts (3) Installation:

To prevent distortions, screw in bolts (3) only until rail (4) makes uniform contact to floor covering (5). 4 Slide bottle holder (1) toward rear and remove Installation: Move hook along rail (4)

to side from rear through long passage in floor covering (5) and pull bottle holder (1) toward front. 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1750ff, Remove bottle holder MODEL 454.0 With retrofitted bottle holder

AR68.10-P-1150FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2871 · Applies to: 453 · AR: AR68.10-P-1150FF

Remove/install center air nozzle 1.10.03 MODEL 454.0 1 Air nozzles 2 Instrument panel top section P68.10-3172-11 P68.10-3171-09 1 Air nozzle 3 Vent cover 5 Retaining clamp 2 Instrument panel top section 4 Remover 6 Retaining clamp Remove

1 Set air distribution to windshield See Operating Instructions 2 Move vent grate (3) on air nozzle (1) to slightly open position 3 Insert remover (4) between ventilation grate (3) and air nozzle housing (1) Remover for air nozzles WF58.50-P-6810-03FF

4 Turn remover (4) to 90° to left and position The retaining clamp (6) is located at the against retaining clamp (6) center below the air nozzle. 5 Pull remover (4) out of air nozzle (1) approx. 2 cm, to release tension on retaining clamp (6) 6 Pull air nozzle (1) carefully approx. 2 cm out Pull air nozzle (1) carefully out of upper of upper part of instrument panel (2) with part of instrument panel (2), otherwise the retainer (4) retaining clips (5, 6) can fall into the ventilation shaft. The retaining clamps (5) are located approx. 10° from the middle in the upper area. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1150ff, Remove/install center air nozzle MODEL 454.0

AR68.10-P-1150SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2873 · Applies to: 453 · AR: AR68.10-P-1150SR

Remove/install center air nozzle 22.03.2016 Model 453 P68.10-5018-08 1 Center outlets 1.1 Catch hook Remove/install

1 Lift catch hooks (1.1) and pull out center air

vent (1) Lift catch hooks (1.1) only slightly. Otherwise they can deform and the center air vent (1) is not held securely. *140589023300 Extraction hook 2 Install in the reverse order 140 589 02 33 00 Extraction hook Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar68.10-p-1150sr, Remove/install center air nozzle Model 453

AR68.10-P-1500FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2874 · Applies to: 453 · AR: AR68.10-P-1500FF

Remove/install cover below instrument panel (left) 13.11.03 MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle P68.30-2857-09 1 Cover 2 Quick-release fitting 3 Bracket Removal/installation

1 Turn quick-release fitting (2) 90° and unclip 2 Fold cover (1) toward rear in lower area and Carefully loosen cover (1) to prevent unclip side latching hooks damage from breaking and scratching 3 Unhook bracket (3) from instrument panel and remove cover (1) 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1500ff, Remove/install cover below instrument panel (left) MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle

AR68.10-P-1500SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2875 · Applies to: 453 · AR: AR68.10-P-1500SR

Remove/install cover below instrument panel (left) 25.04.2018 Model 453 P68.10-4746-09 1 Cover 2 Bolts 3 Bolts 1 Cover 4 Electrical connector 5 Electrical connectors 9 Cable tie E17/16 Left front footwell lamp P68.10-4747-06 Risk of injury Warning during testing and repair Do not expose pyrotechnical component parts AS91.00-Z-0008-01A

operations related to pyrotechnical to temperatures above 100 °C or 212 °F. components Disconnect current supply when working on such component parts. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1500sr, Remove/install cover below instrument panel (left) Model 453

AR68.10-P-1520FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2877 · Applies to: 453 · AR: AR68.10-P-1520FF

Remove/install cover below instrument panel (right) 17.6.04 MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle P68.10-3247-07 1 Cover below instrument panel 4 Retaining clamp 6 Latching hook 2 Opening 5 Bracket 7 Latching hook 3 Opening Remove/Install

1 Unclip latching hook (7) from retaining clips (4) 2 Loosen latching hook (6) from cover below instrument panel (1) in area of openings (3). 3 Fold cover below instrument panel (1) toward rear in lower area and unhook bracket (5) in area of openings (2) 4 Remove cover below instrument panel (1) 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1520ff, Remove/install cover below instrument panel (right) MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle

AR68.10-P-1190FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2878 · Applies to: 453 · AR: AR68.10-P-1190FF, AR68.20-P-2350FG, AR54.21-P-1262FF

Remove/install cover on instrument panel center section 16.8.06 MODEL 454.0 except CODE (C25) smart radio six except CODE (C26) smart radio multimedia navigator except CODE (C28) smart radio five except CODE (C29) smart radio navigator P68.20-3491-08 1 Covering 3 Cover 5 Bolt 2 Stowage compartment 4 Bolts Remove/install

1 Remove cover (3) on the front center console AR68.20-P-2350FG 2 Loosen upper control panel control unit and AR54.21-P-1262FF lay down to side with electrical line connected. 3 Unscrew bolts (5) from stowage compartment (2) and remove stowage compartment (2). 4 Unscrew bolts (4) from cover (1) and remove The electrical connectors for the radio and cover (1) until electrical connectors for radio the antenna connector are clipped into the and antenna connector are accessible. cover (1) from the rear. 5 Unclip electrical connectors on radio and antenna plug from covering (1) and remove covering (1). 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1190ff, Remove/install cover on instrument panel center section MODEL 454.0 except CODE (C25) smart radio six except CODE (C26) smart radio multimedia navigator except CODE (C28) smart radio five except CODE (C29) smart radio navigator

AR68.10-P-1120FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2879 · Applies to: 453 · AR: AR68.10-P-1120FF, AR68.10-P-1000FF, AR68.20-P-2040FF

Remove/install cross member under instrument panel 3.4.04 MODEL 454.0 1 Cross member 2 Rear footwell air outlet 3 Connector 4 Bearing bracket 5 Wiring harness 11 Connector 12 Ground cable 13 Connector 14 Relay holder N2/7 Restraint systems control unit P68.10-3192-06 P62.30-2685-08 1 Cross member 8 Wiring harness K40/1 Fuse and relay module 6 Steering lock 9 Wiring harness N93 Central gateway control unit 7 Jacket tube 10 Bolts Remove/Install

1 Remove instrument panel AR68.10-P-1000FF 2 Remove front floor covering AR68.20-P-2040FF 3 Remove rear footwell air outlet (2) 4 Disconnect electrical connectors from steering lock (6) and loosen electrical leads from retaining clamps on steering lock (6) 5 Remove jacket tube (7) from cross member The jacket tube (7) is fastened to the (1) cross member (1) with four bolts. *BA46.10-P-1003-05A

6 Unplug plug (11) 7 Remove relay holder (14) from cross member (1) 8 Remove fuse and relay module (K40/1) from cross member (1) 9 Remove central gateway control unit (N93) from cross member (1) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1120ff, Remove/install cross member under instrument panel MODEL 454.0

AR68.10-P-1000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2881 · Applies to: 453 · AR: AR68.10-P-1000SR

Remove/install dashboard 25.04.2018 Model 453 P68.10-4724-09 Shown except code V31 (Additional instruments (cockpit clock and tachometer)) 1 Instrument panel 17 Screw R12/8 Front passenger airbag squib 15 Screw 18 Screw 16 Screw 19 Bolts P68.10-4723-09 Shown except code V31 (Additional instruments (cockpit clock and tachometer)) and with code I01 (Air conditioning Plus) 1 Instrument panel N20 Climate control operating unit Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1000sr, Remove/install dashboard Model 453

Screw

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2882 · Applies to: 453 · AR: AR68.10-P-1500SR, AR68.10-P-1402SR, AR54.30-P-6015SR, AR68.30-P-4050SR, AR68.10-P-1580SR (+5 more)

20 Screw S6/1 Instrument panel switch group Risk of injury Warning during testing and repair Do not expose pyrotechnical component parts AS91.00-Z-0008-01A

operations related to pyrotechnical to temperatures above 100 °C or 212 °F. components Disconnect current supply when working on such component parts. Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Information, assessment and legal AH91.00-Z-0000-10A requirements when working with, handling and storing pyrotechnical components Remove/install

1 Remove cover below dashboard (left) AR68.10-P-1500SR 2 Remove glove compartment AR68.10-P-1402SR 3 Remove instrument cluster AR54.30-P-6015SR 4 Remove trim from left and right A-pillar AR68.30-P-4050SR 5.1 Unclip cover from windshield with wedge and Model 453.0/4 unscrew bolts (18) Model 453.3 except code P02 (car2go) 110589035900 Mounting wedge 5.2 Remove cover for card reader from instrument Model 453.3 panel and unscrew bolt (18) with code P02 (car2go) AR68.10-P-1580SR 6 Remove card and key storage module Model 453.3 (except 453.391) with code P02 (car2go) AR80.57-P-0002SR 7 Disconnect electrical connector from additional Model 453 instrument with code V31 (Dashboard instruments (cockpit clock and rev counter)) 8 Remove screw/bolt (15, 16, 17) 9 Remove bolts (19) BA91.60-P-1001-01C Bolt, front passenger airbag unit to instrument panel support 10 Remove bolts (20) 11 Disconnect battery ground line AR54.10-P-0003SR 12 Disconnect electrical connector from passenger airbag squib (R12/8) 13 Disconnect electrical connectors from climate control operating unit (N20) 14 Remove wire from climate control operating Model 453 unit (N20) except code I01 (Air conditioning Plus) 15 Lift instrument panel (1) until electrical Helper required.

connectors on instrument panel switch group (S6/1) are accessible 16 Disconnect electrical connectors from instrument panel switch group (S6/1) 17 Disconnect electrical connector from center Model 453 (except 453.041/341) instrument panel speaker with code 810 (Sound system) 18 Remove instrument panel (1) through Helper required.

passenger door 19 Remove climate control operating unit (N20) When replacing instrument panel (1). 20 Remove additional instrument Model 453 with code V31 (Dashboard instruments (cockpit clock and rev counter)) When replacing instrument panel (1). AR54.30-P-6080SR 21 Remove passenger airbag When replacing instrument panel (1). AR91.60-P-0680SR 22 Remove instrument panel switch group (S6/1) When replacing instrument panel (1). AR54.25-P-1003SR 23 Remove side air vents When replacing instrument panel (1). AR68.10-P-1100SR 24 Remove center air vents When replacing instrument panel (1). AR68.10-P-1150SR 25 Install in the reverse order Check

26 Check Supplemental Restraint System (SRS) with diagnostic system AD00.00-P-2000-06SR

Airbag Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1000sr, Remove/install dashboard Model 453

AR68.10-P-1020FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2884 · Applies to: 453 · AR: AR68.10-P-1020FF

Remove/install dashboard top section 12.04.2019 Model 454.0 Modification notes 16.03.2005 Disconnect electrical connector from the front passenger Operation step 18 airbag squib, added Shown on vehicle with code (V56) auxiliary instruments and coolant display 1 Dashboard top section A15x1 Connector for auxiliary instruments (for code (V56) auxiliary instruments and coolant display) P68.10-3402-06 P68.10-3068-09 1 Dashboard top section 3 Bolts 5 Screw 2 Wiring harness 4 Steering wheel Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1020ff, Remove/install dashboard top section Model 454.0

AR68.10-P-1400FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2887 · Applies to: 453 · AR: AR68.10-P-1400FF, AR68.10-P-1200FF, AR68.30-P-4010FF, AR68.20-P-2350FG

Remove/install glove compartment 13.8.03 MODEL 454.0 P68.10-3041-09 Shown on vehicle with code (LHD) Left-hand steering 1 Glove compartment lid 5 Bolts 9 Plug 2 Paneling 6 Glove compartment 10 Guide 3 Center console cover 7 Footwell paneling 4 Bolt 8 Retaining clamp E13/1 Glove compartment lamp Removal/installation

1 Remove glove compartment cover (1) AR68.10-P-1200FF 2 Remove footwell paneling (7) AR68.30-P-4010FF On vehicles with code (LHD) left-hand steering remove right paneling and on vehicles with code (RHD) right-hand steering remove left paneling 3 Remove center console cover (3) at front AR68.20-P-2350FG 4 Pull paneling (2) out of retaining clips downward and remove 5 Unscrew bolts (4, 5) 6 Unclip glove compartment (6) from retaining Installation:

Ensure that retaining clips clips (arrows) and lower until plug (9) and (arrows) and guide (10) are seated properly. retaining clip (8) are accessible 7 Disconnect plug (9) from glove compartment lamp (E13/1) and loosen retaining clip (8) 8 Remove glove compartment (6) 9.1 Unclip glove compartment lamp (E13/1) When replacing glove compartment (6). 10 Install in the reverse order 11 Check glove compartment lamp (E13/1) for proper function Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1400ff, Remove/install glove compartment MODEL 454.0

AR68.10-P-1402SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2888 · Applies to: 453 · AR: AR68.10-P-1402SR, AR68.10-P-1498SR

Remove/install glove compartment 04.08.2014 MODEL 453 Shown on MODEL 453.###1 with code I63 (Lockable glove compartment) 1 Glove compartment 2 Side paneling 3 Cover P68.10-4718-05 Shown on MODEL 453.###1 with code I63 (Lockable glove compartment) 1 Glove compartment 15 Bolts E13/1 Glove box lamp E17/15 Right front footwell lamp P68.10-4719-12 Remove/install

1 Move front passenger seat towards the rear 2 Unclip side paneling (2) and remove Removal: The passenger airbag shutoff

switch (S68/15) must not be removed. 3 Unclip cover (3) 4 Remove panel at bottom for center AR68.10-P-1498SR instrument panel 5 Unscrew bolts (15) and lay glove compartment (1) down in footwell 6 MODEL 453.0 (except 453.041) Unclip cable tie and disconnect electrical with CODE 877 (ambient lighting) connector from right front footwell lamp (E17/15) MODEL 453.3 (except 453.341) with CODE 877 (ambient lighting) *452589016300 Clip remover 7 Disconnect electrical connector from glove compartment lamp (E13/1) 8 Remove glove compartment (1) from vehicle 9 Remove glove compartment lamp (E13/1) When replacing glove compartment (1). Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1402sr, Remove/install glove compartment MODEL 453

AR68.10-P-1200FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2890 · Applies to: 453 · AR: AR68.10-P-1200FF

Remove/install glove compartment lid 13.11.03 MODEL 454.0 P68.10-3039-08 1 Glove compartment lid 3 Bracket 2 Guide 4 Bracket Remove/install

1 Open glove compartment lid (1) 2 Unhook mount (4) for glove compartment Unhook bracket (4) carefully to prevent cover (1) first at right and then at left damaging glove compartment cover (1) Installation:

Before inserting glove compartment cover (1) check whether stop buffers are seated properly in brackets (4). 3 Fold glove compartment cover (1) downward and unhook bracket (3) from guide (2) 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1200ff, Remove/install glove compartment lid MODEL 454.0

AR68.10-P-1000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2891 · Applies to: 453 · AR: AR68.10-P-1000FF

Remove/install instrument panel 11.5.06 MODEL 454.0 Shown on vehicle with code (LHD) Left- hand steering 1 Instrument panel bottom section P68.10-3130-05 P68.10-3411-09 Shown on vehicle with code (LHD) Left- hand drive vehicle 1 Instrument panel bottom section 3 Guide 5 Center console reinforcement 2 Trim 4 Catch hook 6 Bolt Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1000ff, Remove/install instrument panel MODEL 454.0

AR68.10-P-1580SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2893 · Applies to: 453 · AR: AR68.10-P-1580SR, AR54.30-P-2000SR

Remove/install instrument panel cover 2.7.15 Model 453.3 with code P02 (car2go) 1 Cover 2 Bolts 3 Fastening bracket A50/5 Card reader P68.10-4869-06 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Switch off ignition and remove key from ignition lock 2 Remove card reader (A50/5) on windshield AR54.30-P-2000SR 3 Unclip cover (1) and remove *452589016300 Clip remover 4 Remove screws (2) 5 Unclip mounting console (3) and remove Installation: Ensure that electrical wiring

harnesses are seated correctly. *452589016300 Clip remover 6 Install in the reverse order 452 589 01 63 00 Clip remover Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1580sr, Remove/install instrument panel cover Model 453.3 with code P02 (car2go)

AR68.10-P-1498SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2894 · Applies to: 453 · AR: AR68.10-P-1498SR, AR68.20-P-2000SR, AR68.20-P-2340SR

Remove/install lower center cover for instrument panel 31.03.2016 Model 453 1 Cover 2 Bolts 3 Retaining clips P68.10-4744-06 Remove/install

1 Remove center console AR68.20-P-2000SR 2.1 Remove center mounting console Model 453 with code J58 (Center console with drawer) reinforcement Model 453 with code J59 (Center armrest) AR68.20-P-2340SR 2.2 Remove front part of center console below Model 453 paneling (1) with code J56 (Centre console) 3 Unscrew bolts (2) 4 Unclip paneling (1) Installation: Check retaining clips (3) for

damage. *110589035900 Mounting wedge for damage Replace corresponding retaining clips (3) 5 Install in the reverse order 110 589 03 59 00 Mounting wedge Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1498sr, Remove/install lower center cover for instrument panel Model 453

AR68.10-P-1100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2895 · Applies to: 453 · AR: AR68.10-P-1100FF

Remove/install side air nozzle 13.8.03 MODEL 454.0 1 Air nozzle 2 Instrument panel top section P68.10-3173-11 P68.10-3171-09 1 Air nozzle 3 Vent cover 5 Retaining clamp 2 Instrument panel top section 4 Remover 6 Retaining clamp Remove

1 Set air distribution to windshield See Operating Instructions 2 Move vent grate (3) on air nozzle (1) to slightly open position 3 Insert remover (4) between ventilation grate (3) and air nozzle housing (1) Remover for air nozzles WF58.50-P-6810-03FF

4 Turn remover (4) to 90° to left and position The retaining clamp (6) is located at the against retaining clamp (6) center below the air nozzle. 5 Pull remover (4) out of air nozzle (1) approx. 2 cm, to release tension on retaining clamp (6) 6 Pull air nozzle (1) carefully approx. 2 cm out Pull air nozzle (1) carefully out of upper of upper part of instrument panel (2) with part of instrument panel (2), otherwise the retainer (4) retaining clips (5, 6) can fall into the ventilation shaft. The retaining clamps (5) are located approx. 10° from the middle in the upper area. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1100ff, Remove/install side air nozzle MODEL 454.0

AR68.10-P-1100SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2897 · Applies to: 453 · AR: AR68.10-P-1100SR

Remove/install side air vent 22.03.2016 Model 453 P68.10-5019-08 Shown on right side of vehicle 1 Side vent 1.2 Hook 1.1 Catch hook Remove/install

1 Lift catch hooks (1.1) and pull out side air

vent (1) Lift catch hooks (1.1) only slightly. Otherwise they can deform and the side air vent (1) is not held securely. The left side air vent (1) is equipped with

three catch hooks (1.1). A fixed hook (1.2) is attached to the right side air vent (1) instead of a third catch hook (1.1). *140589023300 Extraction hook 2 Install in the reverse order 140 589 02 33 00 Extraction hook Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1100sr, Remove/install side air vent Model 453

AR68.10-P-1511FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2898 · Applies to: 453 · AR: AR68.10-P-1511FF

Remove/install stowage net on instrument panel 20.1.04 MODEL 454.0 With retrofitted stowage net 1 Stowage net 2 Expansion clip 3 Instrument panel P68.10-3120-11 Remove/Install

1 Remove expansion clips (2) Replace damaged expansion clips (2) 2 Pivot stowage net (1) toward rear and remove Installation:

Ensure that frame on upward from instrument panel (3) stowage net (1) is flush with instrument panel (3). 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.10-p-1511ff, Remove/install stowage net on instrument panel MODEL 454.0 With retrofitted stowage net

SM68.10-P-0008A

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2899 · Applies to: 453 · AR: AR68.10-P-1000SR

Replace instrument panel (code: 1705P68B42) 19.07.2017 Model 453 Operation no. of the operation texts or standard texts and flat rates Category Op. no. Operation text Time Acc. no. Code P 02-4926 Replace instrument panel Check

1 Check whether vehicle is affected by measure. Model 453 as of 111896 up to 124176 SM68.10-P-0008-01AAA Install

2 Replace instrument panel. AR68.10-P-1000SR

Before starting work, check there is no

Supplemental Restraint System (SRS) fault message in the instrument cluster! If an SRS fault message is present, it must be rectified. Operation step 26 "Check Supplemental

Restraint System (SRS) using vehicle diagnosis system" is not necessary. Check

3 Turn key in electronic ignition lock to position 1 This means that the SRS check after

and check if the restraint system warning lamp replacing the instrument panel is then fully permanently goes off after a few seconds. assured. Parts ordering note Part no. Designation Quantity * Instrument panel (Starbucks Edition "coffee launcher") 1 * Parts are to be ordered via your market. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, sm68.10-p-0008a, Replace instrument panel (code: 1705P68B42) Model 453

AZ68.10-P-0002SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2902 · Applies to: 453 · AR: AZ68.10-P-0002SR, AR68.10-P-1100SR, AR82.85-P-2000SR, AR82.60-P-7502SR

Retrofit trim piece on instrument panel 01.03.2018 Model 453.0/3/4 with code 535 (smart Media system) Model 453.0/3/4 with code 537 (smart Audio system) P68.10-4977-08 1 Trim piece 2 Trim piece Remove

1 Unclip cover from instrument cover toward *110589035900 Mounting wedge steering wheel 2 Remove side air vent on driver side AR68.10-P-1100SR

3.1 Remove communication unit Model 453.0/3/4 with code 535 (smart Media system) AR82.85-P-2000SR

3.2 Remove radio Model 453.0/3/4 with code 537 (smart Audio system) AR82.60-P-7502SR

Install

4 Install trim pieces (1, 2) on instrument panel AZ68.10-P-0002-01SR Cleaner *BR00.45-Z-1025-04A 5 Install remaining parts Update Vehicle Documentation (VeDoc) 6 Attach note for trim piece in instrument panel retrofitted according to AZ68.10-P-0002SR under field organization texts to DG (KG) 68 110 589 03 59 00 Mounting wedge Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az68.10-p-0002sr, Retrofit trim piece on instrument panel Model 453.0/3/4 with code 535 (smart Media system) Model 453.0/3/4 with code 537 (smart Audio system)

AR68.20-P-2510FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2905 · Applies to: 453 · AR: AR68.20-P-2510FF

Remove/install CD box 17.1.06 MODEL 454.0 with CODE (I03) 1-disk CD box 1 CD box 2 Bracket 3 Bolts 4 Center console cover at front P68.20-3027-04 Remove/install

1 Pull CD box (1) out of bracket (2) toward rear Installation: CD box (1) should catch

audibly when sliding into bracket (2) 2.1 Undo screws (3) and remove bracket (2) of When replacing bracket (2). front center console cover (4) 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2510ff, Remove/install CD box MODEL 454.0 with CODE (I03) 1-disk CD box

AR68.20-P-2026SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2906 · Applies to: 453 · AR: AR68.20-P-2026SR

Remove/install armrest on center console 19.11.2018 Model 453 with code J59 (Center armrest) Shown on model 453.3 1 Armrest P68.20-5083-06 Shown on model 453.3 1 Armrest 2 Cover 3 Bolts A90/5 Multimedia connection unit (with code 535 (smart media system), code 556 (Radio 56A MM2012 with DAB and PREMIUM SOUND), code 557 (Radio 57A MM2012 without DAB) or code 558 (smart Media system with DAB)) P68.20-5085-12 Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Remove/install

1 Switch off ignition and remove transmitter key 2 Move both front seats forward 3 Fold both front backrest toward front Model 453.3/4 with code J59 (Center armrest) 4 Unclip left and right cover (2) *110589035900 Mounting wedge 5 Remove bolts (3) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2026sr, Remove/install armrest on center console Model 453 with code J59 (Center armrest)

AR68.20-P-2025FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2908 · Applies to: 453 · AR: AR68.20-P-2025FF

Remove/install center armrest 12.12.03 MODEL 454.0 with CODE (S29) Multifunction armrest (DFO/FFO) With retrofitted center armrest 1 Multifunction armrest 2 Cover 3 Cover 4 Left paneling 5 Right paneling 6 Center console 7 Bolts P68.20-3065-06 Removal/installation

1 Move driver and passenger seat toward front See Operating Instructions to end position 2 Unclip rear cover (2) from center console *452589016300

3 Unclip cover (3) with suitable screwdriver 4 Loosen left paneling (4) and right paneling (5) from one another and remove from center console (6) 5 Unscrew bolts (7) and remove multifunction *BA68.20-P-1003-01C

armrest (1) 6 Install in the reverse order Center armrest

Number Designation Model 454.0 BA68.20-P-1003-01C Bolts, center armrest to carrier plate Nm 22 452 589 01 63 00 Snap-release tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2025ff, Remove/install center armrest MODEL 454.0 with CODE (S29) Multifunction armrest (DFO/FFO) With retrofitted center armrest

AR68.20-P-2000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2909 · Applies to: 453 · AR: AR68.20-P-2000FF, AR68.20-P-2350FF, AR68.20-P-2310FF, AR68.20-P-2025FF

Remove/install center console 13.8.03 MODEL 454.0 P68.20-2984-07 1 Bolt 3 Cover 5 Shift lever cover 2 Center console 4 Rear center console cover 6 Retaining clip 7 Bolt Remove/install

1 Remove center console cover (4) AR68.20-P-2350FF 2 Remove shift lever cover (5) AR68.20-P-2310FF 3.1 Remove center armrest Only on vehicles with code (S29) Multi- AR68.20-P-2025FF function armrest (DFO/FFO) 3.2 Unclip cover (3) with suitable tool Only on vehicles without code (S29) Multi- function armrest (DFO/FFO) 4 Unscrew bolt (1) below cover (3) 5 Unclip retaining clip (6) 6 Unscrew bolts (7) 7 Remove center console (2). Observe installation position of electric leads 8 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2000ff, Remove/install center console MODEL 454.0

AR68.20-P-2000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2910 · Applies to: 453 · AR: AR68.20-P-2000SR

Remove/install center console 20.01.2020 Model 453 Modification notes 15.01.2020 Remove drawer (7). Operation step 13. 15.01.2020 Remove screws (6). Operation step 14. Shown on model 453.3 with transmission 700.122 and code J58 (Center console with drawer) 1 Center console 2 Cup holder (except code J59 (Center armrest)) 3 Screw 4 Left side paneling 5 Right side paneling 15 Mounting clip P68.20-4774-06 P68.20-A022-09 Shown on model 453.3 with transmission 710.410 and code J58 (Center console with drawer) 6 Bolts 7 Drawer Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2000sr, Remove/install center console Model 453

Topical note

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2911 · Applies to: 453 · AR: AR68.20-P-2350SR, AR68.20-P-2026SR

Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Remove/install

1 Remove front cover of center console (1). AR68.20-P-2350SR 2 Move driver seat forward. 3 Fold seat backrest of driver's seat toward front.Model 453.3/4 4 Remove screw of cup holder (2). Model 453 except code J59 (Center armrest) 5.1 Remove armrest of center console (1). Model 453 with code J59 (Center armrest) AR68.20-P-2026SR 5.2 Unclip cup holder (2) upwards and release and Model 453 disconnect electrical connectors. except code J59 (Center armrest)

Do not crush or kink or subject electric lines to tension. This will result in damage to the electric lines and can impair their function. 6 Unclip retaining clip (15) of wiring harness from center console (1). 7 Remove bolt (3) . 8 Move driver and front passenger seat toward rear. 9 Fold seat backrest of driver and front Model 453.3/4 passenger seat toward rear. 10 Move selector lever into neutral position. Model 453 with transmission 700.41 11 Pull parking brake lever as far as seventh detent. 12 Remove left side trim (4) and right side trim (5) from center console (1). 13 Remove drawer (7) upwards. Model 453 with code J58 (Center console with drawer) 14 Remove screws (6). 15 Release center console (1) at front and remove. 16 Install in the reverse order. Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2000sr, Remove/install center console Model 453

AR68.20-P-2340FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2912 · Applies to: 453 · AR: AR68.20-P-2340FF, AR82.60-P-7502FG

Remove/install center console reinforcement 16.8.06 MODEL 454.0 P68.10-3486-09 1 Heater operating unit/ventilation 2 Catch hook N22 AAC control and operating unit (without code (I01) Air conditioning (with code (I01) Air conditioning 3 Bolt plus or code (I77) Manual air plus or code (I77) Manual air conditioning) conditioning) P68.10-3487-09 Shown without AAC control and operating unit or heater/ventilation operating unit 6 Bolt N72/1 Upper control panel control unit 4 Bottom section of instrument panel 7 Center console reinforcement 5 Bolt (up to production date 13.1.05) 8 Connector Remove/install

1.1 Remove radio For vehicles with code (C28) smart radio five AR82.60-P-7502FG Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2340ff, Remove/install center console reinforcement MODEL 454.0

AR68.20-P-2340SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2914 · Applies to: 453 · AR: AR68.20-P-2340SR, AR68.20-P-2000SR

Remove/install center console reinforcement 31.03.2016 Model 453 with code J58 (Center console with drawer) Model 453 with code J59 (Center armrest) 1 Center console reinforcement 2 Drawer 3 Retaining clips 4 Side paneling 5 Bolts 6 Cover 7 Bolts P68.20-5039-06 Remove/install

1 Remove center console AR68.20-P-2000SR 2 Open drawer (2) 3 Unscrew screws (5) and remove cover (6) 4 Unclip side paneling (4) and lay down to side Installation:

Check retaining clips (3) for damage. for damage Replace corresponding retaining clips (3) 5 Unscrew bolts (7) and remove center console reinforcement (1) 6 Remove drawer (2) from center console When replacing center console reinforcement reinforcement (1) (1) 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2340sr, Remove/install center console reinforcement Model 453 with code J58 (Center console with drawer) Model 453 with code J59 (Center armrest)

AR68.20-P-2350FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2915 · Applies to: 453 · AR: AR68.20-P-2350FF

Remove/install cover on center console 28.1.04 MODEL 454.0 Rear cover on center console P68.20-3015-07 1 Cover 6 Electrical connection for passenger-side power window 2 Hand brake lever 3 Electrical connection for left rear power window (with code S21/1 Driver-side power window switch (V34) Rear power window (FFO)) S21/2 Passenger-side power window switch 4 Electrical connection for right rear power window (with S21/3 Left rear power window switch (with code (V34) Rear code (V34) Rear power window (FFO)) power window (FFO)) 5 Electrical connection for driver-side power window S21/4 Right rear power window switch (with code (V34) Rear power window (FFO)) Removal/installation

1 Move hand brake lever (2) to uppermost position 2 Unclip (1) in marked areas (arrows) and lift at Carefully unclip cover (1) to prevent rear scratching and breakage 3.1 Disconnect electrical connection for left rear On vehicles with code (V34) Rear power power window (3) from left rear power window window (FFO) switch (S21/3) and electrical connection for right rear power window (4) from right rear power window switch (S21/4) 4 Disconnect electrical connection for driver- side power window (5) from driver-side power window switch (S21/1) and electrical connection for passenger-side power window (6) from passenger-side power window switch (S21/2) 5 Remove cover (1) 6 Install in the reverse order 7 Perform function check Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2350ff, Remove/install cover on center console MODEL 454.0 Rear cover on center console

AR68.20-P-2350FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2916 · Applies to: 453 · AR: AR68.20-P-2350FG

Remove/install cover on center console 20.3.06 MODEL 454.0 Cover on front center console P68.20-3226-07 Shown on vehicles up to production date 3.4.06 with code (I01) Plus air conditioning 1 Center console cover 3 Outer cover (up to production date 4 Rotary switch (up to production date 2 Inner cover (up to production date 2.4.06 or as of production date 2.4.06 or as of production date 2.4.06 or as of production date 3.4.06 without code (I01) Plus air 3.4.06 without code (I01) Plus air 3.4.06 without code (I01) Plus air conditioning) conditioning) conditioning) 5 Bolt Shown on vehicle as of production date 3.4.06 with code (I01) Plus air conditioning 1 Center console cover 6 Rotary switch (as of production date 3.4.06 with code (I01) Plus air conditioning) P68.20-3595-01 Remove/install

1.1 Turn rotary switch (6) until markings (arrows) On vehicles as of production date 3.4.06 with vertically point upward and carefully remove code (I01) Plus air conditioning rotary switch (6). Installation:

Observe position of rotary switch (6). 1.2 Carefully remove rotary switch (4). On vehicles up to production date 2.4.06 and on vehicles as of production date 3.4.06 without code (I01) Plus air conditioning Installation:

Observe position of rotary switch (6). 2.1 Unclip inner coverings (2) with suitable tool. On vehicles up to production date 2.4.06 and on vehicles as of production date 3.4.06 without code (I01) Plus air conditioning Carefully unclip inner coverings (2), otherwise, brackets can break out. Installation:

Observe installation position of inner coverings (2). 3.1 Loosen outer coverings (2) by turning approx. On vehicles up to production date 2.4.06 and 45° to left and remove. on vehicles as of production date 3.4.06 without code (I01) Plus air conditioning Carefully loosen outer coverings (3), otherwise brackets can break out. Installation:

Note installation position of outer coverings (3). 4 Unscrew bolts (5) in bottom area of center console cover (1) 5 Unclip center console cover (1) from bottom to top 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2350fg, Remove/install cover on center console MODEL 454.0 Cover on front center console

AR68.20-P-2350SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2917 · Applies to: 453 · AR: AR68.20-P-2350SR

Remove/install cover on center console 22.03.2016 Model 453 Shown on model 453.3 with transmission 700.122 and code J58 (Center console with drawer) 1 Center console cover 5 Shift gate cover (with transmission 700.12, 711.649) P68.20-5032-11 Shown on model 453.4 with transmission 700.411 1 Center console cover 2 Transmission position display (with transmission 700.41) 3 Electrical connector (model 453.4) 4 Electrical connector (with transmission 700.41) P68.20-5031-06 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Switch on ignition Model 453 with transmission 700.41 2 Move selector lever to travel direction Model 453 with transmission 700.41 3 Switch off ignition 4 Unclip center console cover (1) 452589016300 Clip remover 5 Unclip transmission position display (2) from Model 453 with transmission 700.41 bottom as shown and disconnect electrical connector 6 Disconnect electrical connector (3) Model 453.4 7 Disconnect electrical connection (4) Model 453 with transmission 700.41 8 Unclip shift gate cover (5) from center console Model 453 with transmission 700.12, 711.649 cover (1) 452589016300 Clip remover 9 Guide shift gate cover (5) through center Model 453 with transmission 700.12, 711.649 console cover (1) Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar68.20-p-2350sr, Remove/install cover on center console Model 453

AR68.20-P-2040FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2919 · Applies to: 453 · AR: AR68.20-P-2040FF, AR91.10-P-1000FF, AR68.30-P-4010FF, AR68.30-P-4100FF, AR68.20-P-2000FF (+2 more)

Remove/install floor covering 13.8.03 MODEL 454.0 Front floor covering P68.20-2980-09 1 Accelerator pedal stop 5 Rear floor covering 8 Wiring harness 2 Front floor covering 6 Fire extinguisher mount (with code 9 CD changer wiring harness (with (H21) Fire extinguisher (FFO)) code (C20) CD changer (FFO)) 3 Wiring harness 7 Bolt (with code (H21) Fire 10 Bass module speaker wiring harness 4 Hand brake lever extinguisher (FFO)) (with code (C22) Sound package (FFO)) Remove/install

1 Remove front seats AR91.10-P-1000FF 2 Remove footwell paneling AR68.30-P-4010FF 3 Remove right and left door sill molding AR68.30-P-4100FF 4 Remove center console AR68.20-P-2000FF 5.1 Remove bass module speaker Only on vehicles with code (C22) Sound AR82.62-P-7839FF package (FFO) 6.1 Remove CD changer Only on vehicles with code (C20) CD changer AR82.64-P-7508FF (FFO) 7.1 Unscrew bolts (7) from fire extinguisher Only on vehicles with code (H21) Fire bracket (6) extinguisher (FFO) 8.1 Remove fire extinguisher bracket (6) Only on vehicles with code (H21) Fire extinguisher (FFO) 9.1 Route CD changer wiring harness (9) through Only on vehicles with code (C20) CD changer opening in front floor covering (2) (FFO) 10 Route wiring harnesses (8) through openings in front floor covering (2) 11 Expose front floor covering (2) in area of rear floor covering (5) 12 Lift front floor covering (8) in rear area and On vehicles with code (C22) Sound guide over hand brake lever (4) package (FFO) carefully lift front floor covering (2) to prevent damage to the bass module speaker wiring harness (10). 13.1 Route bass module speaker wiring harness Only on vehicles with code (C22) Sound (10) through opening in front floor covering (2) package (FFO) 14 Lift front floor covering (2) and guide toward Installation:

Ensure that it is routed rear while routing wiring harness (3) through properly in area of accelerator stop (1) opening in front floor covering (2) 15 Remove front floor covering (2) 16 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2040ff, Remove/install floor covering MODEL 454.0 Front floor covering

AR68.20-P-2040SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2920 · Applies to: 453 · AR: AR68.20-P-2040SR, AR91.10-P-1000SR, AR68.30-P-1340SR, AR91.12-P-1021SR, AR68.20-P-2000SR (+1 more)

Remove/install floor covering 15.07.2016 Model 453 6 Lower A-pillar trim 8 Edge guard 9 Screw X11/4 Diagnostic connector P68.20-4777-06 Shown on model 453.0 10 Floor covering 11 Electrical connector 12 Retaining clamp P68.20-4783-06 Remove/install

1 Remove front seats AR91.10-P-1000SR 2 Remove foot support on passenger side AR68.30-P-1340SR 3 Remove rear seat cushion Model 453.0 AR91.12-P-1021SR 4 Remove center console AR68.20-P-2000SR 5.1 Remove center mounting console Model 453 with code J58 (Center console with drawer) reinforcement Model 453 with code J59 (Center armrest) AR68.20-P-2340SR Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2040sr, Remove/install floor covering Model 453

Remove front section of center console below Model 453

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2921 · Applies to: 453 · AR: AR68.30-P-4100SR, AR68.30-P-4100SB

5.2 Remove front section of center console below Model 453 center instrument panel with code J56 (Center console) 6.1 Partially detach door sill on left and right Model 453.0 AR68.30-P-4100SR 6.2 Remove left and right door sill Model 453.3/4 Remove/install door sill molding AR68.30-P-4100SB 7 Partially loosen edge guard (8) on left and right 8 Unscrew bolts (9) and unclip left und right bottom A-pillar paneling (6) 9 Unclip diagnostic connector (X11/4) toward The diagnostic connector (X11/4) is

inside installed on the driver side. 10 Remove bottom A-pillar paneling (6) on left and right 11 Unhook floor covering (10) from retaining clips (12) 12 Guide electrical connectors (11) through floor covering (10) 13 Remove floor covering (10) Helper required.

14 Install in the reverse order Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2040sr, Remove/install floor covering Model 453

AR68.20-P-4800FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2922 · Applies to: 453 · AR: AR68.20-P-4800FF, AR91.10-P-1000FF, AR91.21-P-4000FF, AR68.30-P-4100FF, AR68.20-P-2000FF (+2 more)

Remove/install floor covering in rear 13.8.03 MODEL 454.0 P68.20-2962-08 1 Bolt 4 Rear bench seat 7 Power window switch wiring harnesses 2 Front seats 5 Rear floor covering 8 Paneling 3 Door sill molding 6 Front floor covering Remove/Install

1 Remove front seats (2) AR91.10-P-1000FF 2 Remove rear bench seat (4) AR91.21-P-4000FF 3 Remove left and right door sill molding (3) AR68.30-P-4100FF 4 Remove center console AR68.20-P-2000FF 5.1 Remove subwoofer speaker On vehicles with code (C22) Sound package AR82.62-P-7839FF (FFO) 6.1 Remove CD changer On vehicles with code (C20) CD changer AR82.64-P-7508FF (FFO) 7 Unscrew bolts (1) from left and right belt end *BA91.40-P-1001-01J

fitting 8 Route power window switch (7) through openings in rear floor covering (5) 9 Expose rear floor covering (5) in area of paneling (8) and front floor covering (6) 10 Expose rear floor covering (5) in area of hand brake lever 11 Remove rear floor covering (5) from vehicle 12 Install in the reverse order Seat belts/emergency tensioning retractors

Number Designation Model 454.0 BA91.40-P-1001-01J Bolt, belt end fitting to body Nm 45 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-4800ff, Remove/install floor covering in rear MODEL 454.0

AR68.20-P-2310FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2923 · Applies to: 453 · AR: AR68.20-P-2310FF

Remove/install gearshift lever cover 13.11.03 MODEL 454.0 P68.20-2981-08 1 Shift lever boot 7 Electrical connector (with code (I32) Smoker set (FFO)) 2 Ashtray 8 Retainer lock (with code (I32) Smoker set (FFO)) 3 Shift lever cover 9 Bracket 4 Electrical connector 5 Guide E16 Automatic child seat recognition airbag OFF indicator lamp 6 Latching hook Remove/install

1.1 Remove ashtray (2) Only on vehicles with code (I32) Smoker set (FFO) 2 Unclip catch hook (6) and lift shift lever cover Carefully unclip shift lever cover (3) to (3) prevent scratches or breakage Installation:

Ensure that guide (5) and catch hooks (6) are seated properly. 3 Lift shift lever cover (3) until electrical connector (4) is accessible 4 Disconnect electrical connector (4) from child seat recognition airbag off indicator lamp (E16) 5.1 Unplug electrical connector (7) Only on vehicles with code (I32) Smoker set (FFO) To disconnect electrical connector (7) remove retainer lock (8) 6 Unclip brackets (9) from gearshift lever boot Installation:

Gearshift lever boot (1) can (1) only be clipped in correctly in one position 7 Remove gearshift lever cover (3) Route gearshift lever boot (1) through opening in gearshift lever cover (3) 8 Install in the reverse order 9 Perform function check Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.20-p-2310ff, Remove/install gearshift lever cover MODEL 454.0

Remove paneling in footwell

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2929 · Applies to: 453 · AR: AR68.30-P-4010FF, AR86.10-P-5110FF

1 Remove paneling in footwell On vehicles with code (RHD) Remove left footwell paneling and with code (LHD) Remove right footwell paneling Remove/install paneling in footwell AR68.30-P-4010FF

2.1 Remove fire extinguisher together with On vehicles with code (H21) Fire extinguisher bracket Remove/install fire extinguisher with bracket AR86.10-P-5110FF

3.1 Move passenger seat to end position toward On vehicles without code (H21) Fire front extinguisher 4.1 Remove cover (2) from outer seat rail toward On vehicles without code (H21) Fire rear and unscrew bolt (3) extinguisher 5.1 Move front passenger seat to end position On vehicles without code (H21) Fire toward rear extinguisher 6.1 Pull out stowage shell (4) toward front On vehicles without code (H21) Fire extinguisher 7 Unclip door sill molding (5) in front area and lift 8 Fold over floor paneling (6) of passenger footwell until cover panel (7) is accessible Install

9 Install head of pressing bolt (8) into lug (9) behind cover panel (7); install bracket (10) and pull pressing bolt (8) upward until tongue on bracket (10) makes contact with cover panel (7). 10 Tighten nut (11) 11 Move floor paneling (6) back to initial position and carefully press against bracket (10) until pins on bracket (10) puncture through floor covering (6) 12 Fasten template (12) on pins for bracket (10) The template (12) is integrated in the packaging (16) of the bottle holder (1) 13 Mark passages on floor covering (6) and remove template (12) 14 Cut marked areas (arrows) out of floor covering (6) with suitable blade. 15 Move hook along rail (13) from rear through long passage in floor covering (6) and pull bottle holder (1) toward front. 16 Push back skid (14) and install bolts (15) in holes through rail (13) 17 Screw in bolts (15) To prevent distortions, screw in bolts (15)

only until rail (13) makes uniform contact to floor covering (6). 18 Push skid (14) completely toward front 19 Clip in door sill molding (5) in front area 20 Install footwell paneling On vehicles with code (RHD) Install left footwell paneling and with code (LHD) Install right footwell paneling Remove/install paneling in footwell AR68.30-P-4010FF

21.1 Install fire extinguisher with bracket On vehicles with code (H21) Fire extinguisher Remove/install fire extinguisher with bracket AR86.10-P-5110FF

22.1 Slide stowage shell (4) toward rear On vehicles without code (H21) Fire extinguisher or without retrofitted fire extinguisher. Ensure that stowage shell (4) is seated properly. 23.1 Move passenger seat to end position toward On vehicles without code (H21) Fire front extinguisher 24.1 Screw in bolt (3) On vehicles without code (H21) Fire extinguisher 25.1 Install cover (2) on outer seat rail On vehicles without code (H21) Fire extinguisher Ensure that cover (2) is seated correctly. 26.1 Move passenger seat to initial position On vehicles without code (H21) Fire extinguisher 27.1 Enter special equipment in the vehicle data Only at workshops without DMS Autoline 8.0 card and in the vehicle's online data card dealer system. Code (I10) Beverage holder Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az68.20-p-0008ff, Retrofit bottle holder MODEL 454.0

AZ68.20-P-0050FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2930 · Applies to: 453 · AR: AZ68.20-P-0050FF, AR68.20-P-2000FF

Retrofit center armrest 17.1.06 MODEL 454.0 2 Floor covering 3 Marking 4 Carrier plate 5 Bolts 6 Center console 7 Bolt P68.20-3031-06 1 Multifunction armrest 6 Center console 8 Bolts 9 Left paneling 10 Right paneling 11 Cover P68.20-3032-06 Remove

1 Move driver and passenger seat toward front to end position 2 Remove center console (6) Remove/install center console AR68.20-P-2000FF

3 Cut out floor covering (2) along marking (3) with suitable blade Install

4 Raise floor covering (2) in area of hand brake lever, slide carrier plate (4) below and align on threaded holes in vehicle floor. 5 Tighten screws (5) *BA68.20-P-1002-01C

6 Install center console (6) and fasten in rear area with bolt (7) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az68.20-p-0050ff, Retrofit center armrest MODEL 454.0

Align multifunction armrest (1) on carrier plate

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2931 · Applies to: 453 · AR: AR68.20-P-2000FF

7 Align multifunction armrest (1) on carrier plate (4) 8 Tighten bolts (8) *BA68.20-P-1003-01C

9 Insert guides for left paneling (9) into recesses Ensure that left paneling (9) is seated in center console (6). properly in center console (6) 10 Insert guides right paneling (10) into recesses Ensure that right paneling (10) is seated of center console (6) and arrest right paneling properly in center console (6) and on left (10) with left paneling (9) paneling (9) 11 Clip in cover (11) 12 Install center console (6) The rear beverage holder is no longer installed. Remove/install center console AR68.20-P-2000FF

13 Move driver and passenger seat to initial position 14.1 Enter special equipment in the vehicle data If a DMS Autoline 8.0 dealer system is not card and in the vehicle's online data card available in the workshop. Enter code (10Y) Twinface armrest. Center armrest

Number Designation Model 454.0 BA68.20-P-1002-01C Bolts, carrier plate to vehicle floor Nm 9 BA68.20-P-1003-01C Bolts, center armrest to carrier plate Nm 22 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az68.20-p-0050ff, Retrofit center armrest MODEL 454.0

AN68.30-P-0020FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2932 · Applies to: 453 · AR: AN68.30-P-0020FF, AR68.20-P-2310FF, AR68.20-P-2350FF

Install Brabus accent parts 17.1.06 MODEL 454.0 1 Instrument cluster accent trim parts 2 Accent trim parts, additional instruments (with code (V56) Additional instruments and coolant gauge) 3 Steering gear pitman arm accent trim parts 4 Gearshift lever cover accent trim part 5 Hand brake lever cover accent trim part P68.30-2974-04 Remove/install

1 Move steering column downwards 2 Unclip instrument cluster blinds 3.1 Unclip additional instrument covers For vehicles with code (V56) Additional instruments and coolant gauge 4 Unclip steering gear pitman arm end caps 5 Remove gearshift lever cover Remove/install cover on gearshift lever AR68.20-P-2310FF

6 Remove hand brake lever cover from center console Remove/install cover on center console AR68.20-P-2350FF

7 Install in the reverse order Use accent trims parts (1, 2, 3, 4, 5). 8.1 Enter special equipment in the vehicle data If a DMS Autoline 8.0 dealer system is not card and in the vehicle's online data card available in the workshop. Enter code (I73) BRABUS Carbon Design accent trim part. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, an68.30-p-0020ff, Install Brabus accent parts MODEL 454.0

AR68.30-P-4730FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2933 · Applies to: 453 · AR: AR68.30-P-4730FF

Remove/install console for luggage compartment cover 18.2.05 MODEL 454.0 with CODE (I31) Flexible luggage compartment cover 1 Luggage compartment cover 2 Luggage compartment cover console 3 Bolts P68.30-3176-03 Remove/Install

1 Remove luggage compartment cover (1) 2 Unscrew bolts (3) from left and right luggage compartment cover console (2) 3 Remove left and right luggage compartment cover console (2) 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4730ff, Remove/install console for luggage compartment cover MODEL 454.0 with CODE (I31) Flexible luggage compartment cover

AR68.30-P-4100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2934 · Applies to: 453 · AR: AR68.30-P-4100FF, AR68.30-P-4700FF

Remove/install door sill molding 13.8.03 MODEL 454.0 1 Rear door edge guard 2 Retaining clip 3 Front door edge guard 4 Footwell paneling 5 Entrance plate P68.30-2880-04 Remove/install

1 Remove bottom paneling from B-pillar AR68.30-P-4700FF 2 Remove rear door edge guard (1) and front Door sill moldings shown with seat door edge guard (3) in area of door sill removed for better illustration molding (5) and footwell paneling (4). 3 Loosen footwell paneling (4) in area of door sill molding 4 Remove retaining clips (2) from door sill molding (5). 5 Unclip door sill molding (5) in marked areas Unclip door sill molding (5) carefully to (arrows) from rear toward front with suitable prevent scratching and breakage. tool 6 Unhook guide lug on footwell paneling (4) from door sill molding (4) and move door sill molding (5) toward rear. 7 Remove door sill molding (5). Handle door sill molding (5) carefully to prevent scratching and breakage. Installation:

Ensure that seat belt is routed properly. 8 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4100ff, Remove/install door sill molding MODEL 454.0

AR68.30-P-4100FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2935 · Applies to: 453 · AR: AR68.30-P-4100FG

Remove/install door sill molding 14.2.05 MODEL 454.0 with CODE (I54) Door sill molding (DFO) P68.30-3165-08 1 Door sill molding a Dimension b Dimension Remove

1 Remove door sill molding (1) from longitudinal member outer shell Install

2 Clean longitudinal member outer shell in area of door sill molding (1) with suitable agents. 3 Place door sill molding (1) on longitudinal Dimension (a) is 133 mm and dimension member outer shell and align according to (b) 13.4 mm. dimensions (a, b) 4 Mark position of door sill molding (1) with suitable adhesive tape on longitudinal member outer shell 5 Remove protective foil of adhesive strips from door sill molding (1) and place door sill molding (1) on longitudinal member outer shell according to markings installed and press in firmly Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4100fg, Remove/install door sill molding MODEL 454.0 with CODE (I54) Door sill molding (DFO)

AR68.30-P-4100SB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2936 · Applies to: 453 · AR: AR68.30-P-4100SB

Remove/install door sill molding 18.07.2016 Model 453.3/4 1 Door sill 2 Cap 3 Mounting clip 4 Edge guard A Mounting clip P68.30-3941-05 Remove/install

1 Move seat to forward position 2 Release belt end fitting threaded connection BA91.40-P-1004-01SR Bolt, belt end fitting to B-pillar 3 Loosen lower B-pillar paneling 4 Move seat to rear-most position 5 Remove cap (2) from guide rail 110589035900 Mounting wedge 6 Loosen edge guard (4) on door in area of door sill (1) 7 Loosen retaining clip (3) 452589016300 Clip remover 8 Lift door sill (1), loosen retaining clip (A) 452589016300 Clip remover 9 Remove door sill (1) from B-pillar paneling in Installation: Check retaining clip of door

area of arrow B sill (1), replace if necessary. 10 Install in the reverse order Seat belts/emergency tensioning retractors Number Designation Model 453.3 Model 453.4 BA91.40-P-1004-01SR Bolt, belt end fitting to B-pillar Nm 21 21 452 589 01 63 00 110 589 03 59 00 Clip remover Mounting wedge Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4100sb, Remove/install door sill molding Model 453.3/4

AR68.30-P-4400SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2937 · Applies to: 453 · AR: AR68.30-P-4400SR

Remove/install eyeglass compartment on roof 04.08.2014 MODEL 453 with CODE B18 (Spectacles compartment for driver) Shown on MODEL 453.0 1 Eyeglass compartment 2 Wedge 3 Hinge 4 Retaining clip P68.30-3760-06 Remove/install

1 Open glasses compartment (1) and unclip wedge (2) from hinge (3) 2 Loosen retaining clip (4) at top and bottom with suitable tool ad remove glasses compartment (1) 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4400sr, Remove/install eyeglass compartment on roof MODEL 453 with CODE B18 (Spectacles compartment for driver)

AR68.30-P-1340SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2938 · Applies to: 453 · AR: AR68.30-P-1340SR

Remove/install footrest on passenger side 21.07.2014 MODEL 453 Shown on MODEL 453.0 with CODE 224 Fire extinguisher 1 Passenger side footrest 2 Nuts P68.30-3764-05 Remove/install

1 Move passenger seat toward rear
2 Unscrew nuts (2) 3 Remove footrest on passenger side (1) 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-1340sr, Remove/install footrest on passenger side MODEL 453

AR68.30-P-4450SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2939 · Applies to: 453 · AR: AR68.30-P-4450SRC, AR68.60-P-5480SR

Remove/install front roof frame paneling 13.1.16 Model 453.4 1 Cover 2 Bracket 3 Blind 4 Electrical connector 5 Electrical connectors 6 Electrical wiring harness P68.30-3880-06 Remove/install

1 Remove side supports 2 Remove sun visors AR68.60-P-5480SR 3 Unclip bracket (2) 110589035900 Mounting wedge 4 Unlip cover (3) 110589035900 Mounting wedge 5 Remove electrical connector (4) from paneling (1), and disconnect 6 Disconnect electrical connector (5) and place cover (3) to one side 7 Installation: Unclip paneling (1)

Ensure roof peak seal is in correct installation position. Leaks may occur otherwise.

Do not subject electrical wiring harness (6) to excessive force. Otherwise the electrical wiring harness (6) and mirror mounting paneling can be damaged. 8 Installation: Unclip electrical wiring harness (6) and

remove paneling (1) Ensure that wiring harness (6) is routed correctly. Otherwise the electrical wiring harness (6) may be damaged. 9 Install in the reverse order 110 589 03 59 00 Mounting wedge Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4450src, Remove/install front roof frame paneling Model 453.4

AR68.30-P-4330FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2940 · Applies to: 453 · AR: AR68.30-P-4330FF

Remove/install handle on roof 26.8.03 MODEL 454.0 1 Grab handle 2 Covers 3 Catch hook P68.30-2867-01 P68.30-2868-01 Remove/Install

1 Fold down grab handle (1) 2 Unclip covers (2) with suitable screwdriver 3 Simultaneously press catch hooks (2) together through assembly openings (arrows) with two suitable screwdrivers 4 Remove grab handle (1) 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4330ff, Remove/install handle on roof MODEL 454.0

AR68.30-P-4330SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2941 · Applies to: 453 · AR: AR68.30-P-4330SR

Remove/install handle on roof 16.12.15 Model 453.0/3 1 Grab of handle 2 Wedge 3 Hinge 4 Mounting clip P68.70-2022-05 Remove/install

1 Fold up grab handle (1) and unclip wedges (2) from hinges (3) 2 Loosen retaining clips (4) at top and bottom with suitable tool and remove grab handle (1) 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4330sr, Remove/install handle on roof Model 453.0/3

AR68.30-P-4300FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2942 · Applies to: 453 · AR: AR68.30-P-4300FF, AR68.30-P-4050FF, AR68.60-P-5480FF, AR82.20-P-1100FF, AR82.20-P-0110FF (+4 more)

Remove/install headliner 13.8.03 MODEL 454.0 P68.30-2866-07 Shown on vehicles with code (V29) 1 Edge guard 2 Headliner Electric glass sliding roof (FFO) Remove/Install

1 Remove paneling from A-pillar AR68.30-P-4050FF 2 Remove sun visors AR68.60-P-5480FF 3.1 Remove front overhead control panel On vehicles with code (C27) Telephone AR82.20-P-1100FF preparation including mount and antenna (DFO/FFO) or with code (V29) Electric glass sliding roof (FFO) 3.2 Remove front dome lamp On vehicles without code (C27) Telephone AR82.20-P-0110FF preparation including mount and antenna (DFO/FFO) or without code (V29) Electric glass sliding roof (FFO) 4 Remove handle from roof AR68.30-P-4330FF 5 Remove head restraints from front seats 6 Remove paneling from B-pillars AR68.30-P-4700FF 7 Remove paneling from upper C-pillars AR68.30-P-4490FF 8 Remove rear dome lamp AR82.20-P-0113FF 9 Remove clips (arrows) from headliner (2) 10 Loosen door seal in area of headliner (2) on all doors and on tailgate 11.1 Remove headliner (2) from roof paneling in Only on vehicles with code (E55) Glass roof area of grab handles with sun protection (FFO) Installation:

Ensure that headliner (2) is seated properly. 12.1 Remove edge guard (1) for headliner (2) in Only on vehicles with code (V29) Electric area of glass sliding roof glass sliding roof (FFO) 13 Remove headliner (2) over trunk diagonal Remove headliner (2) carefully because toward rear through rear-end door strong deformation can lead to damage. 14 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4300ff, Remove/install headliner MODEL 454.0

AR68.30-P-4300SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2943 · Applies to: 453 · AR: AR68.30-P-4300SRA, AR68.30-P-4050SR, AR68.30-P-4800SRA, AR68.30-P-4400SR

Remove/install headliner 08.10.2018 Model 453.3 Modification notes 17.09.2018 Adhesive for bonding the roof lining added. Operation steps 15, 16 Shown on MODEL 453.3 with CODE E22 (Panoramic roof) and CODE B18 (Glasses compartment for driver) and CODE I18 (Grab handle for passenger) 1 Headliner 3 Cover 4 Cover 6 Grab handle P68.30-3762-06 Shown on model 453.3 with code E22 (panoramic roof) and Velcro fastening 1 Headliner 5 Velcro strips 20 Retaining clips P68.30-3763-06 Remove

1 Remove left and right A-pillar trim. AR68.30-P-4050SR 2 Remove left and right trim (3). AR68.30-P-4800SRA 3 Remove glasses compartment from roof. Model 453.3 AR68.30-P-4400SR with code B18 (Spectacles compartment for driver) Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4300sra, Remove/install headliner Model 453.3

Remove left and right sun visor.

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2944 · Applies to: 453 · AR: AR68.60-P-5480SR, AR68.30-P-4330SR, AR68.30-P-4400SR, AR68.30-P-4800SRA, AR68.30-P-4050SR

4 Remove left and right sun visor. AR68.60-P-5480SR 5 Remove grab handle (6). Model 453.3 with code I18 (Grab handle for front passenger) AR68.30-P-4330SR 6 Remove retaining clips (20). 452589016300 Clip remover 7 Remove cover (4). 110589035900 Mounting wedge 8 Move seats completely to the rear. 9 Fold seat backrests completely toward the front. 10 Pull roof lining (1) downward at the front until

the electrical wiring harness is accessible. Do not kink roof lining (1) or bend excessively. Otherwise the headliner (1) can crack or break. 11 Release adhesive strips of the electrical wiring Observe routing of the electrical wiring

harness from the roof lining (1). harness and position of the adhesive strips. 12 Release roof lining (1) from roof.

Carefully release roof lining (1) and do not kink or bend excessively. Otherwise the headliner (1) can crack or break. The roof lining (1) is either fastened with

Velcro strips (5) or bonded. If the roof lining (1) is bonded, it will be damaged when released in the bonding area but can be reused. 13 Lower roof lining (1), turn 90° to the right, and

remove at the front passenger door as shown. Do not kink roof lining (1) or bend excessively. Otherwise the headliner (1) can crack or break. Aid of helper required.

Install

14 Remove glue residue If the roof lining (1) was bonded. 15 Prepare bonding areas according to If the roof lining (1) was bonded. manufacturer's instructions. Adhesive parts kit (with heptane cleaner) BR00.45-Z-1142-02A 16 Apply adhesive in the bonding areas to the If the roof lining (1) was bonded. roof lining (1). Adhesive parts kit (with heptane cleaner) BR00.45-Z-1142-02A 17 Guide roof lining (1) through the front

passenger door into the vehicle as shown, turn If the roof lining (1) is bonded, the adhesive 90° to the left, align on the roof, and press on. must not make contact with any other component parts. Otherwise, they can be irreversibly soiled. Aid of helper required.

18 Pull roof lining (1) downward at the front,

position electrical wiring harness, and fix in If the roof lining (1) is bonded, the roof lining place with new adhesive strips. (1) must not be pulled down too far. Otherwise, the roof lining (1) may release again and the adhesion of the adhesive may be impaired.

Do not kink roof lining (1) or bend excessively. Otherwise the headliner (1) can crack or break. Observe routing of the electrical wiring

harness and position of the adhesive strips. 19 Place seats in the default position. 20 Install cover (4). 21 Install retaining clips (20). 22 Install grab handle (6). Model 453.3 with code I18 (Grab handle for front passenger) AR68.30-P-4330SR 23 Install left and right sun visor. AR68.60-P-5480SR 24 Install glasses compartment on roof. Model 453.3 with code B18 (Spectacles compartment for driver) AR68.30-P-4400SR 25 Install left and right trim (3). AR68.30-P-4800SRA 26 Install left and right A-pillar trim. AR68.30-P-4050SR Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4300sra, Remove/install headliner Model 453.3

AR68.30-P-1380SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2946 · Applies to: 453 · AR: AR68.30-P-1380SRC

Remove/install interior paneling on roll bar 16.12.15 Model 453.4 1 Cover P68.30-3873-11 Remove/install

1 Completely open soft top 2 Disconnect front and rear section on paneling Installation: Check catches on front and

(1) and remove rear section of paneling (1) for damage. *452589016300 Clip remover In the event of complaints Replace front and rear section of paneling (1) 3 Install in the reverse order 452 589 01 63 00 Clip remover Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar68.30-p-1380src, Remove/install interior paneling on roll bar Model 453.4

AR68.30-P-4010FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2947 · Applies to: 453 · AR: AR68.30-P-4010FF

Remove/install paneling in footwell 17.11.03 MODEL 454.0 1 Edge guard 2 Panel 3 Hood release P68.30-2899-02 Remove/Install

1 Open front door 2 Loosen edge guard (1) on A-pillar in area of Installation: Ensure that edge guard (1) is

paneling (2) seated properly. 3.1 Unscrew bolt in area of hood release (3) Only when removing paneling (2) with hood release (3). 4.1 Unclip paneling (1) and move out of hood Only when removing paneling (2) with hood release (3) release (3). *452589016300

4.2 Unclip paneling (2) and remove Only when removing paneling (2) without hood release (3). *452589016300

5 Install in the reverse order 452 589 01 63 00 Snap-release tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4010ff, Remove/install paneling in footwell MODEL 454.0

AR68.30-P-4050FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2948 · Applies to: 453 · AR: AR68.30-P-4050FF

Remove/install paneling on A-pillar 13.8.03 MODEL 454.0 1 Edge guard 2 A-pillar paneling P68.30-2898-02 Remove/Install

1 Open front door 2 Detach edge guard (1) from A-pillar in area of Installation: When installing edge guard

A-pillar paneling (2) (1) do not damage guide (arrow) of A-pillar paneling. 3 Unclip A-pillar paneling (2) and remove Installation:

Check retaining clips, replace if necessary. *452589016300

4 Install in the reverse order 452 589 01 63 00 Snap-release tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4050ff, Remove/install paneling on A-pillar MODEL 454.0

AR68.30-P-4050SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2949 · Applies to: 453 · AR: AR68.30-P-4050SR

Remove/install paneling on A-pillar 16.12.15 Model 453 Model 453.0, shown on right side of vehicle 1 A-pillar trim panel 2 Edge guard P68.30-3757-11 Model 453.3, shown on left of vehicle with code V31 (Additional instruments (cockpit clock and tachometer)) 1 A-pillar trim panel 2 Edge guard 3 Cover 4 Screw P68.30-3772-05 Remove/install

1 Detach edges (2) in area of A-pillar paneling (1) 2 Unclip cover (3) and unscrew bolt (4) Model 453.3/4 3 Unclip A-pillar paneling (1) (arrow A) and Installation: Check retaining clips on A-

remove upward (arrow B) pillar paneling (1). *452589016300 Clip remover If complaint present Replace retaining clips on A-pillar paneling (1) 4 Install in the reverse order 452 589 01 63 00 Clip remover Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4050sr, Remove/install paneling on A-pillar Model 453

AR68.30-P-4700FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2950 · Applies to: 453 · AR: AR68.30-P-4700FF

Remove/install paneling on B-pillar 13.8.03 MODEL 454.0 P68.30-2882-09 1 Upper B-pillar paneling 4 Seat belt guide bracket 6 Clip 2 Lower B-pillar paneling 5 Clip 7 Edge guard 3 Cap Remove/Install

1 Remove edge guard (7) from B-pillar on both Installation:

Ensure that edge guard (7) is sides in area of B-pillar paneling. seated properly. 2 Carefully unclip lower B-pillar paneling (2) Installation: Check clips (6), replace if

from top to bottom necessary. 3 Remove lower B-pillar paneling (2) upward out of retaining lugs (arrows) 4 Unclip cap (3) from seat belt guide bracket (4) 5 Unscrew bolt from seat belt guide bracket (4) Installation: Ensure that belt is routed

and remove seat belt guide bracket (4) properly *BA91.40-P-1002-01J

6 Unclip upper B-pillar paneling (1) 7 Remove upper B-pillar paneling (1) upward Installation: Check clips (5), replace if

out of retaining lug (arrow) necessary. 8 Install in the reverse order Seat belts/emergency tensioning retractors

Number Designation Model 454.0 BA91.40-P-1002-01J Seat belt guide bracket bolt Nm 45 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4700ff, Remove/install paneling on B-pillar MODEL 454.0

AR68.30-P-4700SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2951 · Applies to: 453 · AR: AR68.30-P-4700SRC, AR68.30-P-1380SRC, AR68.30-P-4800SRC

Remove/install paneling on B-pillar 16.12.15 Model 453.4 P68.30-3875-08 Shown with CODE 810 (Sound system) 1 Retaining clip 3 Luggage compartment lamp 5 Cover 2 Screw 4 Cover 6 Edge guard P68.30-3879-08 7 Bolts 8 Cover 8.1 Catch Remove/install

1 Remove paneling from rollover bar AR68.30-P-1380SRC 2 Remove side support 3 Close rear soft top and fold up clamping bracket (1) 4 Remove cover (5) AR68.30-P-4800SRC 5 Remove edge guard (6) up to top edge of B- pillar 6 Remove belt end fitting *BA91.40-P-1004-01SR Bolt, belt end fitting to B-pillar Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4700src, Remove/install paneling on B-pillar Model 453.4

AR68.30-P-4490FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2953 · Applies to: 453 · AR: AR68.30-P-4490FF, AR68.30-P-4730FF

Remove/install paneling on C-pillar 13.8.03 MODEL 454.0 P68.30-2881-08 1 Upper C-pillar paneling 4 Bolt 7 Edge guard 2 Lower C-pillar paneling 5 Seat belt guide bracket 8 Expanding clip 3 Cap 6 Expanding clip 9 Floor covering Remove/Install

1 Remove edge guard (7) from left or right C- Installation: Ensure that edge guard (7) is

pillar in area of upper C-pillar paneling (1) and seated properly. lower C-pillar paneling (2) 2 Remove cap (3) from seat belt guide bracket (5) 3 Unscrew bolt (4) from seat belt guide bracket Installation:

Ensure that belt path is (5) and remove seat belt guide bracket (5) correctly routed. *BA91.40-P-1002-01J

4.1 Remove expanding clips (6) On vehicles without code (I31) Flexible luggage compartment cover Installation: Install new expanding clips

(6) to replace damaged ones. *452589016300

4.2 Remove luggage compartment cover console On vehicles with code (I31) Flexible luggage AR68.30-P-4730FF compartment cover 5 Unclip upper C-pillar paneling (1) and remove Installation: Check clips on rear of upper

C-pillar paneling (1), replace if necessary *452589016300

6 Fold back rear bench seat Model 454.0 without code (S33) Double AR91.21-P-4000-01FF folding rear bench seat (3 seats) On model 454.0 with code (S33) Double folding rear bench seat (3 seats): Move rear bench seat to front-most position, retract head restraints and fold over rear seat backrests.Then unlock rear bench seat on release lever and position vertically. 7 Fold floor covering (9) in trunk to side 8 Remove expanding clip (8). Installation:

Replace damaged expanding clips (8) *452589016300

9 Unclip lower C-pillar paneling (2) and remove Installation:

Check clips on rear of lower C-pillar paneling (2), replace if necessary *452589016300

10 Install in the reverse order Seat belts/emergency tensioning retractors

Number Designation Model 454.0 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4490ff, Remove/install paneling on C-pillar MODEL 454.0

AR68.30-P-4785FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2955 · Applies to: 453 · AR: AR68.30-P-4785FF

Remove/install rear center section paneling 14.8.03 MODEL 454.0 1 Edge guard 2 Rear center section paneling 3 Trunk floor cover 4 Spreading clip P68.30-2864-06 Remove/Install

1 Open tailgate 2 Fold trunk floor cover (3) toward front 3 Remove spreading clips (4) 452589016300 Snap-release tool 4 Detach edge guard (1) in area of rear center section paneling (2). 5 Loosen rear center section paneling (2) in Loosen retaining clips in area A from rear area A center section paneling (2) using snap- release tool Check retaining clips, replace if necessary. 452589016300 Snap-release tool 6 Remove rear center section paneling (2) Installation:

Ensure that rear center upward section paneling (2) is seated properly. 7 Install in the reverse order 452 589 01 63 00 Snap-release tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4785ff, Remove/install rear center section paneling MODEL 454.0

AR68.30-P-4800FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2956 · Applies to: 453 · AR: AR68.30-P-4800FF, AR68.30-P-4730FF

Remove/install side paneling in trunk 13.8.03 MODEL 454.0 Shown on right paneling in trunk 1 Upper C-pillar paneling 2 Expanding clip 3 Edge guard 4 Rear center section paneling 5 Side trunk paneling 6 Trunk floor cover 7 Rear bench seat 8 Lower C-pillar paneling 9 Expanding clip P68.30-3175-06 Remove/Install

1 Move rear bench seat (7) to front-most position and fold over rear seat backrest 2 Open rear-end door 3 Remove edge guard (3) in area of left and right side luggage compartment lining (5) 4 Fold trunk floor cover (6) toward front 5 Remove expanding clips (2) Installation: Replace damaged

expanding clips (2). *452589016300

6.1 Remove expanding clips (9) On vehicles except code (I31) Flexible luggage compartment cover Installation: Replace damaged

expanding clips (9). *452589016300

6.2 Remove luggage compartment cover console On vehicles with code (I31) flexible luggage AR68.30-P-4730FF compartment cover 7 Loosen side luggage compartment lining (5) Carefully pull side luggage compartment in area of upper C-pillar paneling (1) and lining (5) out below upper C-pillar paneling (1) lower C-pillar paneling (8) and lower C-pillar paneling (8) Installation:

Ensure that side luggage compartment lining (5) is seated correctly. 8 Fold side luggage compartment lining (5) in area of lower C-pillar paneling (8) to inside and carefully pull out below rear center section paneling (4). 9 Remove side luggage compartment lining (5) from trunk 10 Install in the reverse order 452 589 01 63 00 Snap-release tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4800ff, Remove/install side paneling in trunk MODEL 454.0

AR68.30-P-4800SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2957 · Applies to: 453 · AR: AR68.30-P-4800SRA

Remove/install side paneling in trunk 20.10.2014 MODEL 453.3 1 Screw 2 Edge guard 3.1 Upper trim panel 3.2 Lower trim panel 4 Edge guard 5 Floor covering 6 Screw 7 Cover E18/1 Load compartment lamp P68.30-3785-06 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Switch off ignition and remove ignition key 2 Remove cargo space cover 3 Remove woofer MODEL 453.3 (except 453.341) with CODE 810 (JBL sound system) 4 Loose edge guard (4) in area of upper Installation: Ensure that the edge guard

paneling (3.1) (4) is properly seated. 5 Loosen edge guard (2) in area of upper Installation: Ensure that the edge guard

paneling (3.1) and lower paneling (3.2) (2) is properly seated. 6 Unclip paneling (7) from upper door sill 7 Remove the screw (1) and remove belt end *BA91.40-P-1004-01SR Screw/bolt, belt end fitting to B-pillar fitting 8 Remove floor covering (5) in cargo area 9 Unclip cover and unscrew bolt (6) 10 Unclip lower paneling (3.2) and remove 11 Unclip upper paneling (3.1) and remove 12 Remove cargo area lamp (E18/1) When replacing left upper paneling. 13 Install in the reverse order Seat belts/emergency tensioning retractors Number Designation MODEL 453.3 BA91.40-P-1004-01SR Screw/bolt, belt end fitting to B-pillar Nm 21 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4800sra, Remove/install side paneling in trunk MODEL 453.3

AR68.30-P-4800SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2958 · Applies to: 453 · AR: AR68.30-P-4800SRC

Remove/install side paneling in trunk 16.12.15 Model 453.4 Shown with code 810 (Sound system) and code 723 (Load compartment cover) 1 Cover 2 Woofer (with code 810 (Sound system)) 3 Load compartment cover (with code 723 (Load compartment cover)) 4 Screw 5 Edge guard P68.30-3874-06 Remove/install

1 Move front seat toward front and fold over backrest 2 Remove load compartment cover (3) Model 453.4 with code 723 (Luggage cover) 3 Remove woofer (2) Model 453.4 with code 810 (Sound system) When removing paneling (1) on left side of vehicle. 4 Remove edge guard (5) in area of paneling (1) and remove paneling on door sill 5 Unclip rear paneling on upper door sill 6 Fold up clamping bracket on rear soft top 7 Unscrew bolt (4) 8 Fold floor covering toward front 9 Unclip and remove paneling (1)

Carefully handle paneling (1) in area of rear paneling of door sill. Otherwise the eyes (arrows) or catch hooks on the rear paneling of the door sill be damaged. 10 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-4800src, Remove/install side paneling in trunk Model 453.4

AR68.30-P-2000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2959 · Applies to: 453 · AR: AR68.30-P-2000FF, AR54.30-P-6015FF

Remove/install steering column cover 13.8.03 MODEL 454.0 1 Upper steering column paneling 2 Steering wheel 3 Lower steering column paneling 4 Retaining clamp 5 Lever 6 Bolts 7 Bolt A1 Instrument cluster P68.30-2911-06 Remove/Install

1 Withdraw ignition key 2 Loosen instrument cluster (A1) from AR54.30-P-6015FF instrument panel upper section and lay down to side together with electrical lines connected. 3 Move steering wheel (2) to bottom-most See Operating Instructions position and arrest. 4 Unscrew bolts (6, 7) from lower steering column paneling (3) 5 Loosen upper steering column paneling (1) Upper steering column paneling (1) and from retaining clips (4) and remove lower steering column paneling (3) are connected with five retaining clips (4) 6 Fold lever (5) downward and hold in this Steering wheel adjustment automatically position moves to uppermost position 7 Remover lower steering column paneling (3) 8 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.30-p-2000ff, Remove/install steering column cover MODEL 454.0

AR68.30-P-2000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2960 · Applies to: 453 · AR: AR68.30-P-2000SR

Remove/install steering column cover 21.07.2014 MODEL 453 1 Upper steering column cover 2 Lower steering column trim 3 Lever 4 Bolts P68.30-3741-06 Remove/install

1 Withdraw ignition key 2 Remove screws (4) 3 Unclip upper steering column trim (1) in Installation: When installing, ensure that

direction of arrow (A) and remove upward the lower steering column trim (2) and upper steering column trim (1) arrest. *110589035900 Mounting wedge 4 Fold lever (3) downward and hold in this Steering wheel adjustment automatically position moves to uppermost position. 5 Pivot lower steering column trim (2) in direction of arrow (B) and remove 6 Install in the reverse order 110 589 03 59 00 Mounting wedge Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar68.30-p-2000sr, Remove/install steering column cover MODEL 453

AR68.40-P-0001FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2967 · Applies to: 453 · AR: AR68.40-P-0001FF

Remove/install inside rearview mirror 4.11.03 MODEL 454.0 1 Inside rearview mirror P68.40-2077-01 Remove/Install

1 Uniformly slide inside rearview mirror (1) out Remove inside rearview mirror carefully, of its guide upward and toward rear otherwise windshield can be damaged. 2 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.40-p-0001ff, Remove/install inside rearview mirror MODEL 454.0

AR68.40-P-0001SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2968 · Applies to: 453 · AR: AR68.40-P-0001SR, AR82.30-P-7800SR, AR54.21-P-3000SR

Remove/install inside rearview mirror 13.08.2014 MODEL 453 1 Inside rearview mirror 2 Bracket 3 Base A Arrow direction P68.40-2223-05 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Remove rain/light sensor MODEL 453 with CODE V54 (Rain/light sensor) AR82.30-P-7800SR 2 Remove multifunction camera MODEL 453 with CODE 238 (ACTIVE LANE KEEPING ASSIST) AR54.21-P-3000SR 3 Pry off inside rearview mirror (1) with bracket (2)from base (3) in direction of arrow (A) with suitable tool 4 Install in the reverse order 5 Connect diagnostic unit, read out fault memory MODEL 453 with CODE 238 (ACTIVE LANE KEEPING ASSIST) with CODE V54 (Rain/light sensor) AD00.00-P-2000-06SR

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.40-p-0001sr, Remove/install inside rearview mirror MODEL 453

PE68.49-P-2050BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2969 · Applies to: 453 · AR: PE68.49-P-2050BBA

Electrical function schematic for inside rearview mirror dimming 01.06.2017 Model 453.0/3/4 with code V35 (Automatically dimming interior mirror) Electrical function schematic for inside PE68.49-P-2050-97BBA rearview mirror dimming Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe68.49-p-2050bba, Electrical function schematic for inside rearview mirror dimming Model 453.0/3/4 with code V35 (Automatically dimming interior mirror)

PE68.49-P-2000BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2970 · Applies to: 453 · AR: PE68.49-P-2000BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of automatic dimming inside rearview mirror 11.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code V35 (Automatically dimming interior mirror) except code 494 (US version) Wiring diagram of automatic dimming inside PE68.49-P-2000-97BBA rearview mirror Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe68.49-p-2000bba, Wiring diagram of automatic dimming inside rearview mirror Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code V35 (Automatically dimming interior mirror) except code 494 (US version)

AR68.60-P-5480FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2975 · Applies to: 453 · AR: AR68.60-P-5480FF

Remove/install sun visor 13.8.03 MODEL 454.0 1 Sun visor 2 Cap 3 Bracket 4 Bolt P68.60-2069-06 Remove/Install

1 Fold down sun visor (3) and pivot to side 2 Unclip cap (2) from bracket (3) and remove bracket (3) 3 Unscrew bolt (4) 4 Unclip sun visor (1) and remove Carefully unclip catch hook for sun visor (1) through opening (arrow) with suitable screwdriver, otherwise catch hook can break. 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.60-p-5480ff, Remove/install sun visor MODEL 454.0

AR68.60-P-5480SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2976 · Applies to: 453 · AR: AR68.60-P-5480SR

Remove/install sun visor 28.07.2014 MODEL 453 Shown on model 453.0, left side 1 Sun visor 2 Wedge 3 Hinge 4 Retaining clips 5 Bracket P68.60-2412-06 Remove/install

1 Fold down left and right sun visor (1) and unhook from bracket (5) 2 Unclip wedge (2) with suitable tool 3 Detach retaining clips (4) and remove sun visor (1) with hinge (3) 4 Install in the reverse order 5 Install safety label on sun visor (1) Only when replacing passenger sun visor.

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar68.60-p-5480sr, Remove/install sun visor MODEL 453

AR72.10-P-0550FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2984 · Applies to: 453 · AR: AR72.10-P-0550FF

Adjust front door 13.8.03 MODEL 454.0 1 Striker eye 2 Bolts P72.10-2926-04 3 Front door 4 Bolt 5 Top door hinge 6 Bolt 7 Bolt 8 Bottom door hinge 9 Bolt P72.10-2927-06 Adjust

Risk of injury Danger! to fingers getting jammed or While moving components, ensure that no AS00.00-Z-0011-01A

pinched while removing / installing or aligning body parts or limbs are within the operating hoods, doors, trunk lid/tailgate or sliding roof. range of moving parts. 1 Loosen bolts (2) for striker eye (1) 2 Check gaps on front door (3) all the way BE60.00-P-1003-01M around. 452589012100 Feeler gage 3 Loosen bolts (4) for top door hinge (5) or bolts Do not loosen top door hinge (5) and (9) for bottom door hinge (8) on front door (3) bottom door hinge (8) simultaneously to and adjust transitions in area of A pillar by prevent an unintentional maladjustment. moving front door (3) 4 Tighten bolts (4) for top door hinge (5) and *BA72.10-P-1005-01K

bolts (9) for bottom door hinge (8) on front door (3) 5 Loosen bolts (6) for top door hinge (5) or bolts BE60.00-P-1003-01M Do not loosen top door hinge (5) and (7) for bottom door hinge (8) on A-pillar and bottom door hinge (8) simultaneously to adjust gaps by moving front door (3) prevent an unintentional maladjustment. 452589012100 Feeler gage 6 Tighten bolts (6) for top door hinge (5) and *BA72.10-P-1004-01K

bolts (7) for bottom door hinge (8) on A-pillar 7 Adjust transition from front door (3) to rear The door paneling on the front door (3) door by moving striker eye (1) should be flush with the contour of the rear door or extend a maximum of 1 mm. 8 Tighten bolts (2) for striker eye (1) *BA72.10-P-1006-01K

Test and adjustment values Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-0550ff, Adjust front door MODEL 454.0

AR72.10-P-0550SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2986 · Applies to: 453 · AR: AR72.10-P-0550SRA, AR88.10-P-1000SRA

Adjust front door 16.12.15 Model 453.3/4 Shown on left side of vehicle on model 453.3 1 Front door 2 Front fender 3 Bolts 4 Lock striker 5 Nuts 6 Bolts P72.10-4275-06 Risk of injury Danger ! caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Check

1 Check gap dimensions on front door (1) all AR60.00-P-0700-01SR the way round Front door side window to sidewall paneling BE60.00-P-1017-01CA Front door to sidewall paneling BE60.00-P-1015-01CA Front door to longitudinal member BE60.00-P-1014-01CA Fender to front door BE60.00-P-1012-01CA Front door to A-pillar BE60.00-P-1009-01CA 129589032100 Feeler gauge Remove

2 Remove front fender (2) AR88.10-P-1000SRA Adjust 3 Mark position of lock striker (4) 4 Unscrew screws (3) and remove locking eye (4) 5 Loosen bolt (6) and nuts (5) on A-pillar 6 Adjust gap dimensions by moving front door AR60.00-P-0700-01SR (1)

Carefully move front door (1). If the front door (1) comes into contact with other components, the paint can be damaged. Front door side window to sidewall paneling BE60.00-P-1017-01CA Front door to sidewall paneling BE60.00-P-1015-01CA Front door to longitudinal member BE60.00-P-1014-01CA Fender to front door BE60.00-P-1012-01CA Front door to A-pillar BE60.00-P-1009-01CA 129589032100 Feeler gauge 7 Tighten bolts (6) and nuts (5) on A-pillar *BA72.10-P-1002-01SR Bolt/nut, hinge to body 8 Insert lock striker (4) and screw in bolts (3) up Observe any previous markings.

to stop It should still be possible to adjust the lock

striker (4). Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-0550sra, Adjust front door Model 453.3/4

Adjust transition between front door (1) and

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2987 · Applies to: 453 · AR: AR88.10-P-1000SRA

9 Adjust transition between front door (1) and The contour of the front door (1) must be

side wall by moving lock striker (4) flush with the contour of the side wall or protrude max. 1 mm. 10 Tighten bolts (3) *BA72.10-P-1004-01SR Bolt, striker eye to pillar Install

11 Install front fender (2) AR88.10-P-1000SRA Test and adjustment values for gap dimensions Number Designation Model 453.4 Model 453.3 9 ( 1,5) 9 ( 1,5) BE60.00-P-1009-01CA Front door to A-pillar Dimension "H1" mm Test and adjustment values for gap dimensions Number Designation Model 453.4 Model 453.3 6 ( 1) 6 ( 1) BE60.00-P-1012-01CA Fender to front door Dimension "I1" mm Test and adjustment values for gap dimensions Number Designation Model 453.4 Model 453.3 6 ( 1,5) 6 ( 1,5) BE60.00-P-1014-01CA Front door to longitudinal member Dimension "J" mm Test and adjustment values for gap dimensions Number Designation Model 453.4 Model 453.3 6 ( 1,5) 6 ( 1,5) BE60.00-P-1015-01CA Front door to sidewall paneling Dimension "K" mm Test and adjustment values for gap dimensions Number Designation Model 453.4 Model 453.3 9 ( 1,5) 9 ( 1,5) BE60.00-P-1017-01CA Front door side window to sidewall paneling Dimension "M" mm Front door Number Designation Model 453 BA72.10-P-1002-01SR Bolt/nut, hinge to body Nm 21 Front door Number Designation Model 453 BA72.10-P-1004-01SR Bolt, striker eye to pillar Nm 21 129 589 03 21 00 Feeler gauge Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-0550sra, Adjust front door Model 453.3/4

AR72.10-P-2400FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2988 · Applies to: 453 · AR: AR72.10-P-2400FF

Remove/install exterior door handle on front door 13.8.03 MODEL 454.0 P72.10-2859-07 1 Front door 2 Door handle 3 Panel 4 Bolt 2 Door handle 5 Door paneling 6 Door frame 7 Bracket (only on driver's door) 8 Control cable (only on driver's door) 9 Lock cylinder (only on driver's door) 10 Lever 11 Control cable 12 Bracket 13 Bracket P72.10-2860-04 Remove/install

1 Open front door (1) 2 Unclip paneling (3) in marked area (arrow) and remove 3 Unscrew bolt (4) behind paneling (3) 4 Unhook door handle (2) from door paneling Pull door handle (2) toward rear (5) and door frame (6) 5 Unclip bracket (12) from holder (13) 6 Detach control cable (11) from lever (10) 7 Unhook control cable (11) from door handle (2) 8.1 Unclip bracket (7) from holder (13) Only on driver's door. 9.1 Unhook control cable (8) from lock cylinder (9) Only on driver's door. 10 Remove door handle (2) 11.1 Lightly turn lock cylinder (9) to right and Only on driver's door. remove from door handle (2) When replacing door handle (2) or lock cylinder (9) 12 Install in the reverse order 13 Perform function check Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-2400ff, Remove/install exterior door handle on front door MODEL 454.0

AR72.10-P-1920SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2989 · Applies to: 453 · AR: AR72.10-P-1920SRA, AR72.10-P-1961SRA

Remove/install fixed front door window 16.12.15 Model 453.3/4 Shown on left side of vehicle on model 453.3 1 Screw 2 Bolts 3 Fixed pane 4 Window seal P72.10-4309-03 Remove/install

1 Remove side window in front door AR72.10-P-1961SRA 2 Remove screw/bolt (1) 3 Remove bolts (2) with washers 4 Remove fixed pane (3) upward together with window guide 5 Pull out window seal (4) When replacing stationary window (3). Installation: The window seal (4) must

overlap approx. 3 mm at top. 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-1920sra, Remove/install fixed front door window Model 453.3/4

AR72.10-P-0500FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2990 · Applies to: 453 · AR: AR72.10-P-0500FF, AR68.30-P-4010FF

Remove/install front door 13.8.03 MODEL 454.0 P72.10-2852-09 1 Wiring harness 3 Wiring harness X35/1 Left front door separation point 2 Front door 4 Bolt X35/2 Right front door separation point Removal/installation

Risk of injury Danger! to fingers being jammed or When moving components, ensure that no AS00.00-Z-0011-01A

pinched when Remove/install or aligning body parts or limbs are within the operating hoods, doors, trunk lid/tailgate or sliding roof. range of moving parts. 1 Remove left and right footwell paneling AR68.30-P-4010FF 2 Separate left front door separation point (X35/1) or right front door separation point (X35/2) behind footwell paneling 3 Guide wiring harness (1) or wiring harness (3) Carefully loosen protection hose for wiring through opening in A-pillar toward outside harness (1) and wiring harness (3) from A- pillar 4 Unscrew bolts (4) from left and right front door *BA72.10-P-1001-01K

(2) 5 Remove left and right front door (2) upward Do not handle front door (2) improperly, from door hinges and install in assembly otherwise paintwork may be damaged. device of door or lay down on suitable surface. Helper required *454589005900 Assembly device 6 Install in the reverse order Front door

Number Designation Model 454.0 BA72.10-P-1001-01K Torx bolt for door hinge joint Nm 32 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-0500ff, Remove/install front door MODEL 454.0

AR72.10-P-0500SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2992 · Applies to: 453 · AR: AR72.10-P-0500SRA, AR54.10-P-0003SR, AR88.10-P-1000SRA

Remove/install front door 26.02.2019 Model 453.3/4 Modification notes 26.02.2019 Disconnect ground line from battery, added. Operation Step 3 P72.10-4511-09 Shown on model 453.3 on left side of vehicle 1 Front door 4 Bolts 2 Front fender X35/1 Left front door electrical connector 3 Nuts X35/2 Right front door electrical connector Risk of injury Warning caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Risk of injury Warning during testing and repair Do not expose pyrotechnical component parts AS91.00-Z-0008-01A

operations related to pyrotechnical to temperatures above 100 °C or 212 °F. components Disconnect current supply when working on such component parts. Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Information, assessment and legal AH91.00-Z-0000-10A requirements when working with, handling and storing pyrotechnical components Remove/install

1 Fully lower side window on respective front door (1). 2 Switch off ignition and remove key. 3 Disconnect ground line from battery. Model 453.491 with code 494 (US version) AR54.10-P-0003SR 4 Remove front fender (2). AR88.10-P-1000SRA Installation: Only install front fender (2)

after checking gap dimensions on front door (1). Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar72.10-p-0500sra, Remove/install front door Model 453.3/4

Release and disconnect left front door

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2993 · Applies to: 453 · AR: AR72.10-P-0550SRA

5 Release and disconnect left front door electrical connector (X35/1) or right front door electrical connector (X35/2). 6 Mark position of hinges on body. 7 Unscrew screw/bolts (4). *BA72.10-P-1002-01SR Bolt/nut, hinge to body 8 Unscrew nuts (3), remove front door (1) with

aid of helper, and place down on a suitable Carefully remove front door (1). base. If the front door (1) comes into contact with other components, the paint can be damaged. Installation: Observe any previous

markings. *BA72.10-P-1002-01SR Bolt/nut, hinge to body 9 Install in the reverse order 10 Check gap dimensions of front door (1), adjust AR72.10-P-0550SRA if necessary. Front door Number Designation Model 453 BA72.10-P-1002-01SR Bolt/nut, hinge to body Nm 21 Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar72.10-p-0500sra, Remove/install front door Model 453.3/4

AR72.10-P-2660FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2994 · Applies to: 453 · AR: AR72.10-P-2660FF, AR72.10-P-0500FF

Remove/install front door hinge 13.8.03 MODEL 454.0 1 Front door 2 Bolt 3 Upper door hinge 4 Bolt 5 Bolt 6 Lower door hinge 7 Bolt P72.10-2939-06 Removal/installation

Risk of injury Danger! to fingers being jammed or When moving components, ensure that no AS00.00-Z-0011-01A

pinched when remove/install or aligning body parts or limbs are within the operating hoods, doors, trunk lid/tailgate or sliding roof. range of moving parts. 1 Remove front door (1) and lay down on AR72.10-P-0500FF suitable subsurface 2 Unscrew bolts (2) from upper door hinge (3) Install spacers together with upper door and bolts (7) from lower door hinge (6) on hinge (3) and lower door hinge (6) if present front door (1) When replacing spacers ensure that the spacer thickness is not changed *BA72.10-P-1005-01K

3 Remove upper door hinge (3) and lower door hinge (6) from front door (1) 4 Unscrew bolts (4) from upper door hinge (3) Install spacers together with upper door and bolts (5) from lower door hinge (6) on A- hinge (3) and lower door hinge (6) if present pillar When replacing spacers, ensure that the spacer thickness is not changed *BA72.10-P-1005-01K

5 Remove upper door hinge (3) and lower door hinge (6) from A-pillar. 6 Install in the reverse order Front door

Number Designation Model 454.0 BA72.10-P-1004-01K Torx bolt, door hinge to body Nm 34 BA72.10-P-1005-01K Torx bolt, door hinge to tubular frame Nm 34 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-2660ff, Remove/install front door hinge MODEL 454.0

AR72.10-P-1400FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2995 · Applies to: 453 · AR: AR72.10-P-1400FF, AR72.10-P-6575FF

Remove/install front door inner actuation 13.8.03 MODEL 454.0 1 Panel 2 Grab handle 3 Door paneling 4 Inside door opener 5 Bolt 6 Grab handle cover P72.10-2872-04 1 Panel 3 Door paneling 4 Inside door opener 7 Door foil 8 Bolt 9 Control cable 10 Control cable sleeve 11 Retaining lug 12 Bolts P72.10-2871-12 Remove/install

1 Remove front door paneling (3) AR72.10-P-6575FF 2 Unclip grab handle cover (6) with snap- *452589016300 Snap-release tool release tool 3 Unscrew bolts (5) 4 Remove grab handle (2) 5 Detach door foil (7) from door paneling (3) in Installation: Fasten door foil (7) with

area of paneling (1). suitable double-sided adhesive tape. Replace damaged door foil (7). 6 Unhook control cable sleeve (10) from inside door opener (4) 7 Unhook control cable (9) from inside door opener (4) 8 Unscrew bolts (12) from paneling (1) 9 Unclip retaining lugs (11) in area of paneling (1). 10 Remove paneling (1) 11 Unscrew bolts (8) from inside door opener (4) 12 Remove inside door opener (4) from paneling (1). 13 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-1400ff, Remove/install front door inner actuation MODEL 454.0

AR72.10-P-1400SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2997 · Applies to: 453 · AR: AR72.10-P-1400SR

Remove/install front door inner actuation 21.07.2014 MODEL 453 P72.10-4261-09 1 Door trim 4 Screw 2 Inner actuation 5 Wire 3 Cover 6 Door lock Remove/install

1 Detach cover (3) on side door handle (2) 2 Unscrew bolt (4) on inside door handle (2) 3 Unclip inside door handle (2) from door panel *115589035900 Long wedge (1) using wedge 4 Unclip wire (5) from inside door handle (2) 5 Install in the reverse order Check

6 Mechanically lock front door (6) and check whether it can be opened with the inside door handle (2) 115 589 03 59 00 Long wedge Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-1400sr, Remove/install front door inner actuation MODEL 453

AR72.10-P-4011FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2998 · Applies to: 453 · AR: AR72.10-P-4011FF, AR72.10-P-6575FF

Remove/install front door lock 13.8.03 MODEL 454.0 1 Door lock 2 Bowden cable 3 Bolts P72.10-2866-12 Removal/installation

1 Remove door liner on front door AR72.10-P-6575FF 2 Unscrew bolts (3) from door lock (1) *BA72.10-P-1003-01K

3 Pull control cable (2) out of tubular frame The front door is equipped with a second Bowden cable for the emergency unlocking feature Observe installation position of Bowden cables 4 Remove door lock (1) The central locking motor is integrated in the door lock (1) and cannot be replaced separately. 5 Install in the reverse order Front door

Number Designation Model 454.0 BA72.10-P-1003-01K Torx bolt, door lock to tubular frame Nm 8 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-4011ff, Remove/install front door lock MODEL 454.0

AR72.10-P-4011SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2999 · Applies to: 453 · AR: AR72.10-P-4011SRA, AR72.18-P-1000SRA, AR72.10-P-1400SR

Remove/install front door lock 16.12.15 Model 453.3/4 Shown on left side of vehicle 1 Bolts 2 Door lock 3 Electrical connector 4 Wire 5 Wire P72.10-4294-11 Remove/install

1 Remove door paneling AR72.18-P-1000SRA 2 Remove front door inside door handle AR72.10-P-1400SR 3 Guide inside door handle wire through door trim 4 Remove bolts (1) BA72.10-P-1003-01SR Bolt, lock to front door 5 Remove door lock (2) until electrical connector (3) is accessible 6 Disconnect electrical connection (3) 7 Unclip wiring harness from door lock (2) 452589016300 Clip remover 8 Remove door lock (2) 9 Remove wire (4) and wire (5) from door lock When replacing door lock (2). (2) 10 Install in the reverse order Front door Number Designation Model 453 BA72.10-P-1003-01SR Bolt, lock to front door Nm 12 452 589 01 63 00 Clip remover Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-4011sra, Remove/install front door lock Model 453.3/4

AR72.10-P-4015SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3000 · Applies to: 453 · AR: AR72.10-P-4015SRA

Remove/install front door lock cylinder 16.12.15 Model 453.3/4 P72.10-4307-09 Shown on model 453.3 1 Front door 5 Wire 10 Relay lever 2 Screw 6 Wire 11 Cylinder lock housing 3 Outside door handle 8 Bracket 4 Cap 9 Retaining clamp P72.10-4308-07 7 Lock cylinder 11 Cylinder lock housing C Guides 9 Retaining clamp 12 Spring 10 Relay lever 13 Retaining spring Remove/install

1 Open front door (1) on driver side and unscrew bolt (2) 2 Remove cap (4) 3 Pull outside door handle (3) toward rear (arrow A) and remove until wires (5, 6) are accessible Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-4015sra, Remove/install front door lock cylinder Model 453.3/4

AR72.10-P-6575SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3002 · Applies to: 453 · AR: AR72.10-P-6575SRA, AR72.18-P-1000SRA

Remove/install front door panel 16.12.15 Model 453.3/4 Shown on model 453.3 with code V21 (Electrically adjustable heated outside mirror (FFO)), on left side of the vehicle 1 Door trim 3 Screw 4 Cap 5 Screw 7 Screw 9 Expansion rivet 10 Electrical connector 11 Electrical connector 21 Grommet 26 Electrical wiring harness S50 Outside mirror adjustment switch X35/1 Left front door electrical connector X35/2 Right front door electrical connector P72.10-4512-06 Shown on left door trim (1) 1 Door trim 12 Retaining clips 13 Retaining tabs 15 Inner sealing rail 26 Electrical wiring harness H4/5 Left front door speaker H4/6 Right front door speaker S20/1 Power window switch group, driver side S21/2 Passenger-side power window switch P72.10-4514-06 Risk of injury Danger ! caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Switch off ignition and remove key 2 Remove door paneling AR72.18-P-1000SRA 3 Disconnect left front electrical connector (X35/1) or right front door electrical connector (X35/2) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-6575sra, Remove/install front door panel Model 453.3/4

AR72.10-P-6575FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3004 · Applies to: 453 · AR: AR72.10-P-6575FF, AR72.10-P-0500FF, AR72.18-P-1000FF

Remove/install front door paneling 22.10.03 MODEL 454.0 1 Cover 2 Tubular frame 3 Door paneling 4 Bolt 5 Catch hook 6 Guides 7 Electrical connector M10/3 Left front power window motor M10/4 Right front power window motor P72.10-2868-05 P72.10-2869-09 2 Tubular frame 9 Electrical connector 12 Cable 3 Door paneling 10 Bolt 8 Retaining clamp 11 Bowden cable M10/3 Left front power window motor M10/4 Right front power window motor Removal/installation

1 Move window in front door to uppermost See Operating Instructions position 2 Remove front door AR72.10-P-0500FF 3 Remove front door paneling AR72.18-P-1000FF 4 Unscrew bolt (4) from cover (1) 5 Unclip catch hook (5) and loosen cover (1) 6 Loosen cover (1) in bottom area of guides (6) Installation:When installing cover (1)

and remove ensure that wiring harness is routed properly. 7 Unscrew bolt (arrow) from door liner (3) 8 Unscrew bolt (10) from door liner (3) in area of The bolt (10) of the door liner (3) is located door lock above the bolts of the door lock. 9 Disconnect electrical connector (7) from left front power window motor (M10/3) or right front power window motor (M10/4) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-6575ff, Remove/install front door paneling MODEL 454.0

AR72.10-P-1961SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3006 · Applies to: 453 · AR: AR72.10-P-1961SRA, AR72.18-P-1000SRA

Remove/install front door side window 16.12.15 Model 453.3/4 P72.10-4292-08 Shown on left side of vehicle on model 453.3 1 Side window(s) 4 Support 2 Bolts Risk of injury Danger ! caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Remove

1 Open side window (1) half way 2 Switch off ignition and remove key 3 Remove door paneling AR72.18-P-1000SRA 4 Secure side window (1) against falling down 5 Unscrew screws/bolts (2) 6 Remove side window (1) upward from Place side window (1) down on suitable

window channel in front door base. Install

7 Insert side window (1) 8 Push side window (1) downward until it makes contact with mounts (4), simultaneously slide side window (1) to end stop into rear window guide seal 9 Tighten bolts (2) 10 Install door paneling AR72.18-P-1000SRA Check

11 Check whether side window (1) runs up and down correctly and check power window for proper function Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-1961sra, Remove/install front door side window Model 453.3/4

AR72.10-P-1910FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3007 · Applies to: 453 · AR: AR72.10-P-1910FF, AR72.10-P-0500FF, AR72.18-P-1000FF

Remove/install front door window 13.8.03 MODEL 454.0 1 Window 2 Protective rubber 3 Window mount 4 Bolt P72.10-2861-12 Removal/installation

1 Move window (1) to bottom-most position See Operating Instructions 2 Remove front door AR72.10-P-0500FF 3 Remove front door paneling AR72.18-P-1000FF 4 Loosen bolt (4) on front and rear window Don not unscrew bolts (4) completely mounts (3) *BA72.10-P-1007-01K

5 Lift window (1) upward out of window mounts Installation: Ensure that window (1)

(3) makes uniform contact to stop of front and rear window mount (3) Ensure that protective rubber (2) is seated correctly. 6 Move window (1) downward until it is no longer guided in the upper area of the tubular frame and can be tilted slightly toward outside. 7 Slightly tilt window (1) toward outside in the upper area. 8 Remove window (1) upward between tubular Remove window carefully (1) to prevent frame and side impact protection damaging window seal and window (1) 9 Install in the reverse order 10 Perform function check Front door

Number Designation Model 454.0 BA72.10-P-1007-01K Bolt, side window to power window Nm 7 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-1910ff, Remove/install front door window MODEL 454.0

AR72.10-P-0010SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3008 · Applies to: 453 · AR: AR72.10-P-0010SRA, AR88.70-P-9000SRA

Remove/install front door window guide seal 16.12.15 Model 453.3/4 P72.10-4312-07 Shown on left side of vehicle on model 453.3 1 Front window guide seal 2 Pin 3 Rear window guide seal Remove

1 Completely open side window in front door 2 Remove outside mirror AR88.70-P-9000SRA 3 Loosen pin (2) on front window guide seal (1) 4 Pull front window guide seal (1) upward out of window channel 5 Detach rear window guide seal (3) at top and pull out of window guide seal Install

6 Coat rear window guide seal (3) with Lubricant, rubber assembly 1 l *BR00.45-Z-1010-06A lubricant 7 Slide rear window guide seal (3) downward Ensure that side window is seated

into window guide correctly in rear window guide seal (3). 8 Coat front window guide seal (1) with Lubricant, rubber assembly 1 l *BR00.45-Z-1010-06A lubricant 9 Partially close side window in front door Ensure that the side window runs correctly

in the rear window guide seal (3) and the front window guide. 10 Slide front window guide seal (1) downward Ensure that side window is seated

into window guide correctly in front window guide seal (1). 11 Fasten pin (2) to front seal (1) 12 Install outside mirror AR88.70-P-9000SRA 13 Completely close side in front door Ensure that the side window runs correctly

in the front window guide seal (1) or rear window guide seal (3). Repair materials Number Designation Order number BR00.45-Z-1010-06A Lubricant, rubber assembly 1 l A 000 989 03 67 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-0010sra, Remove/install front door window guide seal Model 453.3/4

AR72.10-P-1800SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3009 · Applies to: 453 · AR: AR72.10-P-1800SRA, AR72.18-P-1000SRA, AR72.10-P-1961SRA

Remove/install front door window lifter 08.11.2017 Model 453.3/4 Modification notes 03.11.2017 Normalize power window motor, added. Operation step 16 Shown on model 453.3 on left side of vehicle 1 Power window 2 Bolts 3 Rivets 5 Door carcass M10/3 Left front power window motor M10/4 Right front power window motor P72.10-4297-06 Risk of injury Warning caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Remove

1 Remove door paneling at respective front door AR72.18-P-1000SRA 2 Remove side window AR72.10-P-1961SRA 3 Disconnect electrical connector at left front power window motor (M10/3) and/or right front power window motor (M10/4) 4 Remove left front power window motor (M10/3) and/or right front power window motor (M10/4) from window lifter (1) 5 Unscrew bolts (2) 6 Drill off rivet heads of rivets (3) and remove

window lifter (1) Do not drill out rivet heads of rivets (3) too far. Door bodyshell (5) and/or window lifter (1) will otherwise be damaged and the damaged component part must be replaced. Use a 7 mm diameter drill bit.

7 Completely remove rivet residues and drilling When reinstalling old power window (1). chips from power window (1) 8 Remove rivet residues and shaving from front

door Completely remove rivet residues. Otherwise remaining rivet residues can cause corrosion damage on front door. Install

9 Insert window lifter (1) 10 Secure window lifter (1) with rivets (3) 11 Tighten screws/bolts (2) 12 Install left front power window motor (M10/3) and/or right front power window motor (M10/4) at window lifter (1) Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar72.10-p-1800sra, Remove/install front door window lifter Model 453.3/4

Connect electrical connector at left front power

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3010 · Applies to: 453 · AR: AR72.10-P-1961SRA, AR72.18-P-1000SRA

13 Connect electrical connector at left front power window motor (M10/3) and/or right front power window motor (M10/4) 14 Install side window AR72.10-P-1961SRA 15 Install door paneling AR72.18-P-1000SRA Check

16 Normalize left front power window motor Fully close side window by means of the

(M10/3) and/or right front power window motor power window switch (1) and hold switch in (M10/4) "Close" position for 3 to 5 s. 17 Check window lifter (1) and left front power window motor (M10/3) and/or right front power window motor (M10/4) for proper operation Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar72.10-p-1800sra, Remove/install front door window lifter Model 453.3/4

AR72.10-P-2662SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3011 · Applies to: 453 · AR: AR72.10-P-2662SRA, AR88.10-P-1000SRA, AR72.18-P-1000SRA, AR72.10-P-0550SRA

Remove/install hinge of front door 16.12.15 Model 453.3/4 Shown on left side of vehicle 1 Electrical connector 2 Cover 3 Nut 4 Screw 5 Bolts 6 Top hinge 7 Nut 8 Screw 9 Bolts 10 Bottom hinge P72.10-4296-06 Remove/install

1 Remove front fender AR88.10-P-1000SRA 2 Remove door paneling AR72.18-P-1000SRA 3 Disconnect electrical connector (1) 4 Unclip cover (2) and lay electrical wiring harness down to side 5 Close front door 6 Mark position of upper hinge (6) or lower hinge (10) 7 Unscrew nut (3) or nut (7) *BA72.10-P-1002-01SR Bolt/nut, hinge to body 8 Unscrew bolts (4, 5) and remove upper hinge When removing top hinge (6). (6) Lower hinge (10) must be installed.

BA72.10-P-1001-01SR Bolt/nut, hinge to front door 9 Unscrew bolts (8, 9) and remove lower hinge When removing bottom hinge (10). (10) Upper hinge (6) must be installed. BA72.10-P-1001-01SR Bolt/nut, hinge to front door 10 Install in the reverse order 11 Adjust gap dimensions on front door (1) AR72.10-P-0550SRA Front door Number Designation Model 453 BA72.10-P-1001-01SR Bolt/nut, hinge to front door Nm 21 Front door Number Designation Model 453 BA72.10-P-1002-01SR Bolt/nut, hinge to body Nm 21 Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar72.10-p-2662sra, Remove/install hinge of front door Model 453.3/4

AR72.10-P-1600FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3012 · Applies to: 453 · AR: AR72.10-P-1600FF, AR72.10-P-6575FF

Remove/install inner sealing rail 13.11.03 MODEL 454.0 1 Door paneling 2 Inner sealing rail P72.10-2881-04 Remove/install

1 Remove front door paneling (1) AR72.10-P-6575FF 2 Remove inner sealing rail (2) from door Installation: The foam rubber layer of paneling (1) inner sealing ring (2) should point toward the window. 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-1600ff, Remove/install inner sealing rail MODEL 454.0

AR72.10-P-1700FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3013 · Applies to: 453 · AR: AR72.10-P-1700FF, AR88.70-P-9000FF, AR88.70-P-9000FG, AR72.10-P-2400FF

Remove/install outer sealing rail 13.11.03 MODEL 454.0 1 Outer sealing rail 2 Snap-release tool P72.10-2882-04 Removal/installation

1 Remove outside mirror completely On vehicles with code (V21) Electrically AR88.70-P-9000FF adjustable and heated outside mirror (FFO) On vehicles without code (V21) Electrically AR88.70-P-9000FG adjustable and heated outside mirror (FFO) 2 Unhook outer door handle from front door AR72.10-P-2400FF Do not unhook Bowden cable 3 Disconnect outer sealing rail (1) with snap- Carefully loosen outer sealing rail (1) to release tool (2) from bottom prevent damaging paint surfaces *452589016300 Snap-release tool 4 Remove outer sealing rail (1) 5 Install in the reverse order 452 589 01 63 00 Snap-release tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-1700ff, Remove/install outer sealing rail MODEL 454.0

AR72.10-P-1800FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3014 · Applies to: 453 · AR: AR72.10-P-1800FF, AR72.10-P-1910FF

Remove/install power window in front door 13.8.03 MODEL 454.0 1 Window 2 Front door 3 Electrical connector 4 Power window 5 Rivet M10/3 Left front power window motor M10/4 Right front power window motor P72.10-2870-12 Remove/install

1 Remove window (1) from front door (2) AR72.10-P-1910FF 2 Disconnect electrical connector (3) from left front power window motor (M10/3) or right front power window motor (M10/4) 3 Drill rivets (5) out of power window (4) Installation:

Install rivets (5) with rivet gun *450589003900 Rivet gun 4 Remove power window (4) 5 Remove remainder of rivets 6 Install in the reverse order 7 Check power window (4) for proper function 450 589 00 39 00 Rivet gun Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-1800ff, Remove/install power window in front door MODEL 454.0

AR72.10-P-0950FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3015 · Applies to: 453 · AR: AR72.10-P-0950FF, AR72.10-P-6575FF, AR72.10-P-4011FF, AR72.10-P-1800FF, AR72.10-P-0550FF

Remove/install tubular frame for front door 22.10.03 MODEL 454.0 1 Tailgate hinge 2 Tubular frame 3 Gasket 4 Retaining clamp P72.10-2863-06 Remove/Install

1 Remove front door liner AR72.10-P-6575FF 2 Remove front door lock AR72.10-P-4011FF 3 Remove power window at front door AR72.10-P-1800FF 4 Remove retaining clamp (4) 5 Remove seal (3) from guide of tubular frame (2) 6 Remove tubular frame (2) from assembly 454589005900 Assembly device device 7 Unscrew bolts from door hinge (1) BA72.10-P-1005-01K

8 Remove door hinges (1) from tubular frame (2) 9 Install in the reverse order 10 Adjust front door AR72.10-P-0550FF Front door

Number Designation Model 454.0 BA72.10-P-1005-01K Torx bolt, door hinge to tubular frame Nm 34 454 589 00 59 00 Assembly tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-0950ff, Remove/install tubular frame for front door MODEL 454.0

AR72.10-P-1100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3016 · Applies to: 453 · AR: AR72.10-P-1100FF

Remove/install window crank 14.11.03 MODEL 454.0 except CODE (V34) Rear power windows (FFO) P72.10-2880-07 1 Door paneling 2 Cover ring 3 Window crank 4 Clamping spring Remove/install

1 Open rear door 2 Turn window crank (3) to bottom-most position 3 Lightly press in door liner (1) in area of window crank (3) and pull out clamping spring upward with suitable tool 4 Remove window crank (3) Installation: Insert clamping spring (4)

into guide on window crank (3) and then press onto shaft on power window 5 Remove cover ring (2) 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.10-p-1100ff, Remove/install window crank MODEL 454.0 except CODE (V34) Rear power windows (FFO)

AR72.12-P-0650FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3019 · Applies to: 453 · AR: AR72.12-P-0650FF

Adjust rear door 13.8.03 MODEL 454.0 1 Rear door 2 Striker eye 3 Bolts P72.12-2488-04 1 Rear door 4 Top door hinge 5 Bottom door hinge 6 Bolt 7 Bolt 8 Bolt 9 Bolt P72.12-2489-06 Adjust

Risk of injury Danger! to fingers getting jammed or While moving components, ensure that no AS00.00-Z-0011-01A

pinched while removing / installing or aligning body parts or limbs are within the operating hoods, doors, trunk lid/tailgate or sliding roof. range of moving parts. 1 Loosen bolts (3) from striker eye (2) 2 Check gap around rear door (1) Gap between rear door and entry BE60.00-P-1004-01M Gap between rear door and C-pillar Gap between front door and rear door BE60.00-P-1003-01M 452589012100 Feeler gage 3 Loosen bolts (6) for top door hinge (4) or bolts The contour of the rear door (1) should be (8) for bottom door hinge (5) on rear door (1) flush with the contour of the front door or lay and adjust transitions in area of A pillar by maximum 1 mm deeper. moving rear door (1) Do not loosen top door hinge (4) and bottom door hinge (5) simultaneously to prevent an unintentional maladjustment. 4 Tighten bolts (6) for top door hinge (4) and BA72.12-P-1004-01G

bolts (8) for bottom door hinge (5) on rear door (1) 5 Loosen bolts (7) for top door hinge (4) or bolts Do not loosen top door hinge (4) and (9) for bottom door hinge (5) on B-pillar and bottom door hinge (5) simultaneously to adjust gaps by moving rear door (1) prevent an unintentional maladjustment. Rear door entry BE60.00-P-1004-01M Rear door to C-pillar 452589012100 Feeler gage 6 Tighten bolts (7) for top door hinge (4) and *BA72.12-P-1005-01G

bolts (9) for bottom door hinge (5) on B-pillar Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-0650ff, Adjust rear door MODEL 454.0

AR72.12-P-1013FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3021 · Applies to: 453 · AR: AR72.12-P-1013FF, AR72.12-P-1011FF

Remove/install inner sealing rail on rear door 13.11.03 MODEL 454.0 1 Door paneling 2 Inner sealing rail P72.12-2478-04 Remove/install

1 Remove rear door paneling (1) AR72.12-P-1011FF 2 Remove inner sealing rail (2) from door Installation: The foam rubber layer of paneling (1) inner sealing ring (2) should point toward the window. 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-1013ff, Remove/install inner sealing rail on rear door MODEL 454.0

AR72.12-P-2310FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3022 · Applies to: 453 · AR: AR72.12-P-2310FF, AR72.12-P-1011FF

Remove/install inside door opener on rear door 13.8.03 MODEL 454.0 P72.12-2476-08 1 Panel 4 Bolt 8 Door foil 2 Door paneling 5 Grab handle 9 Catch hook 3 Inside door opener 6 Handle cover 10 Bolts 7 Control cable 11 Cable Remove/install

1 Remove door paneling (2) on rear door AR72.12-P-1011FF 2 Unclip handle cover (6) with snap-release tool *452589016300 Snap-release tool 3 Remove bolts (4) 4 Remove grab handle (5) 5 Detach door foil (8) in area of paneling (1) Installation:

Fasten door foil (8) with from door paneling (2) suitable double-sided adhesive tape. Replace damaged door foil (8). 6 Unclip control cable (7) from inside door opener (3). 7 Unhook pull wire (11) from inside door opener (3) 8 Unclip retaining hook (9) in area of paneling (1) 9 Remove paneling (1) 10 Unscrew bolts (10) from inside door opener (3) 11 Remove inside door opener (3) from paneling (1) 12 Install in the reverse order 452 589 01 63 00 Snap-release tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-2310ff, Remove/install inside door opener on rear door MODEL 454.0

AR72.12-P-2410FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3023 · Applies to: 453 · AR: AR72.12-P-2410FF

Remove/install outer rear door handle 13.8.03 MODEL 454.0 P72.12-2466-07 1 Rear door 2 Panel 3 Door handle 4 Bolt 3 Door handle 5 Tubular frame 6 Door paneling 7 Control cable 8 Bracket 9 Bracket 10 Lever P72.12-2467-11 Remove/install

1 Open rear door (1) 2 Unclip paneling (2) in marked area (arrow) and remove 3 Unscrew bolt (4) behind paneling (2) 4 Unhook door handle (3) from tubular frame (5) Remove door handle (3) toward rear. and door paneling (6). 5 Unclip bracket (8) from holder (9) 6 Detach control cable (7) from lever (10) 7 Unhook control cable (7) from door handle (3) 8 Remove door handle (3) 9 Install in the reverse order 10 Check door handle (3) for proper function Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-2410ff, Remove/install outer rear door handle MODEL 454.0

AR72.12-P-1014FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3024 · Applies to: 453 · AR: AR72.12-P-1014FF

Remove/install outer sealing rail on rear door 13.11.03 MODEL 454.0 1 Outer sealing rail 2 Snap-release tool P72.12-2479-04 Remove/install

1 Disconnect outer sealing rail (1) with snap- Loosen outer sealing rail carefully, to release tool (2) from bottom prevent to paint surfaces *452589016300 Snap-release tool 2 Remove outer sealing rail (1) upward 3 Install in the reverse order 452 589 01 63 00 Snap-release tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-1014ff, Remove/install outer sealing rail on rear door MODEL 454.0

AR72.12-P-0600FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3025 · Applies to: 453 · AR: AR72.12-P-0600FF

Remove/install rear door 13.8.03 MODEL 454.0 P72.12-2465-09 1 Rear door 2 Protective hose X35/3 Left rear door separation point 3 Bolt X35/4 Right rear door separation point Removal/installation

Risk of injury Danger! to fingers being jammed or When moving components, ensure that no AS00.00-Z-0011-01A

pinched when Remove/install or aligning body parts or limbs are within the operating hoods, doors, trunk lid/tailgate or sliding roof. range of moving parts. 1 Open rear door (1) 2 Loosen protective tube (2) from B-pillar 3 Remove left rear door separation point (X35/3) and right rear door separation point (X35/4) from B-pillar and disconnect 4 Unscrew bolts (3) *BA72.12-P-1001-01G

5 Remove rear front door (1) upward from door Do not handle front door (1) improperly, hinges and install in assembly device of door otherwise paintwork may be damaged. or lay down on suitable surface. Helper required *454589005900 Assembly device 6 Install in the reverse order Rear door

Number Designation Model 454.0 BA72.12-P-1001-01G Torx bolt for door hinge joint Nm 32 454 589 00 59 00 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-0600ff, Remove/install rear door MODEL 454.0

AR72.12-P-2660FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3027 · Applies to: 453 · AR: AR72.12-P-2660FF, AR72.12-P-0600FF

Remove/install rear door hinge 6.2.04 MODEL 454.0 1 Rear door 2 Upper door hinge 3 Lower door hinge 4 Bolt 5 Bolt 6 Bolt 7 Bolt P72.12-2496-06 Remove/Install

Risk of injury Danger! to fingers being jammed or When moving components, ensure that no AS00.00-Z-0011-01A

pinched when remove/install or aligning body parts or limbs are within the operating hoods, doors, trunk lid/tailgate or sliding roof. range of moving parts. 1 Remove rear door (1) and lay down on AR72.12-P-0600FF suitable subsurface 2 Unscrew bolts (5) from upper door hinge (2) Install spacers together with upper door and bolts (7) from lower door hinge (3) on rear hinge (2) and lower door hinge (3) if present door (1) When replacing spacers ensure that the spacer thickness is not changed *BA72.12-P-1005-01G

3 Remove upper door hinge (2) and lower door hinge (3) from rear door (1) 4 Unscrew bolts (4) from upper door hinge (2) Install spacers together with upper door and bolts (6) from lower door hinge (3) on B- hinge (2) and lower door hinge (3) if present pillar When replacing spacers, ensure that the spacer thickness is not changed *BA72.12-P-1004-01G

5 Remove upper door hinge (2) and lower door hinge (3) from B-pillar. 6 Install in the reverse order Rear door

Number Designation Model 454.0 BA72.12-P-1004-01G Torx bolt, door hinge to body Nm 34 BA72.12-P-1005-01G Torx bolt, door hinge to tubular frame Nm 34 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-2660ff, Remove/install rear door hinge MODEL 454.0

AR72.12-P-1011FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3028 · Applies to: 453 · AR: AR72.12-P-1011FF, AR72.10-P-1100FF, AR72.12-P-1940FF, AR72.12-P-0600FF

Remove/install rear door liner 13.8.03 MODEL 454.0 Shown on vehicle with code (V34) Rear power window (FFO) 1 Door lock 2 Tubular frame 3 Electrical connector 4 Retaining clamp 5 Bowden cable 6 Electrical connector (with code (V34) Rear power window (FFO)) 7 Guide 8 Door paneling 9 Bolt 10 Cover 11 Catch hook 12 Clip P72.12-2472-06 M10/5 Left rear power window motor (with code (V34) Rear M10/6 Right rear power window motor (with code (V34) Rear power window (FFO)) power window (FFO)) Removal/installation

1.1 Remove window crank Only on vehicles without code (V34) Rear AR72.10-P-1100FF power window (FFO) 2 Remove triangular window from rear door AR72.12-P-1940FF 3 Remove rear door and install in assembly AR72.12-P-0600FF device *454589005900 Assembly device 4 Unscrew bolt (9) from cover (10) 5 Unclip catch hook (11) and loosen cover (10) 6 Loosen cover (10) in bottom area of guides Installation:When installing cover (10)

(7) and remove ensure that wiring harness is routed properly. 7 Remove spreading clip in door liner (8) in area The spreading clip of the door liner (8) is of door lock (1) located above the bolt of the door lock (1) 8 Unscrew bolt (arrow) from door liner (8) 9.1 Disconnect electrical connector (6) from left Only on vehicles with code (V34) Rear power rear power window motor (M10/5) or right rear window (FFO) power window motor (M10/6) 10 Unclip clip (12) from wiring harness 11 Loosen door liner (8) from tubular frame (2) Installation:

Check retaining clips, from top to bottom replace if necessary 12 Slide door liner (8) upward out of guide of Door liner (8) is guided in area of inner tubular frame (2) sealing rail. Installation: Install door liner (8) from top

into guide of tubular frame (2) 13 Remove door liner (8) until Bowden cable (5) and electrical connector (3) are accessible 14 Separate electrical connector (3) Unclip retaining clips (4) and press in retainer to unlock electrical connector (3) 15 Unclip Bowden cable (5) from door lock (1) 16 Remove door liner (8) 17 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-1011ff, Remove/install rear door liner MODEL 454.0

AR72.12-P-2510FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3030 · Applies to: 453 · AR: AR72.12-P-2510FF, AR72.18-P-1000FG

Remove/install rear door lock 13.8.03 MODEL 454.0 1 Bolts 2 Door lock 3 Inside door opener control cable 4 Electrical connector 5 Outer door handle control cable P72.12-2474-06 Remove/install

1 Remove door paneling from rear door AR72.18-P-1000FG 2 Unscrew bolts (1) from door lock (2) 3 Turn door lock (2) until retaining clip of Do not damage door foil electrical connector (4) and the inside door opener control cable (3) are accessible 4 Disconnect electrical connector (4) from door Before disconnecting electrical connector lock (2) (4) release retaining clip 5 Unhook inside door opener control cable (3) from door lock (2) 6 Remove door lock (2). The rear door CL motor is integrated in the door lock (1) and cannot be replaced separately. 7.1 Unhook outer door handle control cable (5) When replacing door lock (2) from door lock (2) 8 Install in the reverse order 9 Check door lock (2) for proper function Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-2510ff, Remove/install rear door lock MODEL 454.0

AR72.12-P-1810FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3031 · Applies to: 453 · AR: AR72.12-P-1810FF, AR72.12-P-1920FF

Remove/install rear door power window 13.8.03 MODEL 454.0 with CODE (V34) Rear power windows (FFO) 1 Rear door 2 Rivet 3 Power window 4 Side impact protection 5 Opening 6 Electrical connector M10/5 Left rear power window motor M10/6 Right rear power window motor P72.12-2470-12 Remove/install

1 Remove rear door window (1) AR72.12-P-1920FF 2 Disconnect electrical connector (6) from left rear power window motor (M10/5) or right rear power window motor (M10/6) 3 Drill rivets (2) out of power window (3) Carefully drill out rivets (2) to prevent damage to tubular frame, side impact protection (4) or power window (3) Installation: Install new rivets (2) in with

rivet gun. *450589003900 Rivet gun 4 Remove power window (3) 5 Remove drilling chips and rivet residues Remove drilling chips and rivet residues in side impact protection (4) via opening (5) 6 Install in the reverse order 7 Check power window (3) for proper function 450 589 00 39 00 Rivet gun Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-1810ff, Remove/install rear door power window MODEL 454.0 with CODE (V34) Rear power windows (FFO)

AR72.12-P-1810FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3032 · Applies to: 453 · AR: AR72.12-P-1810FG, AR72.18-P-1000FG, AR72.12-P-1920FF, AR72.10-P-1100FF

Remove/install rear door power window 14.11.03 MODEL 454.0 except CODE (V34) Rear power windows (FFO) P72.12-2477-08 1 Door paneling 3 Power window 5 Bracket 2 Rear door 4 Rivets 6 Side impact protection Removal/installation

1 Remove rear door paneling (1) AR72.18-P-1000FG 2 Remove window in rear door AR72.12-P-1920FF 3 Remove window crank AR72.10-P-1100FF 4 Close rear door (2) 5 Drill rivets (4) out of power window (3) Carefully drill out rivets (4) to prevent damaging tubular frame, side impact protection (6) and power window (3). Installation:

Install rivets (4) with rivet gun *450589003900 Rivet gun 6 Move power window (3) downward and Proceed carefully during removal to remove bracket (5) in area of side impact prevent damaging the door foil or door liner protection (6). with the shaft of the crank window. 7 Remove power window (3) with bracket (5) in Proceed carefully during removal to area of side impact protection (6) upward prevent damaging the door foil or door liner with the shaft of the crank window. 8 Remove drilling chips and rivet residues Remove chips and rivet residues in area of side impact protection (6) through opening in front area with suitable tool 9 Install in the reverse order 10 Check power window (3) for proper function 450 589 00 39 00 Rivet gun Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-1810fg, Remove/install rear door power window MODEL 454.0 except CODE (V34) Rear power windows (FFO)

AR72.12-P-1940FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3033 · Applies to: 453 · AR: AR72.12-P-1940FF, AR72.12-P-1920FF

Remove/install rear door triangular window 13.8.03 MODEL 454.0 1 Triangular window 2 Rivet 3 Gasket 4 Tubular frame P72.12-2471-12 Remove/install

1 Remove window in rear door AR72.12-P-1920FF 2 Remove seal (3) in area of triangular window (1) until rivet (2) is easily accessible in the upper area 3 Drill out rivets (2) Carefully drill out rivets (2) to prevent damaging the tubular frame or triangular window (1) Installation: Install new rivets (2) in with

rivet gun. *450589003900 Rivet gun 4 Loosen triangular window (1) from tubular Installation: Ensure that triangular

frame (4) in marked area (arrows) and tilt out window (1) is seated correctly in marked area toward front (arrows). 5 Remove triangular window (1) 6 Remove drilling chips and rivet residues 7 Install in the reverse order 450 589 00 39 00 Rivet gun Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-1940ff, Remove/install rear door triangular window MODEL 454.0

AR72.12-P-0950FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3034 · Applies to: 453 · AR: AR72.12-P-0950FF, AR72.12-P-1810FG, AR72.12-P-1810FF, AR72.12-P-2510FF, AR72.12-P-1011FF (+1 more)

Remove/install tubular frame on rear door 22.10.03 MODEL 454.0 1 Gasket 2 Tubular frame 3 Door hinge assembly P72.12-2473-12 Remove/Install

1 Remove power window from rear door On vehicles without code (V34) Rear power AR72.12-P-1810FG window (FFO) On vehicles with code (V34) Rear power AR72.12-P-1810FF window (FFO) 2 Remove door lock from rear door AR72.12-P-2510FF 3 Remove door liner from rear door AR72.12-P-1011FF 4 Remove seal (1) from guide of tubular frame (2) 5 Remove tubular frame (2) from assembly 454589005900 Assembly device device 6 Unscrew bolts from door hinges (3) BA72.12-P-1005-01G

7 Remove door hinges (3) from tubular frame (2) 8 Install in the reverse order 9 Check gap dimensions of rear door and adjust AR72.12-P-0650FF Rear door

Number Designation Model 454.0 BA72.12-P-1005-01G Torx bolt, door hinge to tubular frame Nm 34 454 589 00 59 00 Assembly tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-0950ff, Remove/install tubular frame on rear door MODEL 454.0

AR72.12-P-1920FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3035 · Applies to: 453 · AR: AR72.12-P-1920FF, AR72.18-P-1000FG

Remove/install window in rear door 13.8.03 MODEL 454.0 Shown on vehicle with code (V34) Rear power window (FFO) 1 Window 2 Bracket 3 Retaining lug P72.12-2469-05 Remove/install

1 Remove door paneling from rear door AR72.18-P-1000FG 2 Move window (1) to bottom-most position 3 Press window (1) down and unclip retaining Carefully remove window (1) out of lug (3), then lift window (1) upward out of bracket (2) to prevent damaging bracket (2) bracket (2) and retaining lug (3). 4 Remove window (1) downward 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.12-p-1920ff, Remove/install window in rear door MODEL 454.0

AR72.18-P-1000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3036 · Applies to: 453 · AR: AR72.18-P-1000FF, AR72.10-P-0500FF, AR72.10-P-2400FF, AR72.10-P-1700FF

Remove/install door paneling 13.8.03 MODEL 454.0 Front door 1 Front door 2 Sealing rail 3 Bolt 4 Door paneling 5 Assembly device
P72.10-2867-12 Removal/installation

1 Remove front door (1) and install in assembly AR72.10-P-0500FF device (5) *454589005900 Assembly device 2 Remove outer door handle from front door (1) AR72.10-P-2400FF 3 Remove outer sealing rail (2) AR72.10-P-1700FF 4 Unscrew bolt (3) from door paneling (4) 5 Unhook door paneling (4) in area of sealing Handle door paneling (4) carefully to rail (2) prevent scratching and breakage Slightly press in door paneling (4) from outside and side upward Helper required for holding front door (1) 6 Slide door paneling (4) downward slightly and as far as possible in direction of arrow 7 Remove door paneling (4) downward from Handle door paneling (4) carefully to front door (1) prevent scratching and breakage 8 Install in the reverse order 454 589 00 59 00 Assembly tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.18-p-1000ff, Remove/install door paneling MODEL 454.0 Front door

AR72.18-P-1000FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3037 · Applies to: 453 · AR: AR72.18-P-1000FG, AR72.12-P-2410FF, AR72.12-P-1014FF

Remove/install door paneling 13.8.03 MODEL 454.0 Rear door P72.18-2016-09 1 Sealing rail 3 Door paneling 5 Door paneling 2 Bolt 4 Door handle 6 Guide Remove/Install

1 Remove outer door handle (4) from rear door AR72.12-P-2410FF 2 Remove sealing rail (1) AR72.12-P-1014FF 3 Unscrew bolt (2) from door paneling (3) 4 Protect longitudinal member in marked area (arrow) against damage with suitable covering material 5 Unhook door paneling (3) in area of outer Slightly press in door paneling (3) from sealing rail (1) outside and side upward 6 Lift door paneling (3) in area of door handle The guide (6) is illustrated with door (4) over guide (6) with suitable tool paneling removed (3) for better illustration 7 Pull off door paneling (3) downward Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.18-p-1000fg, Remove/install door paneling MODEL 454.0 Rear door

AR72.18-P-1000SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3038 · Applies to: 453 · AR: AR72.18-P-1000SRA, AR88.70-P-9000SRA, AR72.10-P-4015SRA, AR88.10-P-1000SRA

Remove/install door paneling 16.12.15 Model 453.3/4 P72.18-2019-09 Shown on left side of vehicle on model 453.3 1 Door paneling 6 Window 2 Screw 7 Seal 3 Sleeve 8 Bracket 4 Window channel strip 9 Catch Remove/install

1 Remove outside mirror AR88.70-P-9000SRA 2 Remove outside door handle on front door AR72.10-P-4015SRA 3 Remove front fender AR88.10-P-1000SRA 4 Remove bracket on front fender from body 5 Remove window channel strip (4) 6 Unscrew bolt (2) from door paneling (1) and remove with sleeve (3) 7 Open door from inside, carefully slide door

paneling (1) toward rear and lift over door Treat door paneling (1) carefully. panel lining in rear area (arrow A) Otherwise damage can be caused by breakage and scratches. Installation:

Do not damage seal (7) on window (6). Otherwise the seal (7) must be replaced. Installation: Seal (7) of window (6) must

run over window channel strip (4). 8 Carefully slide door paneling (1) toward front until brackets (8) are exposed in their guide in the door body shell 9 Slightly lift door paneling (1) in front and rear area of installation location of window channel strip (4) and pull toward outside until catches (9) disengage 10 Carefully slide door paneling (1) toward front Installation: Before installing door

and remove downward paneling (1), pull window channel strip (4) from rear onto door paneling (1). 11 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.18-p-1000sra, Remove/install door paneling Model 453.3/4

AR72.20-P-0002SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3039 · Applies to: 453 · AR: AR72.20-P-0002SRA

Adjust liftgate 06.08.2014 MODEL 453.3 P72.20-3337-08 1 Upper liftgate 4 Nuts 2 Top hinge 5 Upper lock striker 3 Nuts P72.20-3338-09 6 Bottom hinge 8 Lower liftgate 10 Side lock striker 7 Nut 9 Check strap 11 Bolts Page 1 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-0002sra, Adjust liftgate MODEL 453.3

Risk of injury

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3040 · Applies to: 453 · AR: AR72.20-P-2571SRA, AR68.30-P-4300SRA, AR72.20-P-4000SRA, AR72.20-P-2832SR

Danger ! caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Check

1 Check whether upper liftgate (1) and lower AR60.00-P-0700-01SR liftgate (8) can be closed easily and the gap dimensions are with the tolerance range MODEL 453.3 BE60.00-P-1024-01CA MODEL 453.3 BE60.00-P-1023-01CA MODEL 453.3 BE60.00-P-1022-01CA MODEL 453.3 BE60.00-P-1021-01CA *129589032100 Feeler gauge Remove

2 Remove check straps (9) from side lock striker To adjust lower liftgate (8). (10) AR72.20-P-2571SRA 3 Remove side lock striker (10) To adjust lower liftgate (8). 4 Lower headliner To adjust upper liftgate (1). AR68.30-P-4300SRA 5 Remove rear spoiler To adjust upper liftgate (1). AR72.20-P-4000SRA 6 Remove upper lock striker (5) To adjust upper liftgate (1). 7 Remove both gas-filled struts from upper To adjust upper liftgate (1). liftgate (1) AR72.20-P-2832SR Helper required to hold upper liftgate (1).

Adjusting lower liftgate 8 Loosen bolts (11) from hinges (6) It should be possible to move the lower

liftgate (8). 9 Align lower liftgate (8) and tighten bolts (11) AR60.00-P-0700-01SR BA72.20-P-1002-03SR Screw/bolt/nut, liftgate hinge to liftgate 129589032100 Feeler gauge 10 Loosen nuts (7) on hinges (6) It should be possible to move the lower

liftgate (8). 11 Align lower liftgate (8) and tighten nuts (7) AR60.00-P-0700-01SR BA72.20-P-1005-03SR Screw/bolt/nut, liftgate hinge to rear center section 129589032100 Feeler gauge Adjusting upper liftgate 12 Loosen nuts (3) on hinges (2) It should be possible to move the upper

liftgate (1). 13 Align upper liftgate (1) and tighten nuts (3) AR60.00-P-0700-01SR Helper required to hold upper liftgate (1).

BA72.20-P-1002-03SR Screw/bolt/nut, liftgate hinge to liftgate 129589032100 Feeler gauge 14 Loosen nuts (4) on hinges (2) It should be possible to move the upper

liftgate (1). 15 Align upper liftgate (1) and tighten nuts (4) AR60.00-P-0700-01SR Helper required to hold upper liftgate (1).

BA72.20-P-1001-03SR Screw/bolt/nut, liftgate hinge to roof frame 129589032100 Feeler gauge Check

16 Check whether upper liftgate (1) and lower If necessary, repeat adjustment.

liftgate (8) can be closed easily and the gap dimensions are with the tolerance range *129589032100 Feeler gauge Install

17 Install side lock strikers (10) 18 Remove check straps (9) from side lock AR72.20-P-2571SRA strikers (10) Adjust 19 Adjust transition between lower liftgate (8) The transition must be flush.

and edges to taillamp covers and B-pillars by moving side lock stroker (10) Install

Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-0002sra, Adjust liftgate MODEL 453.3

Install upper lock striker (5)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3041 · Applies to: 453 · AR: AR72.20-P-4000SRA, AR68.30-P-4300SRA, AR72.20-P-2832SR

20 Install upper lock striker (5) *BA72.20-P-1006-03SR Screw/bolt, lock striker to liftgate window Adjust 21 Adjust transition between upper liftgate (1) The transition must be flush.

and lower liftgate (8) by moving lock striker (5) Install

22 Install rear spoiler AR72.20-P-4000SRA 23 Install headliner AR68.30-P-4300SRA 24 Install both gas-filled struts on upper liftgate AR72.20-P-2832SR (1) Test and adjustment values for gap dimensions Number Designation MODEL 453.3 4 ( 1,5) BE60.00-P-1021-01CA Side spoiler to sidewall paneling Dimension "Q" mm Test and adjustment values for gap dimensions Number Designation MODEL 453.3 BE60.00-P-1022-01CA Rear window to liftgate Dimension "S" mm 4,5 (1,5) Test and adjustment values for gap dimensions Number Designation MODEL 453.3 BE60.00-P-1023-01CA Taillamp panel to liftgate Dimension "T" mm 4,5 (1,5) Test and adjustment values for gap dimensions Number Designation MODEL 453.3 5 ( 2) BE60.00-P-1024-01CA Bumper to lower liftgate Dimension "U" mm Liftgate Number Designation MODEL 453.3 BA72.20-P-1001-03SR Screw/bolt/nut, liftgate hinge to roof frame Nm 21 Liftgate Number Designation MODEL 453.3 BA72.20-P-1002-03SR Screw/bolt/nut, liftgate hinge to liftgate Nm 21 Liftgate Number Designation MODEL 453.3 BA72.20-P-1005-03SR Screw/bolt/nut, liftgate hinge to rear center section Nm 21 Liftgate Number Designation MODEL 453.3 BA72.20-P-1006-03SR Screw/bolt, lock striker to liftgate window Nm 12 129 589 03 21 00 Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-0002sra, Adjust liftgate MODEL 453.3

AR72.20-P-0002SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3043 · Applies to: 453 · AR: AR72.20-P-0002SRC, AR72.20-P-2571SRA, AR68.30-P-4700SRC

Adjust liftgate 12.1.16 Model 453.4 1 Liftgate 2 Check strap 3 Side lock striker 4 Bolts 5 Hinge 6 Nut P72.20-3500-06 Risk of injury Danger ! caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Check

1 Check whether liftgate (1) can be closed AR60.00-P-0700-01SR easily and the gap dimensions are within the tolerance range Soft top to liftgate BE60.00-P-1032-01CA Bumper to lower liftgate BE60.00-P-1024-01CA Taillamp panel to liftgate BE60.00-P-1023-01CA 129589032100 Feeler gauge Remove

2 Remove check straps (2) from side lock AR72.20-P-2571SRA strikers (3) 3 Remove paneling over side lock strikers (3) AR68.30-P-4700SRC 4 Remove side lock strikers (3) Adjust 5 Loosen bolts (4) of hinges (5) It must be possible to move the liftgate (1).

6 Align liftgate (1) and tighten bolts (4) AR60.00-P-0700-01SR Soft top to liftgate BE60.00-P-1032-01CA Bumper to lower liftgate BE60.00-P-1024-01CA Taillamp panel to liftgate BE60.00-P-1023-01CA BA72.20-P-1002-03SR Screw/bolt/nut, liftgate hinge to liftgate *129589032100 Feeler gauge 7 Loosen nuts (6) of hinges (5) It must be possible to move the liftgate (1).

8 Align liftgate (1) and tighten nuts (6) AR60.00-P-0700-01SR Soft top to liftgate BE60.00-P-1032-01CA Bumper to lower liftgate BE60.00-P-1024-01CA Taillamp panel to liftgate BE60.00-P-1023-01CA BA72.20-P-1005-03SR Screw/bolt/nut, liftgate hinge to rear center section *129589032100 Feeler gauge Install

9 Install side lock strikers (3) Do not yet tighten bolts of side lock strikers

(3). Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-0002src, Adjust liftgate Model 453.4

Install check straps (2) on side lock strikers

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3044 · Applies to: 453 · AR: AR72.20-P-2571SRA, AR68.30-P-4700SRC

10 Install check straps (2) on side lock strikers AR72.20-P-2571SRA (3) Adjust 11 Adjust transition of liftgate (1) to edges of The transition must be flush.

taillamp covers and sideways motion of lock strikers (3) Install

12 Tighten bolts of side lock strikers (3) 13 Install paneling over side lock strikers (3) AR68.30-P-4700SRC Test and adjustment values for gap dimensions Number Designation Model 453.4 4,5 ( 1,5) BE60.00-P-1023-01CA Taillamp panel to liftgate Dimension "T" mm Test and adjustment values for gap dimensions Number Designation Model 453.4 5 ( 2) BE60.00-P-1024-01CA Bumper to lower liftgate Dimension "U" mm Test and adjustment values for gap dimensions Number Designation Model 453.4 8 ( 2) BE60.00-P-1032-01CA Soft top to liftgate Dimension "V4" mm Liftgate Number Designation Model 453.4 BA72.20-P-1002-03SR Screw/bolt/nut, liftgate hinge to liftgate Nm 21 Liftgate Number Designation Model 453.4 BA72.20-P-1005-03SR Screw/bolt/nut, liftgate hinge to rear center section Nm 21 129 589 03 21 00 Feeler gauge Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-0002src, Adjust liftgate Model 453.4

AR72.20-P-3510FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3045 · Applies to: 453 · AR: AR72.20-P-3510FF, AR68.30-P-4490FF, AR82.20-P-0113FF, AR68.30-P-4330FF

Adjust tailgate 3.12.03 MODEL 454.0 P72.20-2375-09 1 Tailgate 4 Nut 7 Striker eye 2 Clip 5 Tailgate hinge 8 Bolt 3 Headliner 6 Bolts 9 Stop buffer Only on vehicles with code (E55) Glass roof with sun protection (FFO) 3 Headliner P72.20-2382-11 Risk of injury Danger! to fingers being jammed or When moving components, ensure that no AS00.00-Z-0011-01A

pinched when Remove/install or aligning body parts or limbs are within the operating hoods, doors, trunk lid/tailgate or sliding roof. range of moving parts. Adjust in longitudinal and transverse direction 1 Remove paneling on C-pillar AR68.30-P-4490FF Only upper C-pillar 2 Remove rear dome lamp AR82.20-P-0113FF 3 Remove clips (2) from headliner (3) 4.1 Remove rear grab handle from roof Only on vehicles with code (E55) Glass roof AR68.30-P-4330FF with sun protection (FFO) 5.1 Unhook headliner (3) in rear area (arrow) Only on vehicles with code (E55) Glass roof with sun protection (FFO) Installation:

Ensure that headliner (3) is seated properly. 6 Press headliner (3) downward To prevent damaging headliner (3), press headliner (3) down only until nuts (4) can be unscrewed Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-3510ff, Adjust tailgate MODEL 454.0

AR72.20-P-3515SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3048 · Applies to: 453 · AR: AR72.20-P-3515SRA

Open tailgate using emergency unlocking feature 22.12.15 Model 453.3/4 Model 453.3 1 Folding rear window lock 2 Emergency release lever P72.20-3493-11 Shown on left side of vehicle on model 453.3 3 Liftgate lock 4 Release lever 5 Lock striker P72.20-3291-11 Run 1 Fold over backrest 2 Remove load compartment cover Model 453.3/4 with code 723 (Luggage cover) 3 Actuate emergency release lever (2) from Model 453.3 inside on lock of folding rear window (1) 4 Using a suitable tool, actuate release lever (4) via lock striker (5) on liftgate lock (3) to the left and right in direction of arrows Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar72.20-p-3515sra, Open tailgate using emergency unlocking feature Model 453.3/4

AR72.20-P-2557SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3050 · Applies to: 453 · AR: AR72.20-P-2557SR, AR72.20-P-4065SR

Remove/install actuator of liftgate door lock 22.12.15 Model 453.0/3 Shown on model 453.0 1 Liftgate 2 Liftgate latch 3 Catch hook 4 Electrical connector S15/1 Trunk lid/liftgate release switch P72.20-3285-04 P72.20-3311-07 Shown on model 453.3 1 Liftgate 5 Bolts S15/1 Trunk lid/liftgate release switch 4 Electrical connector 6 Lock striker Risk of injury Danger ! caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Remove/install

1 Remove paneling from inside of liftgate (1) Model 453.0 2 Remove liftgate latch (2) Model 453.0 AR72.20-P-4065SR 3 Unclip trunk lid/liftgate release switch (S15/1) Model 453.0 through door lock opening (2) on catch tabs (3) and remove trunk lid/liftgate release switch (S15/1) until electrical connection (4) is accessible *452589016300 Clip remover 4 Mark position of lock striker (6) on liftgate (1) Model 453.3 5 Unscrew bolts (5) and remove lock striker (6) Model 453.3 Installation: Position lock striker (6) with

the aid of the applied marks. 6 Unscrew bolts of trunk lid/liftgate release Model 453.3 switch (S15/1) Bolts on trunk lid/liftgate release switch

(S15/1) are located below lock striker (6). 7 Disconnect electrical connection (4) and remove trunk lid/liftgate release switch (S15/1) 8 Install in the reverse order Check

9 Check function of trunk lid/liftgate release switch (S15/1) by mechanically locking the liftgate latch (2) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-2557sr, Remove/install actuator of liftgate door lock Model 453.0/3

AR72.20-P-2555FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3052 · Applies to: 453 · AR: AR72.20-P-2555FF, AR82.30-P-6900FF

Remove/install actuator of rear-end door lock 13.8.03 MODEL 454.0 1 Electrical connector 2 Bolt 3 Catch lug S62/35 Rear door button P72.20-2365-04 Remove/Install

1 Remove tailgate wiper motor AR82.30-P-6900FF 2 Disconnect electrical connector (1) from tailgate button (S62/35) 3 Unscrew bolt (2) 4 Unlock catch lug 83) and remove tailgate button (S62/35) from outside 5 Install in the reverse order 6 Perform function check Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-2555ff, Remove/install actuator of rear-end door lock MODEL 454.0

AR72.20-P-2571SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3053 · Applies to: 453 · AR: AR72.20-P-2571SRA

Remove/install check strap on liftgate 22.12.15 Model 453.3/4 Shown on model 453.3 on right side of vehicle 1 Check strap 2 Screw 3 Screw 4 Liftgate latch P72.20-3330-05 Remove/install

1 Unscrew bolt (2) in area of lock striker Do not loosen both check straps (1)

simultaneously. If it is necessary to replace both check straps (1), replace one after another. 2 Unscrew bolt (3) from liftgate latch (4) 3 Remove check strap (1) 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-2571sra, Remove/install check strap on liftgate Model 453.3/4

AR72.20-P-2832SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3054 · Applies to: 453 · AR: AR72.20-P-2832SR

Remove/install gas-operated strut from tailgate 22.12.15 Model 453.0/3 P72.20-3276-09 Shown on left side of vehicle on model 453.0 1 Pneumatic spring 3 Liftgate 2 Retainer 4 Screwdriver Risk of injury Danger ! from fingers being pinched or Only remove and install pneumatic springs AS00.00-Z-0012-01A

jammed when working on gas struts under when they are not under tension and when the pressure components are properly secured. Risk of injury Danger ! caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Remove/install

1 Secure liftgate (3) with suitable support 2 Lift lower retainer (2) with screwdriver (4),

and remove pneumatic spring (1) from roof Do not remove lower retainer (2). pillar Otherwise the tension on the lower retainer (2) can be lost. Installation: Clip pneumatic spring strut

(1) into ball head with lower retainer (2) installed. 3 Lift upper retainer (2) with screwdriver (4),

and detach and remove pneumatic spring (1) Do not remove upper retainer (2). from liftgate (3) Otherwise the tension on the upper retainer (2) can be lost. Installation: Clip pneumatic spring (1) into

ball head with upper retainer (2) installed. Risk of injury Danger ! caused by drilling gas-filled Wear safety glasses and a face mask. AS00.00-Z-0006-01A

assemblies or components (noncombustible gases) 4 Dispose of removed pneumatic spring (1) When replacing pneumatic spring (1). properly 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-2832sr, Remove/install gas-operated strut from tailgate Model 453.0/3

AR72.20-P-3600FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3055 · Applies to: 453 · AR: AR72.20-P-3600FF

Remove/install gas-operated strut on tailgate 14.8.03 MODEL 454.0 1 Gas-operated strut 2 Retainer 3 Rear door P72.20-2366-01 P72.20-2361-01 Remove/install

Injury hazard Danger! Gas-operated struts are under Remove and install gas-operated struts only AS00.00-Z-0012-01A

high pressure and can pinch and crush body in relaxed position and on components parts during work properly secured. 1 Open tailgate (3) and secure with suitable tool 2 Lift retainer (2) and remove gas-operated strut Do not remove retainer (2), otherwise (1) from tailgate (3) tension on retainer (2) can be lost Installation:

Clip gas-operated strut (1) into ball head (arrow) with retainer (2) installed 3 Lift retainer (2) and remove gas-operated strut Do not remove retainer (2), otherwise (1) from C-pillar tension on retainer (2) can be lost Installation:

Clip gas-operated strut (1) into ball head (arrow) with retainer (2) installed 4 Install in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-3600ff, Remove/install gas-operated strut on tailgate MODEL 454.0

AR72.20-P-2656SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3056 · Applies to: 453 · AR: AR72.20-P-2656SRA, AR72.20-P-1020SRA, AR68.30-P-4300SRA, AR72.20-P-0002SRA

Remove/install hinge of liftgate 06.08.2014 MODEL 453.3 P72.20-3332-08 1 Upper liftgate 3 Headliner 2 Liftgate hinge 4 Nuts Risk of injury Danger ! caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Remove/install

1 Remove upper liftgate (1) AR72.20-P-1020SRA 2 Remove headliner (3) AR68.30-P-4300SRA 3 Unscrew nuts (4) and remove liftgate hinge *BA72.20-P-1001-03SR Screw/bolt/nut, liftgate hinge to roof frame (2) on left and right 4 Install in the reverse order Check

5 Check gap dimensions on upper liftgate (1) AR72.20-P-0002SRA all the way around, correct if necessary Liftgate Number Designation MODEL 453.3 BA72.20-P-1001-03SR Screw/bolt/nut, liftgate hinge to roof frame Nm 21 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-2656sra, Remove/install hinge of liftgate MODEL 453.3

AR72.20-P-0004SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3057 · Applies to: 453 · AR: AR72.20-P-0004SRA, AR72.20-P-1016SRA

Remove/install inner cover on liftgate 06.08.2014 MODEL 453.3 P72.20-3292-09 1 Outside trim of liftgate 3 Lock 2 Hinge bolt 4 Inner cover Remove/install

1 Remove outer paneling from liftgate (1) AR72.20-P-1016SRA 2 Remove hinge bolt (2) toward outside with suitable tool 3 Open lock (3) on inner cover (4) and remove inner cover (4) 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-0004sra, Remove/install inner cover on liftgate MODEL 453.3

AR72.20-P-0004SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3058 · Applies to: 453 · AR: AR72.20-P-0004SRC

Remove/install inner cover on liftgate 12.1.16 Model 453.4 1 Inner cover 2 Tensioning straps 3 Bolts 4 Catches P72.20-3499-12 Remove/install

1 Open liftgate 2 Open tensioning straps (2) 3 Remove bolts (3) 4 Open inner cover (1) and pull upward to Installation: Catches (4) must audibly

remove click into place. 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-0004src, Remove/install inner cover on liftgate Model 453.4

AR72.20-P-0001FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3059 · Applies to: 453 · AR: AR72.20-P-0001FF

Remove/install inner cover on rear end door 14.8.03 MODEL 454.0 P72.20-2359-08 1 Rear-end door 3 Inner cover 4 Clip 2 Cap Remove/Install

1 Open tailgate (1) 2 Pry caps (2) off with suitable screwdriver 3 Unscrew bolts below caps (2) 4 Remove inner cover (3) from tailgate (1) Carefully press inner cover (3) off with snap-release tool to prevent damaging clips (4) *452589016300

5 Pull out inner cover (3) in direction of arrow Replace damaged clips (4) and remove 6 Install in the reverse order 452 589 01 63 00 Snap-release tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-0001ff, Remove/install inner cover on rear end door MODEL 454.0

AR72.20-P-1020SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3060 · Applies to: 453 · AR: AR72.20-P-1020SRA

Remove/install liftgate 06.08.2014 MODEL 453.3 P72.20-3308-08 Shown on upper liftgate 1 Upper liftgate 3 Cover 2 Bottom liftgate 4 Bolts P72.20-3309-08 Shown on upper liftgate 1 Upper liftgate 7 Washer fluid hose 10 Electrical wiring harness 5 Nuts 8 Electrical connector M6/4 Tailgate wiper motor 6 Grommet 9 Electrical connector X19 Rear window heater electrical connectors Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-1020sra, Remove/install liftgate MODEL 453.3

P72.20-3306-09

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3061 · Applies to: 453 · AR: AR72.20-P-4000SRA, AR72.20-P-2832SR, AR72.20-P-0002SRA, AR72.20-P-1016SRA

Shown on lower liftgate 2 Bottom liftgate 14 Screw 11 Door check strap 15 Liftgate hinge 12 Electrical connector 16 Nuts 13 Grommet Risk of injury Danger ! caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Remove/install upper liftgate 1 Remove rear spoiler AR72.20-P-4000SRA 2 Unscrew screws (4) and remove cover (3) 3 Disconnect electrical connectors from rear window heater (X19) 4 Disconnect electrical connections (8,9) 5 Detach grommet (6) 6 Unclip electrical wiring harness and guide out of upper liftgate (1) 7 Guide washer fluid hose (7) out of upper liftgate (1) 8 Unhook gas-filled strut on upper liftgate (1) AR72.20-P-2832SR 9 Unscrew nuts (5) and remove upper liftgate Helper required.

(1) and lay down on suitable base Installation: Repaint visible surfaces on

nuts (5) on left and right if damaged. *BA72.20-P-1002-03SR Screw/bolt/nut, liftgate hinge to liftgate 10 Install in the reverse order Check

11 Check gap dimensions on upper liftgate (1) AR72.20-P-0002SRA all the way around, correct if necessary. Remove/install lower liftgate 12 Remove outer paneling from liftgate AR72.20-P-1016SRA 13 Unscrew bolts (14) and lay door check straps (11) on left and right down to side 14 Disconnect electrical connector (12), loosen grommet (13) and guide subharness out of lower liftgate (2) 15 Mark position of left and right liftgate hinge (15) Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-1020sra, Remove/install liftgate MODEL 453.3

Unscrew nuts (16) on left and right liftgate

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3062 · Applies to: 453 · AR: AR72.20-P-0002SRA

16 Unscrew nuts (16) on left and right liftgate Helper required.

hinge (15), remove liftgate (2) and lay down on suitable subsurface Repaint visible surfaces on nuts (16) and

liftgate hinge (15) on left and right if damaged. *BA72.20-P-1005-03SR Screw/bolt/nut, liftgate hinge to rear center section 17 Install in the reverse order Check

18 Check gap dimensions on lower liftgate (2) all AR72.20-P-0002SRA the way around, correct if necessary. Liftgate Number Designation MODEL 453.3 BA72.20-P-1002-03SR Screw/bolt/nut, liftgate hinge to liftgate Nm 21 Liftgate Number Designation MODEL 453.3 BA72.20-P-1005-03SR Screw/bolt/nut, liftgate hinge to rear center section Nm 21 Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-1020sra, Remove/install liftgate MODEL 453.3

AR72.20-P-1020SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3063 · Applies to: 453 · AR: AR72.20-P-1020SRC, AR72.20-P-1016SRA, AR72.20-P-0002SRC, AR54.65-P-0022SR

Remove/install liftgate 12.1.16 Model 453.4 1 Liftgate 2 Screw 3 Check strap 4 Electrical connector 5 Grommet 6 Hinge 7 Nut P72.20-3501-06 Risk of injury Danger ! caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Remove/install

1 Remove outer paneling from liftgate (1) AR72.20-P-1016SRA 2 Remove bolts (2) and place check straps (3) to one side 3 Disconnect electrical connector (4) from outside 4 Loosen grommet (5) and guide electrical wiring harness out of liftgate (1) 5 Mark position of hinges (6) 6 Unscrew nuts (7), remove liftgate (1) and lay Installation: Observe any previous

down on a suitable surface markings. Helper required.

*BA72.20-P-1005-03SR Screw/bolt/nut, liftgate hinge to rear center section 7 Install in the reverse order 8 Adjust gap dimensions on liftgate (1) AR72.20-P-0002SRC Calibrate 9 Calibrate reversing camera using diagnostic Model 453.4 with code 218 (Rear view camera) system and calibration device Model 453.4 with code V52 (Combination code for rear parking aid and reversing camera) AR54.65-P-0022SR Liftgate Number Designation Model 453.4 BA72.20-P-1005-03SR Screw/bolt/nut, liftgate hinge to rear center section Nm 21 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-1020src, Remove/install liftgate Model 453.4

AR72.20-P-2558SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3064 · Applies to: 453 · AR: AR72.20-P-2558SRC, AR72.20-P-1016SRA

Remove/install liftgate unlocking switch 12.1.16 Model 453.4 1 Cover 2 Electrical connector S15/1 Trunk lid/liftgate release switch P72.20-3497-04 Risk of injury Danger ! caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Remove/install

1 Loosen paneling (1) on outside of liftgate until AR72.20-P-1016SRA trunk lid/liftgate release switch (S15/1) is accessible 2 Release and disconnect electrical connection (2) 3 Release trunk lid/liftgate release switch (S15/1) from inside, and pull outwards to remove 4 Install in the reverse order Check

5 Check function of trunk lid/liftgate release switch (S15/1) by mechanically locking liftgate latches Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar72.20-p-2558src, Remove/install liftgate unlocking switch Model 453.4

AR72.20-P-1016SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3065 · Applies to: 453 · AR: AR72.20-P-1016SRA

Remove/install outside trim on liftgate 22.12.15 Model 453.3/4 Shown on model 453.3 1 Cover 2 Cover (model 453.3) 3 Liftgate inner cover 4 Bolts E19/1 Left license plate lamp E19/2 Right license plate lamp P72.20-3310-06 Shown on model 453.4 with code V52 (combination code for rear parking assist and reversing camera) 1 Cover 5 Electrical connector (model 453.4) 6 Electrical wiring harness (with code 218 (reversing camera) or with code V52 (combination code for rear parking assist and reversing camera) P72.20-3496-04 B84/3x1 Reversing camera electrical connector (with code 218 (reversing camera) or with code V52 (combination code for rear parking assist and reversing camera) Risk of injury Danger ! caused by fingers being No parts of the body or limbs should be within AS00.00-Z-0011-01A

jammed or pinched when removing, installing the operating area when the components are or aligning hoods, doors, trunk lid/rear-end moving. door or sliding roof. Remove/install

1 Unclip cover (2) Model 453.3 2 Open liftgate inner cover (3) Model 453.3 3 Remove screws (4) 4 Fold out paneling (1) in upper area until left license plate lamp (E19/1) and right license plate lamp (E19/2) are accessible 5 Unclip left license plate lamp (E19/1) and right license plate lamp (E19/2) from paneling (1), and remove 6 Disconnect electrical connection (5) Model 453.4 7 Detach electrical connection from backup Model 453.3/4 with code 218 (Rear view camera) camera (B84/3x1) Model 453.3/4 with code V52 (Combination code for rear parking aid and reversing camera) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-1016sra, Remove/install outside trim on liftgate Model 453.3/4

AR72.20-P-3500FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3067 · Applies to: 453 · AR: AR72.20-P-3500FF, AR88.30-P-0500FF, AR72.20-P-0001FF

Remove/install tailgate 3.12.03 MODEL 454.0 P72.20-2376-08 1 Tailgate 3 Electrical connector 5 Gas-operated strut 2 Washer fluid hose 4 Retainer 6 Bolts 1 Tailgate 7 Wiring harness 8 Grommet 9 Grommet P72.20-2379-11 Remove/Install

1 Remove rear spoiler AR88.30-P-0500FF 2 Remove inner cover from tailgate (1) AR72.20-P-0001FF 3 Unclip electrical connector (3) and disconnect 4 Detach grommet (8, 9) from tailgate (1) 5 Before pulling out the wiring harness (7) fasten pulling wire (arrow) and pull wiring harness (7) out of tailgate 6 Pull out washing water hose (2) Injury hazard Danger! Gas-operated struts are under Remove and install gas-operated struts only AS00.00-Z-0012-01A

high pressure and can pinch and crush body in relaxed position and on components parts during work properly secured. 7 Lift retainer (4) with suitable screwdriver and Secure tailgate (1) with suitable tool

remove gas-operated struts (5) from tailgate (1) 8 Remove bolts (6) *BA72.20-P-1002-02G

9 Remove tailgate (1) with helper Lay tailgate (1) down on suitable surface 10 Install in the reverse order 11 Perform function check 12 Check dimensions gaps on tailgate (1) AR60.00-P-0700-01FF BE60.00-P-1005-01M BE60.00-P-1006-01M *452589012100

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-3500ff, Remove/install tailgate MODEL 454.0

If necessary:

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3068 · Applies to: 453 · AR: AR72.20-P-3510FF

Adjust tailgate AR72.20-P-3510FF Test and adjustment values Number Designation Model 454.0 Dimension "M" 5.0 ( 1.0) Gap CBS rear end to C-pillar mm BE60.00-P-1005-01M dimension Dimension "N" 7.0 ( 2.0) CBS rear end to tailgate mm Dimension "O" 6.5 ( 1.0) Gap Tailgate to C-pillar mm BE60.00-P-1006-01M dimension 7.0 ( 1.0) Tailgate to taillamp Dimension"P" mm Dimension "Q" 6.5 ( 2.0) Tailgate to CBS rear end, side mm Tailgate

Number Designation Model 454.0 BA72.20-P-1002-02G Bolt, tailgate hinge to tailgate Nm 9 452 589 01 21 00 Feeler gauge Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-3500ff, Remove/install tailgate MODEL 454.0

AR72.20-P-2560FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3069 · Applies to: 453 · AR: AR72.20-P-2560FF, AR72.20-P-3500FF, AR68.30-P-4490FF, AR82.20-P-0113FF, AR68.30-P-4330FF

Remove/install tailgate hinge 3.12.03 MODEL 454.0 1 Left door hinge 2 Right door hinge 3 Clip 4 Headliner 5 Nut P72.20-2377-03 Only on vehicles with code (E55) Glass roof with sun protection (FFO) 4 Headliner P72.20-2383-11 Remove/Install

1 Remove tailgate AR72.20-P-3500FF 2 Mark installation position of left door hinge (1) Marking facilitates assembly and right door hinge (2) on roof frame 3 Remove paneling on C-pillar AR68.30-P-4490FF Only upper C-pillar 4 Remove rear dome lamp AR82.20-P-0113FF 5 Unclip clips (3) from headliner (4) 6.1 Remove rear grab handle from roof Only on vehicles with code (E55) Glass roof AR68.30-P-4330FF with sun protection (FFO) 7.1 Unhook headliner (4) in rear area (arrow) Only on vehicles with code (E55) Glass roof with sun protection (FFO) Installation:

Ensure that headliner (4) is seated properly. 8 Press headliner (4) downwards To prevent damaging the headliner (4), press headliner (4) down only until nuts (5) can be unscrewed 9 Unscrew nuts (5) and remove left door hinge *BA72.20-P-1001-02G

(1) and right door hinge (2) 10 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-2560ff, Remove/install tailgate hinge MODEL 454.0

AR72.20-P-2550FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3071 · Applies to: 453 · AR: AR72.20-P-2550FF

Remove/install tailgate lock 14.8.03 MODEL 454.0 Shown with inner cover removed 1 Rear-end door 2 Tailgate lock 3 Bolts 4 Electrical connector 5 Electrical connector P72.20-2373-06 Remove/Install

1 Unscrew bolts (3) 2 Remove tailgate door lock (2) from tailgate (1) until electrical connectors (4, 5) are accessible 3 Disconnect electrical connectors (4, 5) and remove tailgate door lock (2) 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-2550ff, Remove/install tailgate lock MODEL 454.0

AR72.20-P-4000SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3072 · Applies to: 453 · AR: AR72.20-P-4000SRA, AR82.35-P-7338SR, AR82.10-P-5375SRA

Removing and installing rear spoiler 13.08.2014 MODEL 453.3 P72.20-3307-09 1 Left rear spoiler side section 5 Rear spoiler 9 Guide 2 Right rear spoiler side section 6 Rear window spray nozzle E21 Center stop lamp 3 Bolts 7 Electrical connector 4 Bolts 8 Retaining lug Remove/install

1 Mask upper roof edge in area of rear spoiler So that roof cannot be damaged.

(5) 2 Open liftgate 3 Unscrew bolts (3) and remove left rear spoiler section (1) and right rear spoiler side section (2) 4 Unscrew bolts (4) and remove rear spoiler (5) Installation: Guide retaining lug (8) into

until rear window spray nozzle (6) is guide (9). accessible 5 Remove rear window spray nozzle (6) AR82.35-P-7338SR 6 Disconnect electrical connector (7) and remove rear spoiler 7 Remove center brake lamp (E21) Only when replacing rear spoiler (5). AR82.10-P-5375SRA 8 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.20-p-4000sra, Removing and installing rear spoiler MODEL 453.3

AZ72.20-P-0005FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3073 · Applies to: 453 · AR: AZ72.20-P-0005FF, AR72.20-P-0001FF

Retrofit roller blind for rear-end door 17.1.06 MODEL 454.0 P72.20-2392-09 1 Rear-end door 3 Inner cover with roller blind 5 Hook 2 Cap 4 Clip 6 Bolt Remove

1 Remove inner cover from rear-end door (1) Remove, install inner cover on rear-end door AR72.20-P-0001FF

2 Remove cap (2) on left and right from rear- end door (1). Install

3 Install inner cover with roller blind (3) on rear- end door (1) Remove/install inner cover on rear-end door AR72.20-P-0001FF

4 Install clip (4) on left and right in rear-end door (1). 5 Insert hook (5) on left and right into rear-end Ensure that hook (5) is seated correctly. door (1) and tighten with bolt (6). 6 Close cover on hooks (5). 7 Check roller blind for proper function 8.1 Enter special equipment in the vehicle data If a DMS Autoline 8.0 dealer system is not card and in the vehicle's online data card available in the workshop. Enter code (I98) Rear window roller blind. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, az72.20-p-0005ff, Retrofit roller blind for rear-end door MODEL 454.0

PE72.29-P-2050BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3075 · Applies to: 453 · AR: PE72.29-P-2050BBA

Electrical function diagram for power windows 13.09.2016 Model 453.0/3/4 with code 584 (Power windows with convenience controls and obstruction sensor) except code 583 (Power windows) Electrical function diagram for power windows PE72.29-P-2050-97BBA Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe72.29-p-2050bba, Electrical function diagram for power windows Model 453.0/3/4 with code 584 (Power windows with convenience controls and obstruction sensor) except code 583 (Power windows)

PE72.29-P-2050BBB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3076 · Applies to: 453 · AR: PE72.29-P-2050BBB

Electrical function diagram for power windows 23.05.2017 Model 453.0/3/4 with code 583 (Power windows) except code 584 (Power windows with convenience controls and obstruction sensor) Electrical function diagram for power windows PE72.29-P-2050-97BBB Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe72.29-p-2050bbb, Electrical function diagram for power windows Model 453.0/3/4 with code 583 (Power windows) except code 584 (Power windows with convenience controls and obstruction sensor)

GF72.29-P-9997KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3077 · Applies to: 453 · AR: GF72.29-P-9997KJ, GF54.21-P-7011KJ, GF72.29-P-0998KJ

Overview of system components for power windows (PW) 19.04.2018 Model 453.0/3/4 P72.29-2820-79 Shown on model 453.0 Code 583 Power windows M10/4n1 Right front power window S21/1 Driver's side power window motor actuation unit (only for switch (vehicles with code code 584 (Power window with 583 (Power window) as of convenience feature and model year 2018) reversing function)) Code 584 Power windows with M14/5s1 Front passenger door central S21/2 Passenger-side power window convenience feature and locking system microswitch switch reversing function F2k2 Front power window relay M14/6s1 Driver door central locking U2019 Valid up to model year 2017 system microswitch (incl. MY 2017) M10/3 Left front power window motor N10/10 Center SAM control unit U2020 Valid as of model year 2018 M10/3n1 Left front power window motor S2 Ignition lock actuation unit (only for code 584 (Power window with convenience feature and reversing function)) M10/4 Right front power window S20/1 Driver's side power window motor switch group (all vehicles up to and including MY 2017 and all vehicles as of model year 2018 with code 584 (Power window with convenience feature and reversing function)) Center SAM control unit, component N10/10 GF54.21-P-7011KJ description Table of contents, function description for GF72.29-P-0998KJ power windows (PW) Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf72.29-p-9997kj, Overview of system components for power windows (PW) Model 453.0/3/4

AR72.29-P-0100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3078 · Applies to: 453 · AR: AR72.29-P-0100FF, AR68.20-P-2350FF

Remove/install front power window switches 13.8.03 MODEL 454.0 Shown on vehicle with code (V34) Rear power window (FFO) 1 Cover S21/1 Left front power window switch S21/2 Right front power window switch P72.29-2266-04 Remove/install

1 Remove rear cover (1) from center console AR68.20-P-2350FF 2 Unclip left front power window switch (S21/1) Carefully unclip left front power window or right front power window switch (S21/2) out switch (S21/1) or right front power window of cover (1) from bottom and remove switch (S21/2) to prevent scratching and breakage 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.29-p-0100ff, Remove/install front power window switches MODEL 454.0

AR72.29-P-0100SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3079 · Applies to: 453 · AR: AR72.29-P-0100SR

Remove/install front power window switches 6.8.14 MODEL 453 Shown on left side of vehicle 2 Assembly wedge 4 Electrical connector S20/1 Power window switch group, driver side P72.10-4260-06 Remove/install

1 Open door and unclip driver side power *110589035900 Mounting wedge window switch group (S20/1) in rear area with assembly (2) and remove until electrical connector (4) is accessible 2 Disconnect electrical connector (4) from driver side power window switch group (S20/1) and remove driver side power window switch group (S20/1) 3 Install in the reverse order 110 589 03 59 00 Mounting wedge Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.29-p-0100sr, Remove/install front power window switches MODEL 453

AR72.29-P-0002FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3080 · Applies to: 453 · AR: AR72.29-P-0002FF, AR68.20-P-2350FF

Remove/install switches for power window in rear doors 13.8.03 MODEL 454.0 with CODE (V34) Rear power windows (FFO) 1 Cover S21/3 Left rear power window switch S21/4 Right rear power window switch P72.29-2267-04 Remove/install

1 Remove rear cover (1) from center console AR68.20-P-2350FF 2 Unclip left rear power window switch (S21/3) Carefully unclip left rear power window or right rear power window switch (S21/4) out switch (S21/3) or right rear power window of cover (1) from bottom and remove switch (S21/4) to prevent scratching and breakage 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.29-p-0002ff, Remove/install switches for power window in rear doors MODEL 454.0 with CODE (V34) Rear power windows (FFO)

AR72.29-P-1860SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3081 · Applies to: 453 · AR: AR72.29-P-1860SRA, AR72.10-P-1961SRA

Remove/installing front door power window motor 16.12.15 Model 453.3/4 1 Bolts 2 Electrical connector M10/3 Left front power window motor M10/4 Right front power window motor P72.29-2826-11 Remove/install

1 Remove side window in front door AR72.10-P-1961SRA 2 Remove bolts (1) 3 Disconnect electrical connector (2) 4 Remove left front power window motor (M10/3) or right front power window motor (M10/4) toward rear 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar72.29-p-1860sra, Remove/installing front door power window motor Model 453.3/4

GF72.29-P-0998KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3082 · Applies to: 453 · AR: GF72.29-P-0998KJ, GF72.29-P-0003KJ, GF72.29-P-9997KJ

Table of contents, function description for power windows (PW) 19.04.2018 Model 453.0/3/4 Power windows (PW (EFH)), function GF72.29-P-0003KJ Overview of system components for power GF72.29-P-9997KJ windows (PW) Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf72.29-p-0998kj, Table of contents, function description for power windows (PW) Model 453.0/3/4

PE72.29-P-2100ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3083 · Applies to: 453 · AR: PE72.29-P-2100ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Wiring diagram for power windows (2-fold) 8.3.06 MODEL 454 as of 3.4.06 PE72.29-P-2100-99ZB Wiring diagram for power windows PE72.29-P-2100-99ZB (2-fold) PE72.29-P-2100-60ZB Legend of wiring diagrams for power windows PE72.29-P-2100-60ZB (2-fold) OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Location and assignment of line and plug GF00.19-P-1000ZA connectors GF00.19-P-2000ZA Location and assignment of ground points GF00.19-P-2000ZA GF00.19-P-3000ZA Location and assignment of Z connector GF00.19-P-3000ZA sleeves (line connectors in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe72.29-p-2100zb, Wiring diagram for power windows (2-fold) MODEL 454 as of 3.4.06

PE72.29-P-2000ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3084 · Applies to: 453 · AR: PE72.29-P-2000ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Wiring diagram for power windows (4-fold) 8.3.06 MODEL 454 as of 3.4.06 PE72.29-P-2000-99ZB Wiring diagram for power windows (4-fold) PE72.29-P-2000-99ZB PE72.29-P-2000-60ZB Legend of wiring diagrams for power windows PE72.29-P-2000-60ZB (4-fold) OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Location and assignment of line and plug GF00.19-P-1000ZA connectors GF00.19-P-2000ZA Location and assignment of ground points GF00.19-P-2000ZA GF00.19-P-3000ZA Location and assignment of Z connector GF00.19-P-3000ZA sleeves (line connectors in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe72.29-p-2000zb, Wiring diagram for power windows (4-fold) MODEL 454 as of 3.4.06

PE72.29-P-2001BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3092 · Applies to: 453 · AR: PE72.29-P-2001BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram for power windows 11.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code 583 (Power windows) except code 584 (Power windows with convenience controls and obstruction sensor) except code ICPA (Standard equipment) Wiring diagram for power windows PE72.29-P-2001-97BBA Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe72.29-p-2001bba, Wiring diagram for power windows Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code 583 (Power windows) except code 584 (Power windows with convenience ...

PE72.29-P-2001BBB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3093 · Applies to: 453 · AR: PE72.29-P-2001BBB, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram for power windows 11.08.2019 Model 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code 583 (Power windows) with code ICPA (Standard equipment) except code 584 (Power windows with convenience controls and obstruction sensor) except code P74 (Comfort package) except code V21 (Electrically adjustable and heated outside mirrors (FFO)) Wiring diagram for power windows PE72.29-P-2001-97BBB Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe72.29-p-2001bbb, Wiring diagram for power windows Model 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code 583 (Power windows) with code ICPA (Standard equipment) except code 584 (Power windows with ...

PE72.29-P-2001BBC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3094 · Applies to: 453 · AR: PE72.29-P-2001BBC, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram for power windows 11.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code 584 (Power windows with convenience controls and obstruction sensor) except code 583 (Power windows) Wiring diagram for power windows PE72.29-P-2001-97BBC Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe72.29-p-2001bbc, Wiring diagram for power windows Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code 584 (Power windows with convenience controls and obstruction sensor) except ...

PE72.29-P-2000ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3095 · Applies to: 453 · AR: PE72.29-P-2000ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Wiring diagram of power windows (4-fold) 2.2.04 MODEL 454 up to 2.4.06 PE72.29-P-2000-99ZA Wiring diagram of power windows (4-fold) PE72.29-P-2000-99ZA PE72.29-P-2000-60ZA Legend of wiring diagram for power windows PE72.29-P-2000-60ZA (4-fold) OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Arrangement and assignment of the wiring GF00.19-P-1000ZA and plug connectors GF00.19-P-2000ZA Arrangement and assignment of ground GF00.19-P-2000ZA points GF00.19-P-3000ZA Arrangement and assignment of Z connector GF00.19-P-3000ZA sleeves (wiring connections in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe72.29-p-2000za, Wiring diagram of power windows (4-fold) MODEL 454 up to 2.4.06

PE72.29-P-2100ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3096 · Applies to: 453 · AR: PE72.29-P-2100ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Wiring diagram of power windows 2-fold 2.2.04 MODEL 454 up to 2.4.06 PE72.29-P-2100-99ZA Wiring diagram of power windows 2-fold PE72.29-P-2100-99ZA PE72.29-P-2100-60ZA Legend of wiring diagram for power windows PE72.29-P-2100-60ZA 2-fold OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Arrangement and assignment of the wiring GF00.19-P-1000ZA and plug connectors GF00.19-P-2000ZA Arrangement and assignment of ground GF00.19-P-2000ZA points GF00.19-P-3000ZA Arrangement and assignment of Z connector GF00.19-P-3000ZA sleeves (wiring connections in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe72.29-p-2100za, Wiring diagram of power windows 2-fold MODEL 454 up to 2.4.06

BE77.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3102 · Applies to: 453 · AR: BE77.00-Z-9999CZ

Test and adjustment values: Smart: Sliding roof, soft top, top attachments 18.09.2019 MODEL all Soft top MODEL 451.4 BE77.30-P-1000-02A Vario roof and soft top mechanism MODEL 451.4 BE77.33-P-1000-01B Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be77.00-z-9999cz, Test and adjustment values: Smart: Sliding roof, soft top, top attachments MODEL all

AR77.20-P-1100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3104 · Applies to: 453 · AR: AR77.20-P-1100FF

Adjust tilting/sliding roof panel 18.12.03 MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO) P77.20-2447-09 Shown on left side of vehicle 1 Glass sliding roof 3 Rear bolt 5 Front bolt 2 Headliner 4 Center bolt P77.20-2436-07 Shown on left side of vehicle 1 Glass sliding roof 7 Rear seal 6 Roof paneling 8 Front seal Check

1 Move roller sun blind to rear-most position See Operating Instructions (open) 2 Open glass sliding roof (1) until front bolts (5) See Operating Instructions on left and right on glass sliding roof (1) are accessible 3 Loosen front left and right bolts (5) from glass Proceed carefully in area of headliner (2) sliding roof (1) to prevent damage or soiling 4 Close glass sliding roof (1) See Operating Instructions 5 Loosen rear bolt (3) and center bolt (4) on left Proceed carefully in area of headliner (2) and right on glass sliding roof (1) to prevent damage or soiling 6 Center glass sliding roof (1) between front Helper required seal (8) and rear seal (7) *452589012100 Feeler gauge 7 Measure height of glass sliding roof (1) in The glass sliding roof (1) should be relation to edges of roof paneling (6) with 1 mm deeper at front and 1 mm higher at rear suitable tool on outer edges than the corresponding edge of the roof paneling (6) 8 Move glass sliding roof (1) at one corner to Proceed carefully in area of headliner (2) the correct position and tighten associated to prevent damage or soiling rear bolt (3) or center bolt (4). Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.20-p-1100ff, Adjust tilting/sliding roof panel MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO)

PE77.20-P-2002ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3106 · Applies to: 453 · AR: PE77.20-P-2002ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Block diagram of tilting/sliding roof (SR) 8.3.04 MODELS 454 PE77.20-P-2002-99ZA Block diagram of tilting/sliding roof (SR) PE77.20-P-2002-99ZA PE77.20-P-2002-60ZA Legend of block diagram of tilting/sliding roof PE77.20-P-2002-60ZA (SR) OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Arrangement and assignment of the wiring GF00.19-P-1000ZA and plug connectors GF00.19-P-2000ZA Arrangement and assignment of ground GF00.19-P-2000ZA points GF00.19-P-3000ZA Arrangement and assignment of Z connector GF00.19-P-3000ZA sleeves (wiring connections in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE77.00-P-1100ZA Further wiring diagrams PE77.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe77.20-p-2002za, Block diagram of tilting/sliding roof (SR) MODELS 454

PE77.20-P-2200BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3111 · Applies to: 453 · AR: PE77.20-P-2200BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Electric wiring diagram for panoramic sliding roof 11.08.2019 Model 453.0 (except 453.091) up to model year 2020 Electric wiring diagram for panoramic sliding PE77.20-P-2200-97BBA sunroof Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe77.20-p-2200bba, Electric wiring diagram for panoramic sliding roof Model 453.0 (except 453.091) up to model year 2020

PE77.20-P-2001ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3112 · Applies to: 453 · AR: PE77.20-P-2001ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Electric wiring diagram for sliding roof 8.3.06 MODEL 454 as of 3.4.06 PE77.20-P-2001-99ZB Electric wiring diagram for sliding roof PE77.20-P-2001-99ZB PE77.20-P-2001-60ZB Legend of electric wiring diagram for sliding PE77.20-P-2001-60ZB roof OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Location and assignment of line and plug GF00.19-P-1000ZA connectors GF00.19-P-2000ZA Location and assignment of ground points GF00.19-P-2000ZA GF00.19-P-3000ZA Location and assignment of Z connector GF00.19-P-3000ZA sleeves (line connectors in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe77.20-p-2001zb, Electric wiring diagram for sliding roof MODEL 454 as of 3.4.06

PE77.20-P-2001ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3113 · Applies to: 453 · AR: PE77.20-P-2001ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Electric wiring diagram, sliding roof 16.12.03 MODEL 454 up to 2.4.06 PE77.20-P-2001-99ZA Electric wiring diagram, sliding roof PE77.20-P-2001-99ZA PE77.20-P-2001-60ZA Legend of wiring diagram, sliding roof PE77.20-P-2001-60ZA OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Arrangement and assignment of the wiring GF00.19-P-1000ZA and plug connectors GF00.19-P-2000ZA Arrangement and assignment of ground GF00.19-P-2000ZA points GF00.19-P-3000ZA Arrangement and assignment of Z connector GF00.19-P-3000ZA sleeves (wiring connections in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe77.20-p-2001za, Electric wiring diagram, sliding roof MODEL 454 up to 2.4.06

AR77.20-P-0003FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3114 · Applies to: 453 · AR: AR77.20-P-0003FF

Remove/install glass sliding roof 17.9.03 MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO) P77.20-2447-09 Shown on left side of vehicle 1 Glass sliding roof 3 Rear bolt 5 Front bolt 2 Headliner 4 Center bolt P77.20-2436-07 Shown on left side of vehicle 1 Glass sliding roof 7 Rear seal 6 Roof paneling 8 Front seal Remove

1 Move roller sun blind to rear-most position See Operating Instructions (open) 2 Open glass sliding roof (1) until rear bolts (3) See Operating Instructions on left and right on glass sliding roof (1) are accessible 3 Unscrew bolts (3) on left and right from glass Proceed carefully in area of headliner (2) sliding roof (1) to prevent damage or soiling 4 Open glass sliding roof (1) until center bolt (4) See Operating Instructions and front left and right bolts (5) on glass sliding roof (1) are accessible 5 Unscrew center bolt (4) and front left and right Proceed carefully in area of headliner (2) bolts (5) on glass sliding roof (1) to prevent damage or soiling 6 Remove glass sliding roof (1) upward Helper required Install

7 Carefully install glass sliding roof (1) on Helper required mounts of roof paneling (6) 8 Loosely screw in center bolts (4) and front left Proceed carefully in area of headliner (2) and right bolts on glass sliding roof (1) to prevent damage or soiling 9 Close glass sliding roof (1) until threads for See Operating Instructions left and right rear bolts (3) on glass sliding roof (1) are accessible Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.20-p-0003ff, Remove/install glass sliding roof MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO)

AR77.20-P-3015FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3116 · Applies to: 453 · AR: AR77.20-P-3015FF, AR68.30-P-4300FF

Remove/install roller sun blind on tilting/sliding roof 19.10.05 MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO) P77.20-2594-09 Shown on vehicle with code (I55) Head airbag (FFO) 1 Bolt 4 Sliding rail 6 Guide rail 2 Roller sun blind 5 Roller blind guide 16 Clip 3 Crossmember P77.20-2442-09 Shown on vehicle with code (I55) Head airbag (FFO) 2 Roller sun blind 8 Bore 9 Clock-type spring 7 Tie strap Remove/install

1 Remove headliner AR68.30-P-4300FF 2 Remove bolts (1) 3 Remove crossmember (3) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.20-p-3015ff, Remove/install roller sun blind on tilting/sliding roof MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO)

AR77.20-P-1330FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3118 · Applies to: 453 · AR: AR77.20-P-1330FF, AR77.20-P-0003FF

Remove/install seal for glass sliding roof 17.9.03 MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO) seals on roof paneling P77.20-2430-08 1 Glass sliding roof 3 Front seal 5 Guide rails 2 Glass sliding roof paneling 4 Glass sliding roof seal 6 Side seal Remove/install

The side seals (6), the front seal (3) and the

glass sliding roof seal (4) can be removed separately. Side seals (6) 1 Remove side seal (6) from glass sliding roof Side seals (6) are glued to glass sliding paneling (2) roof paneling (2) and destroyed during removal Installation: Replace side seals

(6)Ensure that side seals (6) are seated correctly on glass sliding roof paneling (2). 2 Remove glue residues from glass sliding roof Cleaner and primer are included in scope paneling (2), clean gluing surfaces and apply of delivery. primer. Front seal (3) 3 Open glass sliding roof (1) 4 Remove front seal (3) from glass sliding roof The front seal (3) is glued to the glass paneling (2) sliding roof paneling (2) and is damaged during removal Installation: Replace front seal (3).

Ensure that front seal (3) is seated correctly on glass sliding roof paneling (2). 5 Remove glue residues from glass sliding roof Cleaner and primer are included in scope paneling (2), clean gluing surfaces and apply of delivery. primer. Glass sliding roof seal (4) 6 Remove glass sliding roof (1) AR77.20-P-0003FF 7 Move guide rails (5) for glass sliding roof (1) toward front 8 Remove glass sliding roof seal (4) from glass Glass sliding roof seal (4) is glued to glass sliding roof paneling (2). sliding roof paneling (2) and is destroyed during removal. Installation: Replace glass sliding roof

seal (4).Ensure that glass sliding roof seal (4) is seated correctly on glass sliding roof paneling (2) 9 Remove glue residues from glass sliding roof Cleaner and primer are included in scope paneling (2), clean gluing surfaces and apply of delivery. primer. 10 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.20-p-1330ff, Remove/install seal for glass sliding roof MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO) seals on roof paneling

AR77.20-P-1330FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3119 · Applies to: 453 · AR: AR77.20-P-1330FG, AR77.20-P-0003FF

Remove/install seal for glass sliding roof 28.10.03 MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO) seal on glass sliding roof 1 Glass sliding roof 2 Seal P77.20-2429-03 Remove/install

1 Remove glass sliding roof (1) and lay with AR77.20-P-0003FF Lay glass sliding roof (1) down on suitable bottom side down on suitable subsurface subsurface to prevent damaging glass sliding roof (1) 2 Remove seal (2) from glass sliding roof (1) The seal (2) is glued to the glass sliding roof (1) and is destroyed during removal. Installation:

Replace seal (2). Ensure that seal (2) is seated correctly on glass sliding roof (1) 3 Remove glue residues from glass sliding roof Cleaner and primer are included in scope (1), clean gluing surfaces and apply primer of delivery. 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.20-p-1330fg, Remove/install seal for glass sliding roof MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO) seal on glass sliding roof

AR77.20-P-2191FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3120 · Applies to: 453 · AR: AR77.20-P-2191FF, AR68.30-P-4300FF

Remove/install slide block on roller sun blind 16.1.04 MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO) P77.20-2441-09 Show on vehicle with code (I55) Head 1 Bolt 4 Slide block airbag (FFO) 2 Roller sun blind 5 Roller blind guide 3 Cross member 6 Guide rail Removal/installation

1 Remove headliner AR68.30-P-4300FF 2 Remove bolts (1) 3 Remove cross member (3) 4 Slide roller sun blind (2) toward rear and Observe installation position of roller blind loosen slide block (4) from left and right guide guide (5) rail (6) 5 Loosen roller blind guide (5) from anchoring of slide block (4) 6 Pull slide block (4) out of roller sun blind (2) 7 Install in the reverse order 8 Perform function check Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.20-p-2191ff, Remove/install slide block on roller sun blind MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO)

AR77.20-P-2191FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3121 · Applies to: 453 · AR: AR77.20-P-2191FG, AR68.30-P-4300FF

Remove/install slide blocks on roller sun blind 11.11.11 MODEL 454.0 with CODE (E55) Glass roof with sun protection (FFO) P77.20-2444-08 Shown on vehicle with code (I55) Head 1 Rear roller sun blind 3 Guide rail airbag (FFO) 2 Front roller sun blind 4 Slide shoe 5 Screw Shown on rear roller sun blind 1 Rear roller sun blind 4 Slide shoe 6 Roller blind guide P77.20-2446-01 Shown on vehicle with code (I55) Head airbag (FFO) 1 Rear roller sun blind 2 Front roller sun blind 3 Guide rail 6 Roller blind guide 7 Nut 8 Allen screw P77.20-2445-11 Remove

1 Remove headliner AR68.30-P-4300FF 2 Unscrew bolts (5) from front roller sun blind (2) and rear roller sun blind (1) 3 Retract front roller sun blind (2) or rear roller Observe installation position of roller blind sun blind (1) and loosen slide blocks (4) from guide (6) guide rails (3) 4 Pull slide blocks (4) out of guide for front roller Observe installation position of roller blind sun blind (2) or rear roller sun blind (1) and guide (6) remove Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.20-p-2191fg, Remove/install slide blocks on roller sun blind MODEL 454.0 with CODE (E55) Glass roof with sun protection (FFO)

Install

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3122 · Applies to: 453 · AR: AR68.30-P-4300FF

5 Drill 4 mm dia. mounting bore for bolts (5). Carefully drill mounting bore for bolts (5) to prevent damaging guide rail (3) Cover working area Cordless drill/driver, cordless drill gotis://G_58.0_01.1 6 Clean guide rails (3) Wet/dry vacuum cleaner gotis://P_00.12_06.0 7 Install slide blocks (4) in front roller sun blind (2) or rear roller sun blind (1) and hook in roller blind guide (6) 8 Install slide blocks (4) and roller blind guide (6) for front roller sun blind (2) or rear roller sun blind (1) into guide rails (3) 9 Replace bolts (5) with Allen screws (8) and Use M4 9 mm Allen bolts (8). tighten to guide rails (3) with self-locking nuts (7) Notes on self-locking nuts and bolts AH00.00-N-0001-01A 10 Check front roller sun blind (2) or rear roller sun blind (1) for proper function 11 Install headliner AR68.30-P-4300FF Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.20-p-2191fg, Remove/install slide blocks on roller sun blind MODEL 454.0 with CODE (E55) Glass roof with sun protection (FFO)

AR77.20-P-1800FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3123 · Applies to: 453 · AR: AR77.20-P-1800FF, AR68.30-P-4300FF

Remove/install sliding roof drive 16.9.03 MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO) P77.20-2434-08 1 Glass sliding roof cover 3 Roof paneling 6 Electrical connector 2 Headliner 4 Bolts 5 Retainer M12 Tilting/sliding roof (SR) 3 Roof paneling 7 Pinion P77.20-2435-11 Removal/installation

If possible, the glass sliding roof cover (1)

should be closed during all work 1 Remove headliner (2) AR68.30-P-4300FF 2 Unlock retainer (5) and disconnect electrical connector (6) 3 Unscrew bolts (4) from tilting/sliding roof (SR) (M12) 4 Remove tilting/sliding roof (SR) (M12) from roof paneling (3) 5 Carefully pull pinion (7) out of guide and It is possible that the pinion remains on check for wear, replace if necessary the tilting/sliding roof (SR) (M12) instead of in its guide, when removing the tilting/sliding roof (SR) M12) 6 Install in the reverse order 7 Check for proper function and synchronize, For fault description and synchronization, depending on which error occurs see operating instructions Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.20-p-1800ff, Remove/install sliding roof drive MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO)

AR77.20-P-0001FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3124 · Applies to: 453 · AR: AR77.20-P-0001FF

Remove/install switch for tilting/sliding roof 26.2.04 MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO) P77.20-2448-08 1 Headliner S13/2 Tilting/sliding roof switch S13/2x1 Tilting/sliding roof switch connector 2 Overhead control panel Removal/installation

1 Press clips (arrows) back with suitable Installation:

Push overhead control panel screwdriver and unclip overhead control panel (2) into headliner (1) until clips (arrow) (2) engage. 2 Remove overhead control panel (2) from headliner (1) 3 Disconnect connector for SHD switch (S13/2x1) 4 Unclip and remove SHD switch (S13/2) from overhead control panel (2) from rear 5 Install in the reverse order 6 Perform function check Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.20-p-0001ff, Remove/install switch for tilting/sliding roof MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO)

AR77.20-P-2500FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3125 · Applies to: 453 · AR: AR77.20-P-2500FF

Remove/install wind deflector 14.1.04 MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO) 1 Wind deflector P77.25-2009-11 P77.25-2007-09 2 Spring bracket 4 Wind guide net 6 Catch hook 3 Guide rail 5 Spring rod 2 Spring bracket 7 Guide P77.25-2008-11 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.20-p-2500ff, Remove/install wind deflector MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO)

AR77.20-P-2498FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3127 · Applies to: 453 · AR: AR77.20-P-2498FF

Remove/install wind guide for wind deflector 21.1.04 MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO) 1 Wind deflector P77.25-2009-11 P77.25-2007-09 2 Spring bracket 4 Wind guide net 6 Catch hook 3 Guide rail 5 Spring rod Removal/installation

1 Move glass sliding roof cover to rearmost See Operating Instructions position 2 Carefully detach spring rod (5) in center area Installation: Check installation position of

with suitable tool and bend until it can be wind guide net (4), correct if necessary unhooked from the guide (arrow) at right 3 Unhook spring rod (5) from guide (arrow) on left 4 Loosen catch hook (6) and carefully pull spring bracket (2) out of guide rail 5 Remove wind guide net (4) from wind deflector (1) 6 Remove guide rail (3) and spring rod (5) from The wind guide net (4) can be replaced wind guide net (4) separately. 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.20-p-2498ff, Remove/install wind guide for wind deflector MODEL 454.0 with CODE (V29) Electric glass sliding roof (FFO)

AR77.21-P-0200FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3128 · Applies to: 453 · AR: AR77.21-P-0200FF

Remove/install front panoramic roof roller sun blind 19.10.05 MODEL 454.0 with CODE (E55) Glass roof with sun protection (FFO) P77.21-2017-08 Shown on vehicle with code (I55) Head airbag (FFO) 1 Front roller sun blind 4 Bolt 7 Tie strap 2 Carrier 5 Sliding rail 8 Clock-type spring 3 Guide 6 Guide rail 1 Front roller sun blind 5 Sliding rail 9 Roller blind guide P77.21-2019-01 Shown on vehicle with code (I55) Head airbag (FFO) 1 Front roller sun blind 2 Carrier 10 Hole for roller sun blind 11 Hole for clock-type spring P77.21-2020-05 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.21-p-0200ff, Remove/install front panoramic roof roller sun blind MODEL 454.0 with CODE (E55) Glass roof with sun protection (FFO)

Shown on vehicle with code (I55) Head airbag (FFO)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3129 · Applies to: 453 · AR: AR68.30-P-4300FF

1 Front roller sun blind 6 Guide rail 9 Roller blind guide 12 Nut 13 Allen screw 14 Clip P77.21-2123-11 Remove

1 Remove headliner AR68.30-P-4300FF 2.1 Remove bolts (4) Only if bolts (4) have not yet been replaced with nuts (12) and Allen screws (13). 2.2 Unscrew nuts (12) and Allen screw (13) on left Only if bolts (4) have already been replaced and right with nuts (12) and Allen screws (13). 3 Retract front roller sun blind (1) and loosen Note installation position of roller blind sliding rails (5) from guide rails (6) guide (9) 4 Remove tie strap (7) from clock-type spring (8). 5 Loosen guide (3) on front roller sun blind (1) from carrier (2) on left, then slide toward right and turn until hole of clock-type spring (11) is flush with hole in roller sun blind (10) 6 Slide suitable locking pin through hole for Use 1 mm diameter locking pin. clock-type spring (11) and hole for roller sun blind (10) and secure front roller sun blind (1) against twisting or releasing 7 Remove front roller sun blind (1) 8.1 Check clip (14) on right and left guide rail (6), Only when clip (14) has been installed. replace if necessary. Install

9.1 Drill dia. 4 mm mounting holes for bolts (4). Tightening the bolts (4) is no longer possible if the threads in the guide rails (6) are damaged. Carefully drill mounting bores for bolts (4) to prevent damaging guide rail (6) Cover working area *450589017000

Drill (electric/pneumatic) WE58.40-Z-1001-03A 10 Clean guide rails (6) Wet/dry vacuum cleaner WE58.40-Z-1005-03A 11 Install front roller sun blind (1) in carrier (2) on right 12 Pull locking pin out of hole for clock-type Ensure that clock-type spring (8) is seated spring (11) and hole for roller sun blind (10) correctly in carrier (2) and cannot jump out 13 Install guide (3) for front roller sun blind (1) in carrier (2) on left 14 Install tie strap (7) on clock-type spring (8) 15 Install sliding rail (5) and roller blind guide (9) for front roller sun blind (1) in guide rails (6) 16.1 Replace bolts (4) with Allen screws (13) and Tightening the bolts (4) is no longer possible if tighten to guide rails (6) with self-locking nuts the threads in the guide rails (6) are damaged. (12) Use Allen screw (13) with size of M4 9 mm. 16.2 Insert Allen screws (13) into guide rails (6) Only if bolts (4) have already been replaced and tighten with self-locking nuts (12) with nuts (12) and Allen screws (13). Replace self-locking nuts (12). 17 Check front roller sun blinds (1) for proper function 18 Install headliner AR68.30-P-4300FF Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.21-p-0200ff, Remove/install front panoramic roof roller sun blind MODEL 454.0 with CODE (E55) Glass roof with sun protection (FFO)

AR77.21-P-0750SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3131 · Applies to: 453 · AR: AR77.21-P-0750SRA, AR77.21-P-0205SRA

Remove/install panoramic roof 14.09.2017 Model 453.3 with code E22 (Panoramic sunroof) Modification notes 17.08.2017 Workshop equipment is linked in EPC with replacement Only use linked workshop equipment. part. P77.21-2465-09 1 Panoramic roof B Gap dimension 2 Rubber spacers C Gap dimension A Gap dimension Notes on removal/installation of windows AH67.10-P-1000-02RT Preparation 1 Workshop equipment is linked in EPC with Only use linked workshop equipment.

replacement part. Remove

2 Remove roller sun blind from rear panoramic AR77.21-P-0205SRA roof 3 Determine gap dimensions (A), (B) and (C) *129589032100 Feeler gauge with feeler gauge and note Risk of injury Warning from cutting wire tearing or Wear protective gloves and safety glasses. AS67.00-Z-0004-01A

becoming hot and from splinters of glass when cutting out bonded windows 4 Cut out panoramic roof AR77.21-P-0750-01SRA Install

5 Open driver door side window

The side window of the driver door should remain open during the curing time. Otherwise the glass pane can be pressed toward outside by the air when the doors are closed. 6 Replace rubber spacers (2) on panoramic roof Always replace rubber spacers (2).

(1) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.21-p-0750sra, Remove/install panoramic roof Model 453.3 with code E22 (Panoramic sunroof)

Prepare glass pane on panoramic roof for

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3132 · Applies to: 453 · AR: AR77.21-P-0205SRA

7 Prepare glass pane on panoramic roof for AR77.21-P-0750-02SRA installation 8 Prepare panoramic roof frame for installation AR77.21-P-0800-02SRA 9 Apply adhesive material for glass pane on AR77.21-P-0750-04SRA panoramic roof 10 Install glass pane on panoramic roof AR77.21-P-0750-05SRA 11 Remove/install roller sun blind on panoramic AR77.21-P-0205SRA roof 129 589 03 21 00 Feeler gauge Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.21-p-0750sra, Remove/install panoramic roof Model 453.3 with code E22 (Panoramic sunroof)

AR77.21-P-0201FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3133 · Applies to: 453 · AR: AR77.21-P-0201FF

Remove/install rear panoramic roof roller sun blind 19.10.05 MODEL 454.0 with CODE (E55) Glass roof with sun protection (FFO) P77.21-2013-08 Shown on vehicle with code (I55) Head airbag (FFO) 1 Rear roller sun blind 3 Sliding rail 6 Clock-type spring 2 Guide rail 4 Bolt 7 Carrier 5 Tie strap 8 Guide 1 Rear roller sun blind 3 Sliding rail 9 Roller blind guide P77.21-2015-01 Shown on vehicle with code (I55) Head airbag (FFO) 1 Rear roller sun blind 7 Carrier 10 Hole for clock-type spring 11 Hole for roller sun blind P77.21-2014-05 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.21-p-0201ff, Remove/install rear panoramic roof roller sun blind MODEL 454.0 with CODE (E55) Glass roof with sun protection (FFO)

Shown on vehicle with code (I55) Head airbag (FFO)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3134 · Applies to: 453 · AR: AR68.30-P-4300FF

1 Rear roller sun blind 2 Guide rail 9 Roller blind guide 12 Nut 13 Allen screw 14 Clip P77.21-2124-11 Remove

1 Remove headliner AR68.30-P-4300FF 2.1 Remove bolts (4) Only if bolts (4) have not yet been replaced with nuts (12) and Allen screws (13). 2.2 Unscrew nuts (12) and Allen screw (13) on left Only if bolts (4) have already been replaced and right with nuts (12) and Allen screws (13). 3 Retract rear roller sun blind (1) and loosen Note installation position of roller blind sliding rails (3) from guide rails (2) guide (9) 4 Remove tie strap (5) from clock-type spring (6) 5 Loosen guide (8) on rear roller sun blind (1) from carrier (7) on right, then slide toward left and turn until hole of retraction spring (10) is flush with hole in roller sun blind (11) 6 Slide suitable locking pin through hole for Use locking pin with a diameter of 1 mm. clock-type spring (10) and hole for roller sun blind (11) and secure front roller sun blind (1) against twisting or releasing 7 Remove rear roller sun blind (1) 8.1 Check clip (14) on right and left guide rail (2), Only when clip (14) has been installed. replace if necessary. Install

9.1 Drill dia. 4 mm mounting holes for bolts (4). Tightening the bolts (4) is no longer possible if the threads in the guide rails (2) are damaged. Carefully drill mounting bores for bolts (4) to prevent damaging guide rail (2) Cover working area *450589017000

Drill (electric/pneumatic) WE58.40-Z-1001-03A 10 Clean guide rails (2) Wet/dry vacuum cleaner WE58.40-Z-1005-03A 11 Install rear roller sun blind (1) in carrier (7) on left 12 Pull locking pin out of hole for clock-type Ensure that clock-type spring (6) is seated spring (10) and hole for roller sun blind (11) correctly in carrier (7) and cannot jump out 13 Install guide (8) for rear roller sun blind (1) in carrier (7) on right 14 Install tie strap (5) on clock-type spring (6) 15 Install sliding rails (3) and roller blind guide (9) for rear roller sun blind (1) in guide rails (2) 16.1 Replace bolts (4) with Allen screws (13) and Tightening the bolts (4) is no longer possible if tighten to guide rails (2) with self-locking nuts the threads in the guide rails (2) are damaged. (12) Use Allen screw (13) with size of M4 9 mm 16.2 Insert Allen screws (13) into guide rails (2) Only if bolts (4) have already been replaced and tighten with self-locking nuts (12) with nuts (12) and Allen screws (13). Replace self-locking nuts (12). 17 Check rear roller sun blinds (1) for proper function 18 Install headliner AR68.30-P-4300FF Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.21-p-0201ff, Remove/install rear panoramic roof roller sun blind MODEL 454.0 with CODE (E55) Glass roof with sun protection (FFO)

AR77.21-P-0205SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3136 · Applies to: 453 · AR: AR77.21-P-0205SRA, AR68.30-P-4300SRA

Remove/install roller sun blind on panoramic sunroof 06.08.2014 MODEL 453.3 with CODE E22 (Panoramic sunroof) P77.21-2444-07 1 Roller sun blind 2 Bolts 3 Guide rails Remove/install

1 Remove headliner AR68.30-P-4300SRA 2 Close roller sun blind (1)

The rear roller sun blind (1) must be closed (extended). Otherwise the roller sun blind (1) can be damaged during removal and must be replaced. 3 Unscrew bolts (2) from guide rails (3) Installation: Tighten screw/bolts (2) in

diagonally opposite sequence. Start with center bolts (2). 4 Grab roller sun blind (1) at guide rails (3) and

remove from vehicle with aid of helper When removing roller sun blind (1), ensure that it is not rolled up Otherwise the door module (1) can be damaged and must be replaced. 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.21-p-0205sra, Remove/install roller sun blind on panoramic sunroof MODEL 453.3 with CODE E22 (Panoramic sunroof)

AR77.25-P-1000MCO

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3137 · Applies to: 453 · AR: AR77.25-P-1000MCO

Remove/install wind deflector 16.12.15 Model 451.4, 453.4 Shown on model 451.4 1 Wind deflector P77.25-2020-11 Remove

1 Heat wind deflector (1) with heat gun and remove 000 588 00 84 00 Heat gun WS54.00-P-0049B

Clean

2 Clean bonding surfaces

The bonding surface must be free of dust and grease. Otherwise the adhesive force of the glue starts to decrease. Install

3 Model 451.4 Mark installation position of wind deflector (1) with adhesive tape Dimensions: A = 60 mm B = 445 mm Model 453.4 Dimensions: A = 110 mm B = 445 mm 4 Remove protective foil and glue on wind

deflector (1) according to markings Do not touch adhesive or reposition wind deflector (1) after gluing on. Otherwise the adhesive force of the glue starts to decrease. 5 Remove tape Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.25-p-1000mco, Remove/install wind deflector Model 451.4, 453.4

AR77.30-P-1010SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3138 · Applies to: 453 · AR: AR77.30-P-1010SRC

Adjust soft top 13.1.16 Model 453.4 8 Side support 9 Centering pin 9.1 End stop 10 Centering pin P77.30-2669-06 P77.33-2213-08 1 Latch 2 Screw 3 Blind Page 1 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1010src, Adjust soft top Model 453.4

P77.30-2670-06

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3140 · Applies to: 453 · AR: AR68.30-P-4700SRC, AR77.33-P-1008MCO

Notes on soft tops AH77.30-P-0001-01MCO

Adjust 1 Remove side supports (8) 2 Replace centering pins (9) of side supports (8) with centering pins shortened by approx. 30 mm (10) 3 Fit end stops (9.1) of centering pins (9) onto shortened centering pins (10) 4 Remove paneling from B-pillars AR68.30-P-4700SRC 5 Adjust both bearings of side supports (8) on AR77.33-P-1008MCO A-pillar 6 Slightly open rear soft top The retainer must remain engaged in the

top position. 7 Remove cover (3) 8 Loosen bolts (2), center latches (1) and tighten bolts (2) once more 9 Mark installation position of latches (1) 10 Install side supports (8) The side supports (8) must engage

securely in the second catch and their seal must be in contact with the B-pillar. If deviations are present Align latch (1) in question 11 Loosen bolts (7), center both main bearings (6) and tighten bolts (7) once more 12 Mark installation position of main bearings (6) 13 Fold down retainer 14 Fully open rear soft top 15 Helper required. Close rear soft top without interruption, until

latches (5) are just in front of pins (4) If you interrupt this movement, the main bearings (6) may be out of line. If closing movement was interrupted,. repeat operation steps 14, 15 Check

16 Check position of catches (5) in relation to The pins (4) must run centrally into the

pins (4) and side supports (8) catches (5) and the guides (5.1) run securely into the side supports (8). If deviations are present Fold up retainer, align main bearings (6) or catches (1), and fold retainer down again 17 Fully open rear soft top 18 Close rear soft top without interruption

In the event of a collision, interrupt closure of rear soft top immediately. Otherwise soft top components can be damaged. In the event of collision Repeat operation steps 14 to 18 Check

19 Check height offset and clearance of rails

(5.2, 8.1) There must not be any height offset. Otherwise the sliders can be damaged. Make sure rails (5.2, 8.1) on both sides of

the vehicle have approximately the same clearance. If deviations are present Fold up retainer, align main bearings (6) or catches (1), and fold retainer down again 20 Fully open rear soft top 21 Completely close soft top In the event of complaints Adapt position as necessary 22 Check tension of folding roof In the event of complaints Tension folding roof Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1010src, Adjust soft top Model 453.4

AR77.30-P-1102SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3141 · Applies to: 453 · AR: AR77.30-P-1102SRC, AR68.30-P-4700SRC

23 Remove side supports (8) 24 Tighten bolts (7) *BA77.33-P-1001-01SR Bolt, main bearing to B-pillar C 25 Install paneling on B-pillars AR68.30-P-4700SRC 26 Replace centering pins (10) with centering pins (9) 27 Fit end stops (9.1) on centering pins (9) 28 Install side supports (8) Soft top mechanical components Number Designation Model 453.4 BA77.33- Bolt, main bearing to B-pillar Nm 21 P-1001-01SRC Page 4 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1010src, Adjust soft top Model 453.4

AR77.30-P-1152SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3142 · Applies to: 453 · AR: AR77.30-P-1152SRC

Remove/install arresting bolt on rear soft top retaining clip 22.12.15 Model 453.4 P77.30-2663-07 Shown on left side of vehicle 1 Lock pin 5 Spring 2 Retaining clip 6 Screw 3 Screw 7 Lock washer 4 Nut 8 Clamping plate Notes on soft tops AH77.30-P-0001-01MCO

Remove/install

1 Open liftgate 2 Fold up retaining clip (2) Installation: Retaining clip (2) must

engage securely on both sides. 3 Unscrew bolts (3) on left and right of retaining Make sure that nuts (4) are not pushed out

clip (2) of retaining clip (2) housing. 4 Relax tension of spring (5) by slackening bolt (6) 5 Remove circlip (7) 6 Pull out lock pins (1) Installation: Make sure that spring (5) and

clamping plate (8) are positioned correctly. If complaint present Correct position of spring (5) and clamping plate (8) with the aid of bolt (6) 7 Install in the reverse order Check

8 Check that retaining clip (2) is correctly engaged Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1152src, Remove/install arresting bolt on rear soft top retaining clip Model 453.4

AR77.30-P-1111SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3143 · Applies to: 453 · AR: AR77.30-P-1111SRC, AR77.33-P-0001SRC, AR77.33-P-1234SRC

Remove/install folding roof cassette 13.1.16 Model 453.4 1 Roof cassette 2 Soft top locks 3 Soft top control drive unit 4 Electrical wiring harness 5 Bolts P77.30-2671-06 Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Notes on soft tops AH77.30-P-0001-01MCO

Remove/install

1 Detach soft top locks (2) on roof cassette (1) AR77.33-P-0001SRC and pull upwards at rear 2 Remove soft top control drive unit (3) AR77.33-P-1234SRC 3 Guide electrical wiring harness (4) forwards Installation: Make sure that electrical

out of roof cassette (1) wiring harness (4) is routed and secured without chafing or tension. 4 Look out for loose square nuts of soft top Unscrew bolts (5) and remove roof cassette

(1) locks (2) in roof cassette (1). Helper required. 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.30-p-1111src, Remove/install folding roof cassette Model 453.4

AR77.30-P-1100MCO

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3144 · Applies to: 453 · AR: AR77.30-P-1100MCO

Remove/install folding top 28.06.2017 Model 451.4, 453.4 P77.31-2188-07 Shown on model 451.4 1 Folding roof 3 Sealing strip 5 Tension cable retaining plate 2 Seal 4 Rear soft top 6 Screw Shown on model 451.4 1 Folding roof 7 Side support 8 Clamping plate (model 451.4) 9 Screw 10 Tensioning strap 11 Sliding plate P77.31-2189-06 Page 1 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1100mco, Remove/install folding top Model 451.4, 453.4

P77.31-2304-08

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3145 · Applies to: 453 · AR: AR77.33-P-2030MCO, AR77.31-P-1005MCO

Shown on model 453.4 1 Folding roof 10 Tensioning strap 17 Cover (model 453.4) 9 Screw 16 Clamping piece (model 453.4) Installation, shown on model 451.4 12 Drive cable 13 Guide 14 Slider 15 Slider A Distance P77.31-2190-06 P77.31-2191-08 Shown on model 451.4 1 Folding roof 12 Drive cable 11 Sliding plate 13 Guide Notes on soft tops AH77.30-P-0001-01MCO Remove

1 Remove roof cassette rear spoiler AR77.33-P-2030MCO 2.1 Remove inside roof lining Model 451.4 AR77.31-P-1005MCO 2.2 Remove headliner from roof cassette Model 453.4 AR77.31-P-1005MCO Page 2 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1100mco, Remove/install folding top Model 451.4, 453.4

Remove seal (2) from rear soft top (4) and fold

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3146 · Applies to: 453 · AR: AR77.30-P-1104MCO

3 Remove seal (2) from rear soft top (4) and fold toward front 4 Unscrew bolts (6) and fold folding roof (1) toward front 5 Remove cover (17) Model 453.4 6 Mark length of left and right tensioning straps (10) on roof cassette 7 Remove screw/bolts (9) 8.1 Remove clamping plates (8) Model 451.4 8.2 Remove clamping pieces (16) Model 453.4 9 Pull tensioning straps (10) out of roof cassette 10 Remove left and right side support (7) 11 Actuate left and right side support recognition Helper required.

sensors (arrow), simultaneously actuate power soft top switch in closing direction and extend folding roof (1) until slide plates (11) are exposed 12 Unhook left and right drive cable (12) from slide plates (11) 13 Pull folding roof (1) with sliders (14, 15) out of Helper required.

both guides (13) on roof cassette, and remove Install

14.1 Connect diagnostic system and cancel coding Model 451.4 of power soft top switch AD00.00-P-2000-04MCC

Soft top control

Power soft top switch 14.2 Connect diagnostic system and denormalize Model 453.4 soft top AD00.00-P-2000-06SR

Control units view

Body Rear control unit Adaptations Initial startup 15 Measure and compare clearance (A) between If clearances (A) differ by more than 1 mm drive cables (12) and guides (13) Synchronize drive cable (12) AR77.30-P-1104MCO 16 Slide folding roof (1) with sliders (14) into Helper required.

central track of guides (13) 17 Slide folding roof (1) with central sliders (15) Helper required.

into inner track of guides (13) 18 Hook drive cables (12) into slide plates (11) Helper required.

19 Align slide plates (11) as shown and carefully Helper required.

pull into outer and central tracks of guides (13) by actuating power soft top switch 20 Pull tensioning straps (10) into roof cassette The tensioning straps (10) should not be

twisted. 21.1 Guide tensioning straps (10) through clamping Model 451.4 plates (8), tension according to markings and tighten bolts (9) 21.2 Tension tensioning straps (10) according to Model 453.4 markings, insert clamping pieces (16) and tighten bolts (9) 22 Install side supports (7) 23 Close folding roof (1) Check

24 Fold back folding roof (1) and check tensioning The side edges of the folding roof (1)

strap (10 ) for tension should be flush with the contour of the side supports (7). In the event of complaints Loosen relevant bolt (9) and retension tensioning strap (10) 25 Check bonding of folding roof (1) on left and Model 453.4 right If folding roof (1) can no longer bond securely. Replace non-reusable adhesive residues with new sealing strip, and fill defects Sealing strip 119.32 Terostat 20 2 mm *BR00.45-Z-1088-01A 26 Insert cover (17) Model 453.4 Page 3 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1100mco, Remove/install folding top Model 451.4, 453.4

Open folding roof (1) approx. 10 cm

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3147 · Applies to: 453 · AR: AR77.30-P-1102MCO, AR77.30-P-1102SRC, AR77.31-P-1005MCO, AR77.33-P-2030MCO, AR77.30-P-1010MCO (+1 more)

27 Open folding roof (1) approx. 10 cm 28 Align tension cable retaining plates (5) and Ensure that creases are not present in the

tighten bolts (6) folding roof (1). If there are creases in cover of folding roof (1) Tension folding roof (1) Model 451.4 AR77.30-P-1102MCO Model 453.4 AR77.30-P-1102SRC 29 Remove loose parts of old adhesive tape in It is not necessary to remove sections of

cross-hatched area of seal (2) and replace adhesive tape adhering well. with new, double-sided adhesive tape Use double-sided adhesive tape with a width of 19 or 25 cm. Teroson double-sided adhesive tape, for *BR00.45-Z-1075-02A bonding trim strips and emblems (UV-resistant and weatherproof, black) (width 12 mm), order no.: 107.64 A (width 19 mm), order no.: 107.96 K (width 25 mm), order no.: 117.05 Y 30 Pull off protective foil of double-sided adhesive tape and stick seal (2) onto rear soft top (4) without any creases 31.1 Install headliner Model 451.4 AR77.31-P-1005MCO 31.2 Fit headliner to roof cassette Model 453.4 AR77.31-P-1005MCO 32 Install roof cassette rear spoiler AR77.33-P-2030MCO 33.1 Code power soft top switch, read out fault Model 451.4 memory and disconnect diagnostic system AD00.00-P-2000-04MCC

Soft top control

Power soft top switch 33.2 Normalize soft top, read out fault memory and Model 453.4 connect diagnostic system AD00.00-P-2000-06SR

Control units view

Body SG-FOND - Rear control unit Adaptations Initial startup Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 34 Start engine and allow to idle 35 Adjust A-pillar soft top support Model 451.4 AR77.30-P-1010-01MCO If the folding roof (1) was replaced, it

needs approx. 72 h to be completely free of tension. This process can be accelerated by moistening the folding roof. Longitudinal misalignment between side BE77.30-P-1001-02A support and roof cassette Insertion depth of mounting frame bow for soft BE77.30-P-1005-02A top in front side support bearing Insertion depth of soft top to roof peak seal *BE77.30-P-1004-02A If the entry position of the folding roof (1) in the A-pillar soft top support or the insertion depth of the folding roof (1) in relation to the roof peak seal is not correct. Adjust soft top AR77.30-P-1010MCO 36 Close folding roof (1) Model 453.4 If the folding roof (1) was replaced, it

needs approx. 72 h to be completely free of tension. This process can be accelerated by moistening the folding roof. In the event of complaints Adjust soft top AR77.30-P-1010SRC 37 Turn off engine Page 4 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1100mco, Remove/install folding top Model 451.4, 453.4

AR77.30-P-1112SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3149 · Applies to: 453 · AR: AR77.30-P-1112SRC, AR77.30-P-1100MCO, AR77.30-P-1104MCO, AR77.30-P-1150SRC

Remove/install guide tube for drive cable 22.12.15 Model 453.4 P77.30-2666-09 1 Guide tubes 5 Electrical wiring harness 2 Retaining clip 6 Bolts 3 Rear soft top 7 Seal 4 Latch Notes on soft tops AH77.30-P-0001-01MCO

Remove/install

1 Remove folding roof AR77.30-P-1100MCO 2 Remove folding roof drive cable AR77.30-P-1104MCO 3 Open liftgate 4 Fold up retainer (2) 5 Detach rear soft top (3) from latches (4) and AR77.30-P-1150SRC position as shown

Do not remove seals (7) from rear soft top (3). Otherwise the sealing compound must be replaced. 6 Detach electrical wiring harness (5) from Installation: Replace cable ties.

guide tubes (1) 7 Remove bolts (6) 8 Remove guide tube (1) 9 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1112src, Remove/install guide tube for drive cable Model 453.4

AR77.30-P-1150SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3150 · Applies to: 453 · AR: AR77.30-P-1150SRC, AR77.30-P-1100MCO

Remove/install rear soft top 13.1.16 Model 453.4 P77.30-2672-09 1 Rear soft top 5 Roof cassette 9 Electrical connector 2 Bolts 6 Reinforcement 10 Retaining rail 3 Retaining clip 7 Seal 11 Retaining rail 4 Retaining strips 8 Reinforcement Notes on soft tops AH77.30-P-0001-01MCO

Remove/install

1 Remove folding roof AR77.30-P-1100MCO 2 Pull all retaining strips (4) of water pocket out of rear window frame 3 Fold up retainer (3) 4 Remove bolts (2) of reinforcements (6) 5 Detach reinforcements (6) and seals (7) from Installation: Check bonding of seals (7).

roof cassette (5) and fold back rear soft top (1) In the event of complaints Repair or replace defective bonds Rear window sealing profile BR00.45-Z-1084-01A 6 Guide electrical connector (9) through rear soft top (1) and pull reinforcement (8) out of roof cassette (5) 7 Pull retaining strip (11) out of retainer (3) from 110589035900 Mounting wedge outside towards inside 8 Fold down retainer (3) and turn rear soft top (1) down 9 Pull retaining strip (10) out of rear window Installation: Align marking of retaining

frame and detach rear soft top (1) strip (10) with marking on rear window frame. *110589035900 Mounting wedge 10 Remove clips still in retainer (3) or rear Installation: Fit clips on retaining strips

window frame (10 or 11). 11 Remove seals (7) and reinforcements (6) When replacing rear soft top (1) Installation: Check bonds.

In the event of complaints Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.30-p-1150src, Remove/install rear soft top Model 453.4

AR77.30-P-1151SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3152 · Applies to: 453 · AR: AR77.30-P-1151SRC, AR77.30-P-1152SRC

Remove/install rear soft top retaining clip 22.12.15 Model 453.4 P77.30-2664-09 1 Retaining clip 4 Notch lever 2 Rear soft top 5 Seal 3 Screw Notes on soft tops AH77.30-P-0001-01MCO

Remove/install

1 Open liftgate 2 Fold up retaining clip (1) 3 Unhook rear soft top (2) from retaining clip (1) from outside towards inside 4 Secure rear soft top (2) and rear window so they cannot fold down 5 Remove clips remaining in retaining clip (1) Installation: Fit clips on hook-in lug on

with suitable tool rear soft top (2). 6 Fold down retaining clip (1) 7 Unscrew bolts (3) and remove retaining clip Make sure that nuts of bolts (3) are not

(1) pushed out of retaining clip (1) housing. Installation:

Position retaining clip (1) and engage notch levers (4). 8 Remove notch levers (4) When replacing retaining clip (1). 9 Remove lock pin When replacing retaining clip (1). AR77.30-P-1152SRC 10 Pull seal (5) out of retaining clip (1) When replacing retaining clip (1). 11 Install in the reverse order Check

12 Check that retaining clip (1) is correctly engaged Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1151src, Remove/install rear soft top retaining clip Model 453.4

AR77.30-P-3352MCC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3153 · Applies to: 453 · AR: AR77.30-P-3352MCC, AR68.30-P-4450MCV, AR68.30-P-4450MCO, AR68.30-P-4450SRC

Remove/install roof peak seal 22.12.15 Model 451.4, 453.4 P77.30-2431-07 Shown on left side of vehicle on model 451.4 1 Roof peak seal 3 Roof frame 2 Seal 4 A-pillar Model 453.4, shown on left side of vehicle 5 Bolts 6 Guide P77.30-2661-12 Notes on soft tops AH77.30-P-0001-01MCO

Remove

1 Open soft top 2 Remove side supports 3 Model 451.4 Remove front roof frame paneling AR68.30-P-4450MCV with code 494 (US version) Model 451.4 AR68.30-P-4450MCO except code 494 (US version) Model 453.4 AR68.30-P-4450SRC 4 Unscrew bolts (5) on left and right Model 453.4 5 Remove roof peak seal (1) starting at marked area (arrow) 6 Pull off gasket (2) Clean

7 Clean roof frame (3) and A-pillar (4) in area of Cleaner *BR00.45-Z-1025-04A seal (2) Install

Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.30-p-3352mcc, Remove/install roof peak seal Model 451.4, 453.4

Position seal (2) on roof frame (3) and A-pillar Rear window sealing profile

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3154 · Applies to: 453 · AR: AR68.30-P-4450MCV, AR68.30-P-4450MCO, AR68.30-P-4450SRC, AR77.30-P-1010SRC, AR77.30-P-1010MCO

8 Position seal (2) on roof frame (3) and A-pillar Rear window sealing profile *BR00.45-Z-1084-01A (4) on left and right 9 Press roof peak seal (1) on A-pillar (4) onto

body flange starting at top left and top right Install roof peak seal (1) as narrow as possible and drive down with plastic mallet in the radiuses. Leaks can occur otherwise. The roof peak seal (1) and side wall seal at

the left or right must make contact in the center of the door sill without gap (arrow). Model 453.4 Ensure that guides (6) on right and left are seated correctly in body. 10 Check seating of roof peak seal (1) In the event of complaints Realign sealing lip of roof peak seal (1) 11 Install side supports 12 Check installation position of roof peak seal In the event of complaints (1) Realign roof peak seal (1) 13 Tighten bolts (5) on left and right Model 453.4 14 Model 451.4 Install front roof frame paneling AR68.30-P-4450MCV with code 494 (US version) Model 451.4 AR68.30-P-4450MCO except code 494 (US version) Model 453.4 AR68.30-P-4450SRC 15 Close soft top Check

16 Check position of roof peak seal (1) in If complaint present relation to soft top Adjust soft top Model 453.4 AR77.30-P-1010SRC Model 451.4 AR77.30-P-1010MCO Repair materials Number Designation Order number BR00.45-Z-1025-04A Cleaner A 005 989 19 71 BR00.45-Z-1084-01A Rear window sealing profile A 004 989 60 20 Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.30-p-3352mcc, Remove/install roof peak seal Model 451.4, 453.4

AR77.30-P-3350MCC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3155 · Applies to: 453 · AR: AR77.30-P-3350MCC

Remove/install side wall seal 22.12.15 Model 451.4, 453.4 Shown on left side of vehicle on model 451.4 1 Side wall seal 2 B-pillar P77.30-2432-06 Model 453.4, shown on left side of vehicle 3 Screw 4 Guide P77.30-2662-06 Notes on soft tops AH77.30-P-0001-01MCO

Remove

1 Open folding roof and rear soft top until the side wall seal (1) is exposed 2 Remove side support 3 Remove bolts (3) Model 453.4 4 Pull off side wall seal (1) starting at marked area (arrow A) Install

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-3350mcc, Remove/install side wall seal Model 451.4, 453.4

First insert guide of side wall seal (1) into

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3156 · Applies to: 453 · AR: AR77.30-P-1010SRC, AR77.30-P-1010MCO

5.1 First insert guide of side wall seal (1) into Model 451.4 cutout (arrow B) on B-pillar (2), then press side wall seal (1) manually onto body flange and drive down with plastic mallet

The side wall seal (1) should be inserted as tightly as possible at the radiuses. Leaks can occur otherwise. The right and left side wall seal (1) should

make contact at the center of the rear end panel without gap (arrow A). The lip of the side wall seal (1) must contact the body without any contortions. 5.2 First insert guide of side wall seal (1) into Model 453.4 cutout (arrow B) on B-pillar (2) and into cutout (arrow C) above rear lamp, then press side wall seal (1) manually onto body flange and drive down with plastic mallet

The side wall seal (1) should be inserted as tightly as possible at the radiuses. Leaks can occur otherwise. Ensure guide (4) is seated correctly in B-

pillar. The right and left side wall seal (1) should

make contact at the center of the rear end panel without gap (arrow A). The lip of the side wall seal (1) must contact the body without any contortions. 6 Tighten bolts (3) Model 453.4 Ensure correct installation position of tabs

under bolts (3). 7 Install side support 8 Close soft top Check

9 Check position of side wall seal (1) in relation If complaint present to soft top Adjust soft top Model 453.4 AR77.30-P-1010SRC Model 451.4 AR77.30-P-1010MCO Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-3350mcc, Remove/install side wall seal Model 451.4, 453.4

AR77.30-P-1200MCO

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3157 · Applies to: 453 · AR: AR77.30-P-1200MCO, AR77.33-P-2000MCO

Remove/install soft top bow on soft top 22.12.15 Model 451.4, 453.4 Shown on left side of vehicle on model 451.4 1 Soft top bow 2 Retaining rail 3 Folding roof 4 End piece 5 Slider 6 Slider P77.30-2396-05 Notes on soft tops AH77.30-P-0001-01MCO

Remove/install

1 Remove sliding rail (5, 6) and end pieces (4). AR77.33-P-2000MCO 2 Detach soft top bow (1) from retaining strips (2) on folding roof (3) 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.30-p-1200mco, Remove/install soft top bow on soft top Model 451.4, 453.4

AR77.30-P-1104MCO

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3158 · Applies to: 453 · AR: AR77.30-P-1104MCO, AR77.30-P-1100MCO

Remove/install soft top drive cable 22.12.15 Model 451.4, 453.4 Shown on model 451.4 1 Folding roof 2 Cover (model 451.4) 3 Nut (model 451.4) 4 Housing cover 5 Guide tube 6 Drive cable 7 Pinion 8 Housing P77.30-2391-06 Shown on model 451.4 with folding roof removed 6 Drive cable 9 Guide A Distance P77.30-2392-04 Shown on left side of vehicle on model 453.4 6 Drive cable 10 Sliding plate P77.30-2665-01 Notes on soft tops AH77.30-P-0001-01MCO

Remove

1.1 Remove folding roof (1) Model 451.4 AR77.30-P-1100MCO 1.2 Detach folding roof (1) from roof cassette and Model 453.4 unhook drive cables (6) from left and right slide plates (10) AR77.30-P-1100MCO 2 Remove cover (2) Model 451.4 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1104mco, Remove/install soft top drive cable Model 451.4, 453.4

Model 453.4

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3159 · Applies to: 453 · AR: AR77.30-P-1100MCO

3 Model 453.4 Unscrew nuts (3) and remove housing cover (4) The housing cover (4) is fastened with bolts instead of nuts (3). 4 Lift guide tube (5) on drive cable (6) 5 Pull drive cable (6) out of guides (9)

Observe installation locations of drive cables (6). Otherwise the folding roof (1) may suffer malfunction or damage. Install

6 Insert drive cable (6) into guides (9) until the

distance (A) between ends of drive cable (6) Observe installation locations of drive cables and guides (9) is same on left and right (6). Otherwise the folding roof (1) may suffer malfunction or damage. 7 Align pinion (7) and insert guide tubes (5) and drive cables (6) in housing (8) 8 Model 453.4 Put on housing cover (4) and position nuts (3) The housing cover (4) is fastened with bolts instead of nuts (3). 9 Check distance (A) between drive cable (6) The ends of the drive cable (6) should

and guides (9) have the same distance (A) to the guides (9) on left and right. If deviations are present Take off housing cover (4), lift guide tubes (5), correct position of drive cables (6) and attach housing cover. Then perform operation steps 7 to 9 again 10 Model 453.4 Tighten nuts (3) The housing cover (4) is fastened with bolts instead of nuts (3). 11 Install cover (2) Model 451.4 12.1 Install folding roof (1) Model 451.4 AR77.30-P-1100MCO 12.2 Hook drive cables (6) into left and right slide Model 453.4 plates (10) and attach folding roof (1) to roof cassette AR77.30-P-1100MCO Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1104mco, Remove/install soft top drive cable Model 451.4, 453.4

AR77.30-P-1108SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3160 · Applies to: 453 · AR: AR77.30-P-1108SRC, AR68.30-P-4700SRC, AR77.30-P-1010SRC

Remove/install soft top main bearing 12.1.16 Model 453.4 Shown on left side of vehicle 1 Main bearing 2 Electrical connector 3 Electrical wiring harness 4 Screw 5 Retaining clip 6 Screw 7 Bolts 8 Roof cassette 9 Bolts P77.30-2667-06 Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Notes on soft tops AH77.30-P-0001-01MCO

Remove/install

1 Remove paneling on B-pillar AR68.30-P-4700SRC Installation: Only install paneling on B-

pillar following a successful check of the soft top. 2 Mark position of main bearing (1) at two suitable points on B-pillar 3 Disconnect electrical connector (2) 4 Detach electrical wiring harness (3) from main bearing (1) 5 Unscrew bolt (4) 6 Fold down retainer (5) Do not engage retainer (5).

7 Remove bolt (6) Make sure that nut of bolt (6) is not

pressed out of retainer (5) housing. Installation: To tighten bolt (6), the

retainer (5) must be folded down and engaged. 8 Remove bolts (7) Installation: Helper required to position

roof cassette (8). 9 Unscrew bolts (9) and remove main bearing Installation: Observe any previous

(1) markings. *BA77.33-P-1001-01SR Bolt, main bearing to B-pillar C 10 Disconnect electrical connector at soft top drive electric motor 11 Install in the reverse order Check

12 Check soft top for proper function If complaint present Adjust soft top AR77.30-P-1010SRC Soft top mechanical components Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.30-p-1108src, Remove/install soft top main bearing Model 453.4

AR77.30-P-1109MCO

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3162 · Applies to: 453 · AR: AR77.30-P-1109MCO, AR77.30-P-1100MCO

Remove/install soft top roof cassette 28.06.2017 Model 451.4, 453.4 Shown on left side of vehicle on model 451.4 1 Roof cassette seal 2 Rear soft top 3 Guide 4 Paneling (model 451.4) 5 Sealing strip (model 451.4) P77.31-2192-06 Notes on soft tops AH77.30-P-0001-01MCO Remove

1 Remove folding roof AR77.30-P-1100MCO 2.1 Pull roof cassette seal (1) on left and right, Model 451.4 from rear toward front, out of guide (3) 2.2 Pull seal of roof cassette (1) on left and right Model 453.4 out of guides (3) backwards from the front, detach from rear soft top (2) and remove Clean

3 Remove sealing and adhesive residues and Cleaner *BR00.45-Z-1025-04A clean sealing and bonding areas Check

4 Check sealing on seal of roof cassette (1) Model 453.4 If complaint present Replace seal Rear window sealing profile *BR00.45-Z-1084-01A Install

5.1 Insert roof cassette seal (1) from front toward Model 451.4 rear into guide (3) Insert roof cassette seal (1) so that it is

flush with the guide (3). The sealing lip on the roof cassette seal (1) should make contact with rear soft top covering (2) over the entire length. 5.2 Insert seal of roof cassette (1) flush in guides Model 453.4 (3) backwards from the front, and press onto rear soft top (2) The seal of the roof cassette (1) must be in

contact and bonded with the rear soft top (2) along its entire length. 6 Lift roof cassette seal (1) in front area (arrow) Model 451.4 and additionally glue to guide (3) On left and right side of vehicle.

Ultra-fast super glue 20 g. Sabesto *BR00.45-Z-1095-02A 7 Lift roof cassette seal (1) at rear and attach Model 451.4 sealing strip (5) to paneling (4) Length of sealing strip (5) approx. 50 mm.

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1109mco, Remove/install soft top roof cassette Model 451.4, 453.4

Sealing strip 119.32 Terostat 20

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3163 · Applies to: 453 · AR: AR77.30-P-1100MCO

2 mm *BR00.45-Z-1088-01A 8 Remove protective foil from sealing strip (5) Model 451.4 and firmly press on roof cassette seal (1) The sealing lip on the roof cassette seal (1)

should make contact with rear soft top covering (2) over the entire length. 9 Install folding roof AR77.30-P-1100MCO Repair materials Number Designation Order number BR00.45-Z-1025-04A Cleaner A 005 989 19 71 BR00.45-Z-1084-01A Rear window sealing profile A 004 989 60 20 Sealing strip 119.32 Terostat 20 2 mm BR00.45-Z-1088-01A Henkel AG & Co. KGaA www.loctite.de BR00.45-Z-1095-02A Ultra-fast super glue 20 g. Sabesto Adolf Würth GmbH & Co. KG Reinhold-Würth-Str. 12-17 74653 Künzelsau-Gaisbach Germany Tel. +49 7940 15-0 Fax +49 7940 15-1000 Item no.: 089309 http://www.wuerth.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.30-p-1109mco, Remove/install soft top roof cassette Model 451.4, 453.4

AR77.30-P-1102SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3164 · Applies to: 453 · AR: AR77.30-P-1102SRC, AR77.33-P-2030MCO

Tension folding top 28.06.2017 Model 453.4 P77.31-2301-09 1 Folding roof 2 Sealing strips 4 Tension cable retaining plate 1.1 Seal 3 Bolts 5 Tension cable P77.31-2302-08 1 Folding roof 7 Screw 6 Tensioning strap 8 Clamping piece Notes on soft tops AH77.30-P-0001-01MCO Disassemble

1 Remove roof cassette rear spoiler AR77.33-P-2030MCO Page 1 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.30-p-1102src, Tension folding top Model 453.4

Remove seal (1.1) from rear soft top and fold

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3165 · Applies to: 453 · AR: AR77.33-P-2030MCO, AR77.30-P-1010SRC

2 Remove seal (1.1) from rear soft top and fold forward 3 Remove bolts (3) 4 Release bonding on left and right in cross- hatched area and fold folding roof (1) with tension cable retaining plates (4) forward 5 Pull left and right tensioning straps (6) out of roof cassette by means of bolt (7) Engage 6 Unscrew left and right bolt (7) until tensioning strap (6) can be loosened by lifting the clamping piece (8) 7 Lift left and right clamping pieces (8), tension The side edges of the folding roof (1)

tensioning strap (6), press in clamping piece should be flush with the contour of the side (8) and tighten bolt (7) supports. Check

8 Open folding roof (1) and close again 9 Fold folding roof (1) forward and check tension The side edges of the folding roof (1)

of tensioning straps (6 ) should be flush with the contour of the side supports. In the event of complaints Retension left or right tensioning strap (6) Assemble

10 Insert extended length of tensioning straps (6) in roof cassette 11 Open folding roof (1) approx. 10 cm 12 Check bonding on left and right in cross- If folding roof (1) can no longer bond securely. hatched area Replace non-reusable adhesive residues with new sealing strip, and fill defects Sealing strip 119.32 Terostat 20 2 mm *BR00.45-Z-1088-01A 13 Fold back folding roof (1) with tension cable retaining plates (4) 14 Align folding roof (1) with tension cable There must be no creases.

retaining plates (4), press on left and right in cross-hatched area and tighten bolts (3) 15 Close folding roof (1) Check

16 Check tension of tension cable (5) The spring of tension cable (5) must be

slighted tensioned, as shown. If end stop of tension cable (5) is in contact with a tension cable retaining plate (4). Correct position of tension cable retaining plate (4) in question 17 Remove loose parts of old adhesive tape on Adhesive tape with good adhesion does

seal (1.1) not have to be removed. 18 Replace removed adhesive tape of seal (1.1) Use double-sided adhesive tape with a

width of 19 or 25 cm. Teroson double-sided adhesive tape, for BR00.45-Z-1075-02A bonding trim strips and emblems (UV-resistant and weatherproof, black) (width 12 mm), order no.: 107.64 A (width 19 mm), order no.: 107.96 K (width 25 mm), order no.: 117.05 Y 19 Pull off protective foil of adhesive tape and stick seal (1.1) onto rear soft top without any creases Sealing strip 119.32 Terostat 20 2 mm 20 Replace sealing strips (2) BR00.45-Z-1088-01A 21 Install roof cassette rear spoiler AR77.33-P-2030MCO Check

Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 22 Start engine 23 Check soft top for proper function In the event of complaints Adjust soft top AR77.30-P-1010SRC 24 Turn off engine Page 2 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.30-p-1102src, Tension folding top Model 453.4

AR77.33-P-1010MCO

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3167 · Applies to: 453 · AR: AR77.33-P-1010MCO

Remove, instal side support seal 22.12.15 Model 451.4, 453.4 P77.33-2148-09 Shown on left side support (1) on model 451.4 1 Side support 1.3 Guide 2.2 Instancing 1.1 Guide 2 Side support seal 2.3 Tab 1.2 Guide pin 2.1 Tab Shown on left side support (1) on model 451.4 1 Side support 1.4 Guide rail 1.5 Guide rail cutout 2 Side support seal P77.33-2149-06 Notes on soft tops AH77.30-P-0001-01MCO

Remove

1 Completely open soft top Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.33-p-1010mco, Remove, instal side support seal Model 451.4, 453.4

Remove side support (1)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3168 · Applies to: 453 · AR: AR77.30-P-1010SRC, AR77.30-P-1010MCO

2 Remove side support (1)

Lay side support (1) down on suitable subsurface. Otherwise the side support (1) can be damaged when removing side support seal (2). 3 Remove side support seal (2) from side Before removal, observe route and

support (1) position of side support seal (2). Check

4 Check condition of side support (2) and look If complaint present for signs of damage Replace side support seal (2) Install

5 Moisten side support seal (2) at connection points with lubricant 6 Replace seal at front end of side support (2) Model 453.4 seal Rear window sealing profile *BR00.45-Z-1084-01A 7 Insert guide (1.1) of side support (1) into Ensure that guide pin (1.2) is seated

shackle (2.1) on side support seal (2) correctly. 8 Insert shackle (2.3) into guide (1.3) Ensure shackle (2.3) is correctly seated.

9 Ensure instancing (2.2) is correctly seated. Position side support seal (2) along entire

length (arrows) of side support (1), and press Ensure that side support seal (2) is seated in correctly in guide rail (1.4) and guide rail cutout (1.5). 10 Install side support (1) 11 Close soft top Check

12 Check position of side wall seal (2) in relation If complaint present to soft top Adjust soft top Model 453.4 AR77.30-P-1010SRC Model 451.4 AR77.30-P-1010MCO Repair materials Number Designation Order number BR00.45-Z-1084-01A Rear window sealing profile A 004 989 60 20 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.33-p-1010mco, Remove, instal side support seal Model 451.4, 453.4

AR77.33-P-2100SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3169 · Applies to: 453 · AR: AR77.33-P-2100SRC

Remove/install B-pillar catch 13.1.16 Model 453.4 P77.33-2213-08 1 Latch 2 Screw 3 Blind 1 Latch 3 Blind 4 Pin 5 Latch 5.1 Guide P77.33-2214-05 Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.33-p-2100src, Remove/install B-pillar catch Model 453.4

Latch

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3170 · Applies to: 453 · AR: AR68.30-P-4700SRC, AR77.30-P-1010SRC

1 Latch 5 Latch 5.2 Rail 8.1 Rail P77.30-2670-06 Notes on soft tops AH77.30-P-0001-01MCO

Remove

1 Remove paneling on B-pillar AR68.30-P-4700SRC 2 Open rear soft top cover 3 Remove cover (3) 4 Mark installation position of latch (1) 5 Unscrew bolts (2) and remove latch (1) Install

6 Position latch (1) in line with markings and tighten bolts (2) Check

7 Install side support The side support must engage securely in

the second catch and its seal must be in contact with the B-pillar. In the event of complaints Adjust latch (1) as necessary 8 Close rear soft top and make sure that pin (4)

and guide (5.1) are correctly positioned In the event of a collision, interrupt closure of rear soft top immediately. Otherwise soft top components can be damaged. Helper required.

The pin (4) must run centrally into the catch (5) and the guide (5.1) run securely into the side support. In the event of a collision or other deviations Adjust soft top AR77.30-P-1010SRC 9 Check height offset of rails (5.2, 8.1)

There must not be any height offset. Otherwise the sliders can be damaged. If deviations are present Adjust soft top AR77.30-P-1010SRC 10 Remove side support 11 Put on cover (3) 12 Close rear soft top 13 Fold up clamping bracket on rear soft top 14 Install paneling at B-pillar AR68.30-P-4700SRC Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.33-p-2100src, Remove/install B-pillar catch Model 453.4

AR77.33-P-0001SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3171 · Applies to: 453 · AR: AR77.33-P-0001SRC, AR77.30-P-1112SRC

Remove/install folding roof cassette soft top lock 13.1.16 Model 453.4 Shown on left side of vehicle 1 Soft top lock 2 Electrical wiring harness 3 Bolts 4 Screw 5 Screw 6 Switches 7 Carrier plate P77.33-2217-06 Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Notes on soft tops AH77.30-P-0001-01MCO

Remove/install

1 Remove guide tubes of relevant drive cable AR77.30-P-1112SRC 2 Unhook electrical wiring harness (2) from roof cassette 3 Remove bolts (3) 4 Pull soft top lock (1) upwards at rear Removal: This releases the soft top lock

(1). Installation: Lock soft top lock (1) using

pin of B-pillar latch. Pay attention to routing of wiring harness (2). 5 Unscrew bolt (4) 6 Pull soft top lock (1) upwards and out, and turn over 7 Uncrew bolts (5) and remove carrier plate (7) Observe installation location of bolts (5).

of soft top lock (1) 8 Unclip switches (6) and place to one side

The guide pins and spring steel sheets must not be damaged or bent. Otherwise the soft top may suffer malfunction or damage. Only one switch (6) is installed on right

side of vehicle. The switches (6) may be replaced individually. 9 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.33-p-0001src, Remove/install folding roof cassette soft top lock Model 453.4

AR77.33-P-2030MCO

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3172 · Applies to: 453 · AR: AR77.33-P-2030MCO, AR82.10-P-5375SRA, AR82.10-P-5375MCC, AR77.30-P-1102SRC, AR77.30-P-1102MCO

Remove/install roof cassette spoiler 03.11.2016 Model 451.4, 453.4 P77.33-2123-09 Shown on model 451 1 Roof spoiler 3 Seal E21 Center stop lamp 2 Screw 4 Sealing Notes on soft tops AH77.30-P-0001-01MCO

Remove

1 Remove center brake lamp (E21) Model 453.4 AR82.10-P-5375SRA Model 451.4 AR82.10-P-5375MCC 2 Unscrew bolts (2) and remove roof spoiler (1) Helper required.

3 Remove old sealant from roof spoiler (1) and seal (4) Check

4 Check seal (4) for wrinkle-free and complete If the seal (4) does not make complete contact bonding or is wrinkled. Repeat gluing on seal (4) Model 453.4 AR77.30-P-1102SRC Model 451.4 AR77.30-P-1102MCO Install

5.1 Replace seals (3) by approx. 30 mm long Model 451.4 sealing strip Sealing strip 119.32 Terostat 20 2 mm *BR00.45-Z-1088-01A 5.2 Replace seals (3) Model 453.4 Seals (3) are available from the EPC.

6 Helper required. Position spoiler (1) and tighten bolts (2)

Alternately and uniformly tighten bolts (2). 7 Install center brake lamp (E21) Model 453.4 AR82.10-P-5375SRA Model 451.4 AR82.10-P-5375MCC Repair materials Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.33-p-2030mco, Remove/install roof cassette spoiler Model 451.4, 453.4

AR77.33-P-1008MCO

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3174 · Applies to: 453 · AR: AR77.33-P-1008MCO, AR68.30-P-4450MCO, AR68.30-P-4450MCV, AR68.30-P-4450SRC, AR77.30-P-1010SRC (+1 more)

Remove/install side support bearing 22.12.15 Model 451.4, 453.4 Shown on left side of vehicle on model 451.4 1 Side support bearing 2 Screw P77.33-2120-04 Shown on left side of vehicle on model 451.4 3 Side support P77.33-2119-01 Notes on soft tops AH77.30-P-0001-01MCO

Remove

1 Completely open soft top 2 Remove side support (3) 3 Model 451.4 Remove front roof frame paneling AR68.30-P-4450MCO except code 494 (US version) Model 451.4 AR68.30-P-4450MCV with code 494 (US version) Model 453.4 AR68.30-P-4450SRC 4 Mark position of side support bearing (1) Model 453.4 5.1 Unscrew bolts (2), rotate side support bearing Model 451.4 (1) 90° and detach from A-pillar 5.2 Unscrew bolts (2) and remove side support Model 453.4 bearing (1) Install

6.1 Insert side support bearing (1) in A-pillar and Model 451.4 rotate 90° 6.2 Position side support bearing (1) on A-pillar Model 453.4 Observe any previous markings.

7 Tighten bolts (2) 8 Install side support (3) Check

9 Check transitions between A-pillar and side Model 453.4 support (3) Contour of side support (3) must be slightly

below contour of A-pillar. If complaint present Correct position of side support bearing (1) by loosening bolts (2) 10 Check soft top for proper function If complaint present Adjust soft top Model 453.4 AR77.30-P-1010SRC Model 451.4 AR77.30-P-1010MCO 11 Model 451.4 Install front roof frame paneling AR68.30-P-4450MCO except code 494 (US version) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.33-p-1008mco, Remove/install side support bearing Model 451.4, 453.4

Model 451.4

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3175 · Applies to: 453 · AR: AR68.30-P-4450MCV, AR68.30-P-4450SRC

AR68.30-P-4450MCV with code 494 (US version) Model 453.4 AR68.30-P-4450SRC Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.33-p-1008mco, Remove/install side support bearing Model 451.4, 453.4

AR77.33-P-2010MCO

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3176 · Applies to: 453 · AR: AR77.33-P-2010MCO, AR77.30-P-1100MCO

Remove/install slide plate on soft top 12.02.2016 Model 451.4, 453.4 P77.33-2128-09 Shown on folding roof (3), model 451.4 1 Sliding plate 3 Folding roof 5 Jack 2 Tensioning strap 4 Compression spring Notes on soft tops AH77.30-P-0001-01MCO

Remove/install

1 Remove folding roof (3) AR77.30-P-1100MCO 2 Pull tensioning straps (2) out of sliding rails Installation: Ensure that tensioning straps

and end pieces (2) are not twisted when pulled in. 3 Remove slide plates (1) with compression Installation: Ensure that smaller bushings

springs (4) from roof edge are installed correctly. 4 Remove sockets (5) from roof edge Only when replacing slide plates (1). 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.33-p-2010mco, Remove/install slide plate on soft top Model 451.4, 453.4

AR77.33-P-2000MCO

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3177 · Applies to: 453 · AR: AR77.33-P-2000MCO, AR77.30-P-1100MCO

Remove/install soft top bow slider 22.12.15 Model 451.4, 453.4 P77.33-2215-08 Shown on left side of vehicle on model 451.4 1 Folding roof 4 Rear sliding rail 2 Tensioning strap 5 Center sliding rail 3 End piece 9 End piece P77.33-2216-07 Shown on left side of vehicle on model 451.4 3 End piece 7 Bow spring 4 Rear sliding rail 8 Bow spring 5 Center sliding rail 9 End piece 6 Bow spring Notes on soft tops AH77.30-P-0001-01MCO

Remove

1 Remove folding roof (1) AR77.30-P-1100MCO 2 Pull tensioning straps (2) out of rear sliding rails (4), center sliding rails (5) and end pieces (3) 3 Pull rear sliders (4) and bow springs (6) out of soft top bow and end pieces (3) 4 Pull center sliders (5) and bow springs (7) out of soft top bow and end pieces (3) 5 Pull end pieces (3) out of soft top bows and remove from pockets in folding roof (1) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.33-p-2000mco, Remove/install soft top bow slider Model 451.4, 453.4

Unhook end pieces (9) from pockets, pull out

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3178 · Applies to: 453 · AR: AR77.30-P-1100MCO

6 Unhook end pieces (9) from pockets, pull out of soft top bows and detach from bow springs (8) 7 Remove bow springs (8) from roof peak (arrow) Install

8 Hook end pieces (3) into pockets in folding roof (1) and insert in soft top bows 9 Match new bow springs (6, 7, 8) to new rear Match the same as previously removed

sliders (4), new center sliders (5) and end bow springs (6, 7, 8). pieces (9) 10 Install new bow springs (8) in roof peak 11 Install new bow springs (7) in new center sliders (5) 12 Install new bow springs (7) in end pieces (3) and insert center sliders (5) in soft top bows 13 Install new bow springs (6) in new rear sliders (4) 14 Install new bow springs (6) in end pieces (3) and insert rear sliders (4) in soft top bows 15 Pull tensioning straps (2) into rear sliding rails (4), center sliding rails (5) and end pieces (3) 16 Install folding roof (1) AR77.30-P-1100MCO Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.33-p-2000mco, Remove/install soft top bow slider Model 451.4, 453.4

AR77.33-P-1234SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3179 · Applies to: 453 · AR: AR77.33-P-1234SRC, AR77.30-P-1100MCO

Remove/install soft top control drive unit 22.12.15 Model 453.4 1 Folding roof 2 Bolts 3 Cover 4 Electrical connector 5 Bolts 6 Guide tubes A52 Soft top control drive unit P77.39-2387-06 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Notes on soft tops AH77.30-P-0001-01MCO

Remove/install

1 Detach folding roof (1) from roof cassette as AR77.30-P-1100MCO shown 2 Remove screws/bolts (2) and remove cover (3) 3 Mark position of drive cables in relation to one another (arrows) 4 Remove bolts (5) 5 Lift guide tubes (6) and take out soft top Installation: Take note of markings on

control drive unit (A52) drive cables, and align with one another. Observe routing of electrical lines.

6 Release and unplug electrical connector (4) and remove soft top control drive unit (A52) 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.33-p-1234src, Remove/install soft top control drive unit Model 453.4

AR77.35-P-1000SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3180 · Applies to: 453 · AR: AR77.35-P-1000SRC

Remove, install rear soft top window 12.1.16 Model 453.4 P77.35-2028-08 1 Rear window 6 Retaining rail 2 Electrical connectors 7 Clips 3 Bolts 8 Rear soft top 4 Retaining strips 9 Struts 5 Rear window frame Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Notes on soft tops AH77.30-P-0001-01MCO

Remove

1 Open liftgate 2 Move front seats forward and fold 3 Separate electrical connectors (2) 4 Remove bolts (3) 5 Release retainer 6 Pull retaining strips (4) out of rear window frame (5) 7 Starting from one side, pull retaining strip (6) out of rear window frame (5) and remove rear window (1) 8 Remove clips (7) still in rear window frame *110589035900 Mounting wedge (5) Clean

9 Clean sealing surfaces on rear window frame (5) and rear soft top (8) Install

10 Fit clips (7) to retaining strip (6) on rear soft top (8) 11 Engage retainer 12 Position rear window (1) on rear soft top (8) and on struts (9), and tighten bolts (3) 13 Starting from one side, press retaining strip (6) into rear window frame (5) 14 Press retaining strips (4) into rear window frame (5) 15 Connect electrical connectors (2) Check

16 Check soft top for proper function If complaint present Adjust soft top Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.35-p-1000src, Remove, install rear soft top window Model 453.4

AR77.30-P-1010SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3181 · Applies to: 453 · AR: AR77.30-P-1010SRC

110 589 03 59 00 Mounting wedge Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar77.35-p-1000src, Remove, install rear soft top window Model 453.4

AR77.35-P-1001SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3182 · Applies to: 453 · AR: AR77.35-P-1001SRC, AR77.35-P-1000SRC

Remove, install rear soft top window seal 12.1.16 Model 453.4 1 Seal 2 Rear window P77.35-2029-10 Remove

1 Remove rear window (2) AR77.35-P-1000SRC 2 Pull seal (1) out of rear window frame (2) Check

3 Check seal (1) for damage and wear If complaint present Replace seal (1) Clean

4 Clean sealing surfaces on rear window frame (2) and rear soft top Install

5 Starting from the middle, press bottom of seal (1) into rear window frame (2) 6 Install rear window (2) AR77.35-P-1000SRC Check

7 Check that rear window (2) and rear soft top are tight Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.35-p-1001src, Remove, install rear soft top window seal Model 453.4

AR77.39-P-1010SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3183 · Applies to: 453 · AR: AR77.39-P-1010SRC, AR68.30-P-4700SRC, AR77.33-P-0001SRC, AR77.33-P-1234SRC, AR77.39-P-4010SRC

Remove, install rear soft top drive wiring harness 13.1.16 Model 453.4 P77.39-2388-07 1 Electrical wiring harness 3 Electrical connector 2 Soft top control drive unit 4 Electrical connectors Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Remove left B-pillar paneling AR68.30-P-4700SRC 2 Remove switches of soft top locks AR77.33-P-0001SRC 3 Remove soft top control drive unit (2) AR77.33-P-1234SRC 4 Remove left soft top drive electric motor AR77.39-P-4010SRC 5 Disconnect electrical connector (3) at soft top drive electric motor right from above 6 Disconnect electrical connectors at rear window 7 Disconnect electrical connectors (4) 8 Detach electrical wiring harness (1) from

body, main bearings and roof cassette, and Make sure that electrical wiring harness (1) is remove routed correctly. Otherwise the electrical wiring harness (1) can be damaged due to shearing or chafing. 9 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.39-p-1010src, Remove, install rear soft top drive wiring harness Model 453.4

AR77.39-P-4010SRC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3184 · Applies to: 453 · AR: AR77.39-P-4010SRC, AR68.30-P-4700SRC

Remove/install rear soft top motor 12.1.16 Model 453.4 Shown on left side of vehicle 1 Locking plate 2 Bolts 3 Drive axle bearing 4 Electrical wiring harness 5 Strut 6 Nut 7 Screw 8 Electrical connector 9 Rubber guide M12/7 Left soft top drive electric motor M12/8 Right soft top drive electric motor P77.35-2030-06 Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Notes on soft tops AH77.30-P-0001-01MCO

Remove/install

1 Remove paneling on B-pillar AR68.30-P-4700SRC 2 Remove lock washer (1) 3 Unscrew screws/bolts (2) 4 Pull out drive axle with drive axle bearing (3) 5 Detach electrical wiring harness (4) from strut (5) 6 Counterhold nut (6) and remove bolt (7) 7 Move left soft top drive electric motor (M12/7) Installation: Make sure that left soft top

or right soft top drive electric motor (M12/8) drive electric motor (M12/7) or right soft top downwards to remove, and disconnect drive electric motor (M12/8) is correctly seated electrical connector (8) in rubber guide (9). 8 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar77.39-p-4010src, Remove/install rear soft top motor Model 453.4

Remove screw/bolt of cup holder (1) and

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3474 · Applies to: 453 · AR: AR68.20-P-2026SR

4.1 Remove screw/bolt of cup holder (1) and Model 453 with code 535 (smart Media system) unclip cup holder (1) upwards except code J59 (Center armrest) Model 453 with code 556 (Radio 56A MM2012 with DAB and PREMIUM SOUND) except code J59 (Center armrest) Model 453 with code 557 (RADIO 57A MM2012 without DAB) except code J59 (Center armrest) Model 453 with code 558 (smart Media system with DAB) except code J59 (Center armrest) 4.2 Remove armrest from center console and Model 453 with code 535 (smart Media system) place to one side with connected lines with code J59 (Center armrest) Model 453 with code 556 (Radio 56A MM2012 with DAB and PREMIUM SOUND) with code J59 (Center armrest) Model 453 with code 557 (RADIO 57A MM2012 without DAB) with code J59 (Center armrest) Model 453 with code 558 (smart Media system with DAB) with code J59 (Center armrest) AR68.20-P-2026SR 5 Disconnect connector socket (2) from interior socket (X58/1) 6 Disconnect electrical connector from multimedia connection unit (A90/5) 7 Unclip and remove multimedia connection unit (A90/5) 8 Install in the reverse order Check

9 Check multimedia connection unit (A90/5) for proper operation Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar82.60-p-1033sr, Remove/install multimedia connection unit in rear stowage compartment Model 453 with code 535 (smart Media system) Model 453 with code 556 (Radio 56A MM2012 with DAB and PREMIUM SOUND) Model 453 with code 557 (RADIO 57A MM2012 without DAB) ...

Notes on avoiding damage to electronic

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3481 · Applies to: 453 · AR: AR68.10-P-1190FF, AR54.21-P-1262FF, AR68.20-P-2350FG, AZ54.21-P-0001FF

AH54.00-P-0001-01A

components due to electrostatic discharge 1 Remove cover (1) from instrument panel center section. Remove/install cover on instrument panel AR68.10-P-1190FF

center section Install

2 Route radio electrical connectors (7) and Number of radio electrical connectors (7) antenna plug (6) out of the radio recess and depends on the vehicle equipment connect to the smart radio five (A2) The radio electrical connectors (7) are coded and not interchangeable. 3 Insert smart radio five (A2) into the radio recess and fasten in place using the screws (4) 4 Insert stowage compartment (2) and fasten in place using screws (5) 5 Install upper control panel control module Remove/install upper control panel control AR54.21-P-1262FF

unit 6 Install cover (3) at the front of the center console Remove/install cover on center console AR68.20-P-2350FG

7 Retrofit central gateway control unit AZ54.21-P-0001FF 8 Read out fault memory, delete if necessary and activate smart radio five (A2) Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory *WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system 9.1 Enter special equipment in the vehicle data At workshops without DMS Autoline 8.0 card and in the vehicle's online data card dealer system. Add code (C28) smart radio five. Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS Compact diagnosis system for passenger cars 6511 1801 00 Parts ordering notes Part no. Designation Quantity Design group 82 (see smart radio five EPC) In combination with Design group 54 (see Central gateway control unit (CGW) EPC) Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.60-p-0003ff, Retrofit radio MODEL 454.0 with CODE (C08) Radio preinstallation incl. rod antenna (FFO) Retrofit smart radio five

AZ82.60-P-0003FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3482 · Applies to: 453 · AR: AZ82.60-P-0003FG, AR68.10-P-1190FF, AR82.60-P-7502FG, AR46.10-P-0100FF, AR46.10-P-0200FF (+1 more)

Retrofit radio 18.8.06 MODEL 454.0 Retrofit smart radio six P82.60-5703-09 1 Multifunction steering wheel A1 Instrument cluster A45 Clock spring contact 2 Cable harness, antenna A2/4 smart radio six N93 Central gateway control unit 3 Adapter wiring harness 9 Combination plug 10 Radio antenna connector 11 Bolts A2/4 smart radio six P82.60-5707-04 Modification notes 2.8.06 Repair method completely modified All steps Removing

Notes on avoiding damage to electronic AH54.00-P-0001-01A

components due to electrostatic discharge 1.1 Remove cover on center part of instrument For vehicles without code (C28) smart radio panel five Remove/install cover on instrument panel AR68.10-P-1190FF

center section 1.2 Remove smart radio five For vehicles with code (C28) smart radio five Remove/install radio AR82.60-P-7502FG

2.1 Remove steering wheel For vehicles without code (I49) Multifunction steering wheel Remove/install steering wheel AR46.10-P-0100FF

3.1 Remove spiral contact coil (A45) For vehicles without code (I49) Multifunction steering wheel Remove/install clock spring contact AR46.10-P-0200FF

4.1 Remove instrument cluster (A1) For vehicles without code (C18) Onboard computer (FFO) Remove/install instrument cluster AR54.30-P-6015FF

Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.60-p-0003fg, Retrofit radio MODEL 454.0 Retrofit smart radio six

AZ82.60-P-0003FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3485 · Applies to: 453 · AR: AZ82.60-P-0003FH, AR68.10-P-1190FF, AR82.60-P-7502FG, AR46.10-P-0100FF

Retrofit radio 18.8.06 MODEL 454.0 Retrofit smart radio six with CD changer P82.60-5714-07 1 Adapter wiring harness 2 Cable harness, antenna 3 Multifunction steering wheel 4 Holder for CD changer A1 Instrument cluster A2/4 smart radio six A2/6 CD changer A45 Clock spring contact N93 Central gateway control unit P82.60-5705-06 9 Combination plug 10 Radio antenna connector 11 Bolts A2/4 smart radio six P82.60-5707-04 Removing

Notes on avoiding damage to electronic AH54.00-P-0001-01A

components due to electrostatic discharge 1.1 Remove cover on center part of instrument For vehicles without code (C28) smart radio panel five Remove/install cover on instrument panel AR68.10-P-1190FF

center section 1.2 Remove smart radio five For vehicles with code (C28) smart radio five Remove/install radio AR82.60-P-7502FG

2.1 Remove steering wheel For vehicles without code (I49) Multifunction steering wheel Remove/install steering wheel AR46.10-P-0100FF

Page 1 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.60-p-0003fh, Retrofit radio MODEL 454.0 Retrofit smart radio six with CD changer

Remove/install cover on instrument panel

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3490 · Applies to: 453 · AR: AR68.10-P-1190FF, AR82.60-P-7502FG, AR46.10-P-0100FF, AR46.10-P-0200FF, AR54.30-P-6015FF (+5 more)

AR68.10-P-1190FF

center section 1.2 Remove smart radio five For vehicles with code (C28) smart radio five Remove/install radio AR82.60-P-7502FG

2.1 Remove steering wheel For vehicles without code (I49) Multifunction steering wheel Remove/install steering wheel AR46.10-P-0100FF

3.1 Remove spiral contact coil (A45) For vehicles without code (I49) Multifunction steering wheel Remove/install clock spring contact AR46.10-P-0200FF

4.1 Remove instrument cluster (A1) For vehicles without code (C18) Onboard computer (FFO) Remove/install instrument cluster AR54.30-P-6015FF

5 Remove right front seat Remove/install front seat AR91.10-P-1000FF

6 Remove footwell trim at the right A-pillar Remove/install paneling in footwell AR68.30-P-4010FF

7 Remove right-hand side entrance strip Remove/install door sill molding AR68.30-P-4100FF

8 Remove antenna cable Remove/install antenna cable AR82.62-P-1200FF

9 Remove radio antenna Remove/install antenna AR82.70-P-8951FF

10 Remove control unit holder Remove/install control unit holder AR54.21-P-0001-01FF

Install

11 Retrofit radio/telephone antenna (A2/21) AZ82.85-P-0001-14FF 12 Retrofit new antenna wiring harness (3) AZ82.70-P-0002-01FG Use protective coverings to cover plugs and connectors on fiber optic cable before installing new antenna wiring harness (3). Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 13 Retrofit adapter wiring harness (2) for smart AZ82.60-P-0003-01FF radio six (A2/4) 14 Install control unit holder Remove/install control unit holder AR54.21-P-0001-01FF

15.1 Install headliner On vehicles with code (E55) Glass roof with sun protection (FFO) Only fasten headliner in place with left grab handles and rear interior lamp. Install edge guard in area of headliner on left front and left rear door cutout. Remove/install headliner AR68.30-P-4300FF

16 Position headliner and install edge guards in area of headliner on right front and right rear door cutout 17.1 Install edge guard of headliner in area of On vehicles with code (V29) electric glass electric glass sliding roof sliding roof (FFO) 18 Install paneling on right B-pillar Remove/install paneling on B-pillar AR68.30-P-4700FF

19 Install grab handle on roof at right Remove/install handle on roof AR68.30-P-4330FF

20 Install sun visors Remove/install sun visor AR68.60-P-5480FF

21 Install paneling on right A-pillar Remove/install paneling on A-pillar AR68.30-P-4050FF

22 Retrofit hands-free system microphone group AZ82.70-P-0005-08FF (B25) 23.1 Retrofit frame (7) and overhead control panel On vehicles without code (V29) Electric glass AZ82.20-P-0100FF (6) for hands-free system sliding roof (FFO) 23.2 Install front overhead control panel (6) On vehicles with code (V29) electric glass sliding roof (FFO) Remove/install front overhead control panel AR82.20-P-1100FF

24.1 Retrofit central gateway control unit (N93) For vehicles without code (C28) smart radio AZ54.21-P-0001FF five 25 Retrofit UPCI [UHI] portable CTEL holder AZ82.70-P-0005-02FG (A34/15) with wiring harness for hands-free system (1) 26 Install glove compartment Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.60-p-0003fi, Retrofit radio MODEL 454.0 smart radio six with hands-free system retrofitting

Remove/install glove compartment

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3491 · Applies to: 453 · AR: AR68.10-P-1400FF, AR54.21-P-1262FF, AR82.70-P-8918FG, AZ82.70-P-0010FF, AR46.10-P-0200FF (+5 more)

AR68.10-P-1400FF

27 Remove protective covers from fiber optic cable of new antenna wiring harness (3) Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 28 Connect radio antenna connector (10) to smart radio six (A2/4) 29 Connect combination connector (9) to smart radio six (A2/4) 30 Insert smart radio six (A2/4) into radio recess and secure in place using screws (11) 31 Install upper control panel control module Remove/install upper control panel control AR54.21-P-1262FF

unit 32.1 Install telephone console (5) On vehicles with code (C10) Telephone console (DFO) Remove and install bracket for portable CTEL AR82.70-P-8918FG

32.2 Retrofit telephone console (5) On vehicles without code (C10) Telephone AZ82.70-P-0010FF console (DFO) 33.1 Install new clock spring contact (A45) For conversion to code (I49) Multifunction steering wheel Remove/install clock spring contact AR46.10-P-0200FF

34.1 Install multifunction steering wheel (4) For conversion to code (I49) Multifunction steering wheel When retrofitting a multifunction steering wheel (4) the airbag unit must also be replaced. Remove/install steering wheel AR46.10-P-0100FF

35.1 Install new instrument cluster (A1) with For conversion to code (C18) Onboard onboard computer computer (FFO) Remove/install instrument cluster AR54.30-P-6015FF

36 Install right-hand door sill molding Remove/install door sill molding AR68.30-P-4100FF

37 Install footwell trim at right A-pillar Remove/install paneling in footwell AR68.30-P-4010FF

38 Retrofit Universal Portable CTEL Interface AZ82.70-P-0005-04FG (UPCI [UHI]) control unit (N123/1) 39 Clip corresponding portable CTEL receiver The portable CTEL receiver should match into UPCI [UHI] portable CTEL holder the respective mobile phone. (A34/15) 40 Install right front seat Remove/install front seat AR91.10-P-1000FF

41 Using STAR DIAGNOSIS in the audio gateway control unit menu activate the Universal Portable CTEL Interface (UPCI [UHI]) control unit (N123/1) via a MOST ring query Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory 42.1 Code the instrument cluster (A1) with onboard For conversion to code (C18) Onboard computer and multifunction steering wheel (4) computer (FFO) and in the control unit adaptations menu using code (I49) Multifunction steering wheel STAR DIAGNOSIS. Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory 43 Read out fault memory, clear if necessary and operate smart radio six (A2/4) using STAR DIAGNOSIS Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory 44.1 Retrofit special equipment to be added to At workshops without DMS Autoline 8.0 vehicle data card and vehicle data card online dealer system. Add code (C25) smart radio six, code (C27) Telephone preparation incl. fastener and antenna (DFO/FFO) and code (C30) Hands-free system and depending on conversion scope code (C18) Onboard computer (FFO) and code (I49) Multifunction steering wheel. Parts ordering notes Part no. Designation Quantity Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.60-p-0003fi, Retrofit radio MODEL 454.0 smart radio six with hands-free system retrofitting

Remove cover on center part of instrument

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3494 · Applies to: 453 · AR: AR68.10-P-1190FF, AR82.60-P-7502FG, AR46.10-P-0100FF, AR46.10-P-0200FF, AR54.30-P-6015FF (+5 more)

1.1 Remove cover on center part of instrument For vehicles without code (C28) smart radio panel five Remove/install cover on instrument panel AR68.10-P-1190FF

center section 1.2 Remove smart radio five For vehicles with code (C28) smart radio five Remove/install radio AR82.60-P-7502FG

2.1 Remove steering wheel For vehicles without code (I49) Multifunction steering wheel Remove/install steering wheel AR46.10-P-0100FF

3.1 Remove spiral contact coil (A45) For vehicles without code (I49) Multifunction steering wheel Remove/install clock spring contact AR46.10-P-0200FF

4.1 Remove instrument cluster (A1) For vehicles without code (C18) Onboard computer (FFO) Remove/install instrument cluster AR54.30-P-6015FF

5 Remove right front seat Remove/install front seat AR91.10-P-1000FF

6 Remove footwell trim on right A-pillar Remove/install paneling in footwell AR68.30-P-4010FF

7 Remove right-hand side entrance strip Remove/install door sill molding AR68.30-P-4100FF

8 Remove antenna cable Remove/install antenna cable AR82.62-P-1200FF

9 Remove radio antenna Remove/install antenna AR82.70-P-8951FF

10 Remove control unit holder Remove/install control unit holder AR54.21-P-0001-01FF

Install

11 Retrofit radio/telephone antenna (A2/21) AZ82.85-P-0001-14FF 12 Retrofit new antenna wiring harness (3) AZ82.70-P-0002-01FG Use protective covers for plugs and connectors on the fiber optic cable before installation of the new antenna wiring harness (3). Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 13 Retrofit adapter wiring harness (2) for smart AZ82.60-P-0003-01FF radio six (A2/4) 14 Install control unit holder Remove/install control unit holder AR54.21-P-0001-01FF

15.1 Install headliner For vehicles with code (E55) Glass roof with sun protection (FFO) Fasten headliner with left grab handles and the rear interior lamp only. Install edge guards in area of headliner at left front and rear door cutout. Remove/install headliner AR68.30-P-4300FF

16 Position headliner and install edge guards in area of headliner at right front and rear door cutout 17.1 Install edge guard of headliner in area of On vehicles with code (V29) electric glass electric glass sliding roof sliding roof (FFO) 18 Install paneling on right B-pillar Remove/install paneling on B-pillar AR68.30-P-4700FF

19 Install grab handle on roof at right Remove/install handle on roof AR68.30-P-4330FF

20 Install sun visors Remove/install sun visor AR68.60-P-5480FF

21 Install paneling on right A-pillar Remove/install paneling on A-pillar AR68.30-P-4050FF

22 Retrofit hands-free system microphone group AZ82.70-P-0005-08FF (B25) 23.1 Retrofit frame (8) and overhead control panel On vehicles without code (V29) Electric glass AZ82.20-P-0100FF (7) for hands-free system sliding roof (FFO) 23.2 Install front overhead control panel (7) On vehicles with code (V29) electric glass sliding roof (FFO) Remove/install front overhead control panel AR82.20-P-1100FF

24.1 Retrofit central gateway control unit (N93) For vehicles without code (C28) smart radio AZ54.21-P-0001FF five Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.60-p-0003fj, Retrofit radio MODEL 454.0 Retrofit smart radio six with CD changer and hands-free system

Retrofit UPCI [UHI] portable CTEL holder

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3495 · Applies to: 453 · AR: AR68.10-P-1400FF, AR54.21-P-1262FF, AR82.70-P-8918FG, AZ82.70-P-0010FF, AR46.10-P-0200FF (+5 more)

25 Retrofit UPCI [UHI] portable CTEL holder AZ82.70-P-0005-02FG (A34/15) with wiring harness for hands-free system (1) 26 Install glove compartment Remove/install glove compartment AR68.10-P-1400FF

27 Remove protective covers from fiber optic cable of new antenna wiring harness (3) Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 28 Connect radio antenna connector (10) to smart radio six (A2/4) 29 Connect combination plug (9) to smart radio six (A2/4) 30 Insert smart radio six (A2/4) into the radio recess and fasten in place using the screws (11) 31 Install upper control panel control module Remove/install upper control panel control AR54.21-P-1262FF

unit 32.1 Install telephone console (6). For vehicles with code (C10) Telephone console (DFO) Remove and install bracket for portable CTEL AR82.70-P-8918FG

32.2 Retrofit telephone console (6) For vehicles without code (C10) Telephone AZ82.70-P-0010FF console (DFO) 33.1 Install new clock spring contact (A45) For conversion to code (I49) Multifunction steering wheel Remove/install clock spring contact AR46.10-P-0200FF

34.1 Install multifunction steering wheel (4) For conversion to code (I49) Multifunction steering wheel When retrofitting a multifunction steering wheel (4), the airbag unit must also be replaced. Remove/install steering wheel AR46.10-P-0100FF

35.1 Install new instrument cluster (A1) with For conversion to code (C18) Onboard onboard computer computer (FFO) Remove/install instrument cluster AR54.30-P-6015FF

36 Install right-hand door sill molding Remove/install door sill molding AR68.30-P-4100FF

37 Install footwell trim on right A-pillar Remove/install paneling in footwell AR68.30-P-4010FF

38 Retrofit Universal Portable CTEL Interface AZ82.70-P-0005-04FG (UPCI [UHI]) control unit (N123/1) 39 Clip corresponding portable CTEL bracket The portable CTEL holder is geared into UPCI [UHI] portable CTEL holder towards the respective mobile phone. (A34/15) 40 Adjust installation position of CD changer AZ82.64-P-0001-11FF (A2/6) 41 Retrofit CD changer (A2/6) with bracket for AZ82.64-P-0001-13FF CD changer (5) under front seat at right 42 Install right front seat Remove/install front seat AR91.10-P-1000FF

43 Using STAR DIAGNOSIS, in the audio gateway control unit menu, activate the CD changer (A2/6) and the Universal Portable CTEL Interface (UPCI [UHI]) control unit (N123/1) via a MOST ring query Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory *WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system 44.1 Code instrument cluster (A1) with onboard For conversion to code (C18) Onboard computer and multifunction steering wheel computer (FFO) and (4), in control unit adaptations menu, using code (I49) Multifunction steering wheel STAR DIAGNOSIS Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory *WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system 45 Read out fault memory, delete if necessary and activate smart radio six (A2/4) using STAR DIAGNOSIS Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory *WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.60-p-0003fj, Retrofit radio MODEL 454.0 Retrofit smart radio six with CD changer and hands-free system

Notes on avoiding damage to electronic

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3547 · Applies to: 453 · AR: AR68.30-P-4050FF, AR68.60-P-5480FF, AR82.20-P-1100FF, AR68.30-P-4330FF, AR68.30-P-4700FF (+5 more)

AH54.00-P-0001-01A

components due to electrostatic discharge Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 1 Remove paneling on right A-pillar AR68.30-P-4050FF 2 Remove sun visors AR68.60-P-5480FF 3 Remove front overhead control panel AR82.20-P-1100FF 4 Remove grab handles from right of roof AR68.30-P-4330FF 5 Remove paneling from right B-pillar AR68.30-P-4700FF 6 Undo edge guards in area of headliner at front and rear right door cutouts 7.1 Remove edge guard from headliner in area of On vehicles with code (V29) electric glass electric glass sliding roof sliding roof (FFO) 8 Disconnect the radio connector (A2/21x1) and the power supply connector (A2/21x3) from the radio/telephone antenna wiring harness (A2/21) through the overhead control panel installation opening in the headliner 9.1 Disconnect the GPS antenna connector In vehicles with code (C26) smart radio (A2/23x1) through the overhead control panel multimedia navigator or code (C29) smart installation opening in the headliner radio navigator. 10.1 Carefully lower headliner at right-hand side On vehicles with code (E23) Full roof (FFO) or until the antenna wiring harness (17) and the code (V29) Electric glass sliding roof (FFO) telephone connector (A2/21x2) are accessible Take care when lowering headliner to avoid kinking or cracking. 10.2 Remove entire headliner Only vehicles with code (E55) Glass roof with AR68.30-P-4300FF sun protection (FFO) 11 Disconnect telephone connector (A2/21x2) 12 Unclip retaining clips (arrow A) of antenna When exposing the antenna wiring wiring harness (17) and expose antenna harness (17), please pay attention to the wiring harness (17) in area of roof and at right telephone antenna plug (12) of the telephone A-pillar connection (A2/21x2), the radio/telephone antenna power supply coupling (13) of the power supply connection (A2/21x3), the radio antenna plug (14) of the radio connection (A2/21x1) and the hands-free system microphone group plug (15) of the hands-free system microphone group connection (B25x1). In vehicles with code (C26) smart radio multimedia navigator or code (C29) smart radio navigator, attention must also be paid to the GPS antenna coupling (16) of the GPS antenna connection (A2/23x1). 13 Remove right front seat AR91.10-P-1000FF 14 Remove glove compartment AR68.10-P-1400FF 15 Remove right-hand side entrance strip AR68.30-P-4100FF 16 Remove CD changer (A2/6) AR82.64-P-7508FF 17 Remove Universal Portable CTEL Interface AR82.70-P-7010FF (UPCI [UHI]) control unit (N123/1) 18 Lift front floor covering (19) until CD changer Take care when lifting front floor covering branch-off line (11) and Universal Portable (19) to avoid kinking or cracking. CTEL Interface branch-off line (10) are accessible 19 Unclip retaining clips (arrows C) and expose Please take care not to remove the CD changer branch-off line (11) and Universal protective caps on the CD changer fiber optic Portable CTEL Interface branch-off line (10) cable plug (11.2) and the Universal Portable as far as cable duct (20) CTEL Interface fiber-optic cable plug (10.1) when exposing the CD change branch-off line (11) and the Universal Portable CTEL Interface branch-off line (10). 20 Guide antenna wiring harness (17) out of cable duct (20) and expose 21 Undo nut of ground (right footwell) (W36), Installation:

Replace cable ties (arrows remove cable tie (arrows B) and expose B). antenna wiring harness (17) 22 Remove smart radio six, smart radio navigator AR82.60-P-7502FF or smart radio multimedia navigator (A40/3) 23 Remove control unit bracket AR54.21-P-0001-01FF 24 Disconnect interior/audio connector (X39/52) The interior/audio connector (X39/52) is located behind the carrier of the central gateway control unit and connects the antenna wiring harness (17) and the adapter wiring harness (2). Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar82.62-p-1200fg, Remove/install antenna cable MODEL 454.0 with CODE (C27) Telephone preparation incl. fastener and antenna (DFO/FFO) with CODE (C20) smart CD changer

CD changer branch-off line

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3550 · Applies to: 453 · AR: AR68.30-P-4050FF, AR68.60-P-5480FF, AR82.20-P-1100FF, AR82.20-P-0110FF, AR68.30-P-4330FF (+2 more)

8 CD changer branch-off line 15 Radio connector A2/23x1 GPS antenna connector (with code (C26) smart radio 12 Cable harness, antenna 16 Cable duct multimedia navigator or code 14 Voltage supply connector 17 Front floor covering (C29) smart radio navigator) W36 Ground (right footwell) P82.62-3107-09 1 Radio combination plug 3 Adapter wiring harness X39/52 Interior/audio connector 1.1 Fiber optic cable connector 12 Cable harness, antenna Remove/install

Notes on avoiding damage to electronic AH54.00-P-0001-01A

components due to electrostatic discharge Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 1 Remove paneling on right A-pillar AR68.30-P-4050FF 2 Remove sun visors AR68.60-P-5480FF 3.1 Remove front overhead control panel On vehicles with code (V29) electric glass AR82.20-P-1100FF sliding roof (FFO) 3.2 Remove/install front dome lamp On vehicles without code (V29) Electric glass AR82.20-P-0110FF sliding roof (FFO) 4 Remove grab handles from right of roof AR68.30-P-4330FF 5 Remove paneling from right B-pillar AR68.30-P-4700FF 6 Undo edge guards in area of headliner at front and rear right door cutouts 7.1 Remove edge guard from headliner in area of On vehicles with code (V29) electric glass electric glass sliding roof sliding roof (FFO) 8 Disconnect the radio connector (15) and the power supply connector (14) from the radio/ telephone antenna wiring harness (A2/20) through the overhead control panel installation opening in the headliner 9.1 Disconnect the GPS antenna connector In vehicles with code (C26) smart radio (A2/23x1) from the GPS antenna wiring multimedia navigator or code (C29) smart harness (A2/23) through the overhead control radio navigator. panel installation opening in the headliner 10.1 Carefully lower headliner at right side until On vehicles with code (E23) Full roof (FFO) or antenna wiring harness (12) is accessible code (V29) Electric glass sliding roof (FFO) Take care when lowering headliner to avoid kinking or cracking. 10.2 Remove entire headliner Only vehicles with code (E55) Glass roof with AR68.30-P-4300FF sun protection (FFO) Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar82.62-p-1200fh, Remove/install antenna cable MODEL 454.0 with CODE (C20) smart CD changer

Notes on avoiding damage to fiber optic

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3554 · Applies to: 453 · AR: AR68.30-P-4050FF, AR68.60-P-5480FF, AR82.20-P-1100FF, AR68.30-P-4330FF, AR68.30-P-4700FF (+5 more)

AH82.60-P-0001-05AK cables during repair work 1 Remove paneling on right A-pillar AR68.30-P-4050FF 2 Remove sun visors AR68.60-P-5480FF 3 Remove front overhead control panel AR82.20-P-1100FF 4 Remove grab handles from right of roof AR68.30-P-4330FF 5 Remove paneling from right B-pillar AR68.30-P-4700FF 6 Undo edge guards in area of headliner at front and rear right door cutouts 7.1 Remove edge guard from headliner in area of On vehicles with code (V29) electric glass electric glass sliding roof sliding roof (FFO) 8 Disconnect the radio connector (A2/21x1) and the power supply connector (A2/21x3) through the overhead control panel installation opening in the headliner 9.1 Disconnect the GPS antenna connector In vehicles with code (C26) smart radio (A2/23x1) through the overhead control panel multimedia navigator or code (C29) smart installation opening in the headliner radio navigator. 10.1 Carefully lower headliner at right-hand side On vehicles with code (E23) Full roof (FFO) or until the antenna wiring harness (11) and the code (V29) Electric glass sliding roof (FFO) telephone connector (A2/21x2) are accessible Take care when lowering headliner to avoid kinking or cracking. 10.2 Remove entire headliner Only vehicles with code (E55) Glass roof with AR68.30-P-4300FF sun protection (FFO) 11 Disconnect telephone connector (A2/21x2) 12 Unclip retaining clips (arrow A) of antenna When exposing the antenna wiring wiring harness (11) and expose antenna harness (11), please pay attention to the wiring harness (11) in area of roof and at right telephone antenna plug (12) of the telephone A-pillar connection (A2/21x2), the radio/telephone antenna power supply coupling (13) of the power supply connection (A2/21x3), the radio antenna plug (14) of the radio connection (A2/21x1) and the hands-free system microphone group plug (15) of the hands-free system microphone group connection (B25x1). In vehicles with code (C26) smart radio multimedia navigator or code (C29) smart radio navigator, attention must also be paid to the GPS antenna coupling (16) of the GPS antenna connection (A2/23x1). 13 Remove right front seat AR91.10-P-1000FF 14 Remove glove compartment AR68.10-P-1400FF 15 Remove right-hand side entrance strip AR68.30-P-4100FF 16 Remove Universal Portable CTEL Interface AR82.70-P-7010FF (UPCI [UHI]) control unit (N123/1) 17 Lift front floor covering (18) until Universal Take care when lifting front floor covering Portable CTEL Interface branch-off line (10) is (18) to avoid kinking or cracking. accessible 18 Unclip retaining clips (arrows C) and expose Please ensure that the protective cap of Universal Portable CTEL Interface branch-off the Universal Portable CTEL Interface fiber line (10) as far as cable duct (19) optic cable connector (10.1) is not removed when the Universal Portable CTEL Interface branch-off line (10) is being exposed. 19 Release antenna wiring harness (11) from cable duct (19) and expose 20 Undo nut of ground (right footwell) (W36), Installation:

Replace cable ties (arrows remove cable tie (arrows B) and expose B). antenna wiring harness (11) 21 Remove smart radio six, smart radio navigator AR82.60-P-7502FF or smart radio multimedia navigator (A40/3) 22 Remove control unit bracket AR54.21-P-0001-01FF 23 Disconnect interior/audio connector (X39/52) The interior/audio connector (X39/52) is located behind the carrier of the central gateway control unit and connects the antenna wiring harness (11) and the adapter wiring harness (4). Installation:

Make interior/audio connector connection (X39/52) with adapter wiring harness power supply coupling (2) and adapter wiring harness power supply connector (3). 24 Disconnect telephone antenna coupling (5) and telephone power supply coupling (6) from Universal Portable CTEL Interface wiring harness (17) in radio recess Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar82.62-p-1200fi, Remove/install antenna cable MODEL 454.0 with CODE (C27) Telephone preparation incl. fastener and antenna (DFO/FFO)

Remove right-hand side entrance strip

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3596 · Applies to: 453 · AR: AR68.30-P-4100FF, AR82.62-P-1200FF, AR82.62-P-1200FH, AR82.70-P-8951FF, AR68.30-P-4300FF (+5 more)

4 Remove right-hand side entrance strip Remove/install door sill molding AR68.30-P-4100FF

5 Remove control unit holder Remove/install control unit holder AR54.21-P-0001-01FF

6 Remove antenna cable Remove/install antenna cable For vehicles without code (C20) smart CD AR82.62-P-1200FF

changer and without code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) For vehicles with code (C20) smart CD AR82.62-P-1200FH changer 7 Remove radio antenna Remove/install antenna AR82.70-P-8951FF

Install

8 Retrofit radio/telephone antenna (A2/21) AZ82.85-P-0001-14FF 9 Retrofit new antenna wiring harness (3) AZ82.70-P-0002-01FG Use protective covers for plugs and connectors on the fiber optic cable before installation of the new antenna wiring harness (3). Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 10.1 Retrofit adapter wiring harness (4) For vehicles without code (C20) smart CD AZ82.60-P-0003-01FF changer 11 Install control unit holder Remove/install control unit holder AR54.21-P-0001-01FF

12.1 Install headliner For vehicles with code (E55) Glass roof with sun protection (FFO) Fasten headliner with left grab handles and the rear interior lamp only. Install edge guards in area of headliner at left front and rear door cutout. Remove/install headliner AR68.30-P-4300FF

13 Position headliner and install edge guards in area of headliner at right front and rear door cutout 14.1 Install edge guard of headliner in area of On vehicles with code (V29) electric glass electric glass sliding roof sliding roof (FFO) 15 Install paneling on right B-pillar Remove/install paneling on B-pillar AR68.30-P-4700FF

16 Install grab handle on roof at right Remove/install handle on roof AR68.30-P-4330FF

17 Install sun visors Remove/install sun visor AR68.60-P-5480FF

18 Install paneling on right A-pillar Remove/install paneling on A-pillar AR68.30-P-4050FF

19 Retrofit hands-free system microphone group AZ82.70-P-0005-08FF (B25) 20.1 Retrofit frame (6) and overhead control panel On vehicles without code (V29) Electric glass AZ82.20-P-0100FF (5) for hands-free system sliding roof (FFO) 20.2 Install front overhead control panel (5) On vehicles with code (V29) Electric glass sliding roof (FFO). Remove/install front overhead control panel AR82.20-P-1100FF

21 Retrofit UPCI [UHI] portable CTEL holder AZ82.70-P-0005-02FG (A34/15) with wiring harness for hands-free system (1) 22 Install glove compartment Remove/install glove compartment AR68.10-P-1400FF

23 Remove protective covers from fiber optic cable of new antenna wiring harness (3) Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 24.1 Connect plug for GPS antenna (8) to smart For vehicles with code (C26) smart radio radio navigator (A2/56) or smart radio multimedia navigator or with code (C29) smart multimedia navigator (A40/3) radio navigator 25 Connect combination plug (7) and plug for radio antenna (9) to smart radio six (A2/4), smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) 26 Insert smart radio six (A2/4), smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) into radio recess and fasten in place using the screws (10) Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.70-p-0005fh, Retrofit hands-free system MODEL 454.0 with CODE (C25) smart radio six except CODE (C27) Telephone preparation incl. fastener and antenna (DFO/FFO) Retrofit hands-free system MODEL 454.0 with CODE (C26) ...

AZ82.70-P-0010FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3598 · Applies to: 453 · AR: AZ82.70-P-0010FF, AR68.20-P-2510FF, AZ68.20-P-0006FF

Retrofit telephone console 17.1.06 MODEL 454.0 1 Telephone console 2 Bracket 3 Bolts 4 Center console cover at front P82.70-5087-06 Remove

1.1 Remove CD box on front center console For vehicles with code (I03) 1-disk CD box covering (4) Remove/install CD box AR68.20-P-2510FF

Install

2 Determine installation location of bracket (2) On vehicles with code (LHD) left-hand for the telephone console (1) drive vehicle, install outer right bracket (2). On vehicles with code (RHD) right-hand drive vehicle, install outer left bracket (2). 3 Drill bore-holes for the screws (3) through the Ensure that you only drill through the center console front cover (4) center console front cover (4), otherwise the bracket (2) cannot be attached using the screws (3). Drill holes to Ø 2 mm. Remove drilling chips. *450589017000

Wet/dry vacuum cleaner WE58.40-Z-1005-03A Rechargeable drill / screwdriver WH58.30-Z-1007-20A 4 Position bracket (2) and screw in screws (3) 5 Slide telephone console (1) onto the bracket Telephone console (1) must audibly latch (2) onto the bracket (2). 6.1 Install CD box on front center console For vehicles with code (I03) 1-disk CD box covering (4) As a consequence of retrofitting the

telephone bracket (1) the CD box must be positioned at another location. Refer to: Retrofit CD box AZ68.20-P-0006FF 7.1 Enter special equipment in the vehicle data If the workshop does not have recourse to the card and in the vehicle's online data card DMS Autoline 8.0 dealer system. Enter code (C10) Telephone console (DFO). Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.70-p-0010ff, Retrofit telephone console MODEL 454.0

Remove/install cover on instrument panel

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3602 · Applies to: 453 · AR: AR68.10-P-1190FF, AR82.60-P-7502FG, AR82.60-P-7502FF, AR46.10-P-0100FF, AR46.10-P-0200FF (+5 more)

AR68.10-P-1190FF

center section 1.2 Remove radio On vehicles with code (C28) smart radio five or with code (C25) smart radio six Remove/install radio For vehicles with code (C28) smart radio five AR82.60-P-7502FG

On vehicles with code (C25) smart radio six AR82.60-P-7502FF 2 Remove steering wheel On vehicles without code (I49) Multifunction steering wheel Remove/install steering wheel AR46.10-P-0100FF

3 Remove spiral contact coil (A45) On vehicles without code (I49) Multifunction steering wheel Remove/install clock spring contact AR46.10-P-0200FF

4 Remove instrument cluster (A1) On vehicles without code (C18) Onboard computer (FFO) Remove/install instrument cluster AR54.30-P-6015FF

5 Remove control unit bracket Remove/install control unit bracket AR54.21-P-0001-01FF

6 Remove antenna cable Remove/install antenna cable On vehicles without code (C20) smart CD AR82.62-P-1200FF

changer and without code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) On vehicles with code (C20) smart CD AR82.62-P-1200FG changer and with code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) On vehicles with code (C20) smart CD AR82.62-P-1200FH changer On vehicles with code (C27) Telephone AR82.62-P-1200FI preparation incl. fastener and antenna (DFO/ FFO) Install

7 Retrofit new antenna wiring harness (2) AZ82.70-P-0002-01FF 8 Retrofit adapter wiring harness (1) for smart On vehicles without code (C25) smart radio AZ82.60-P-0003-01FF radio navigator (A2/56) or smart radio six or without code (C28) smart radio five multimedia navigator (A40/3) 9 Retrofit and connect GPS antenna (A2/23) AZ82.61-P-0003-02FF 10 Install control unit bracket Remove/install control unit bracket AR54.21-P-0001-01FF

11 Install headliner On vehicles with code (E55) Glass roof with sun protection (FFO) Fix headliner in place with the left grab handles and the rear interior lamp only. Install edge guards in area of headliner on left front and rear door cutout. Remove/install headliner AR68.30-P-4300FF

12 Position headliner and install edge guards in area of headliner on right front and rear door cutout 13 Install edge guard of headliner in area of On vehicles with code (V29) electric glass electric glass sliding roof sliding roof (FFO) 14 Install paneling on right B-pillar Remove/install paneling on B-pillar AR68.30-P-4700FF

15 Install grab handles on right of roof Remove/install handle on roof AR68.30-P-4330FF

16 Install sun visors Remove/install sun visor AR68.60-P-5480FF

17 Install paneling on right A-pillar Remove/install paneling on A-pillar AR68.30-P-4050FF

18.1 Install overhead control panel in front On vehicles with code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) or with code (V29) Electric glass sliding roof (FFO) Remove/install front overhead control panel AR82.20-P-1100FF

18.2 Install front dome lamp On vehicles without code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) and without code (V29) Electric glass sliding roof (FFO) Remove/install front dome lamp AR82.20-P-0110FF

19 Retrofit central gateway control unit (N93) On vehicles without code (C25) smart radio AZ54.21-P-0001FF six or without code (C28) smart radio five Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.85-p-2003ff, Install navigation unit MODEL 454.0 except CODE (C26) smart radio multimedia navigator with CODE (V33) ESP Retrofitting smart radio navigator or smart radio multimedia navigator MODEL 454.0 except CODE ...

Install glove compartment

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3603 · Applies to: 453 · AR: AR68.10-P-1400FF, AR54.21-P-1262FF, AR46.10-P-0200FF, AR46.10-P-0100FF, AR54.30-P-6015FF (+3 more)

20 Install glove compartment Remove/install glove compartment AR68.10-P-1400FF

21 Connect combination plug (9) to smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) 22 Connect radio antenna plug (10) and GPS antenna plug (11) to smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) 23 Insert smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) into radio recess and tighten with the bolts (12) 24 Install upper control panel control module Remove/install upper control panel control AR54.21-P-1262FF

unit 25 Install new clock spring contact (A45) For modification to code (I49) Multifunction steering wheel Remove/install clock spring contact AR46.10-P-0200FF

26 Install multifunction steering wheel (3) For modification to code (I49) Multifunction steering wheel When retrofitting a multifunction steering wheel (3), the airbag unit must also be exchanged. Remove/install steering wheel AR46.10-P-0100FF

27 Install new instrument cluster (A1) with For modification to code (C18) Onboard onboard computer computer (FFO) Remove/install instrument cluster AR54.30-P-6015FF

28 Fold over floor covering in area of right front Only when an antenna wiring harness was seat and align removed from vehicles with code (C20) smart CD changer or with code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO). 29 Install right door sill molding Only when an antenna wiring harness was removed from vehicles with code (C20) smart CD changer or with code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO). Remove/install door sill molding AR68.30-P-4100FF

30 Install footwell trim at right A-pillar Only when an antenna wiring harness was removed from vehicles with code (C20) smart CD changer or with code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO). Remove/install paneling in footwell AR68.30-P-4010FF

31 Install right front seat Only when an antenna wiring harness was removed from vehicles with code (C20) smart CD changer or with code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO). Remove/install front seat AR91.10-P-1000FF

32 Code instrument cluster (A1) in control unit For modification to code (C18) Onboard adaptations menu using onboard computer computer (FFO) and code (I49) Multifunction and multifunction steering wheel (3) via STAR steering wheel DIAGNOSIS Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory 33 Read out fault memory, delete if necessary and activate smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) via STAR DIAGNOSIS Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory 34 Enter newly added special equipment in At workshops without DMS Autoline 8.0 vehicle data card and in online vehicle data dealer system. card Code (C26) smart radio multimedia navigator or code (C29) smart radio navigator and depending on conversion scope Add code (C18) Onboard computer (FFO) and code (I49) Multifunction steering wheel. Parts ordering notes Part no. Designation Quantity Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.85-p-2003ff, Install navigation unit MODEL 454.0 except CODE (C26) smart radio multimedia navigator with CODE (V33) ESP Retrofitting smart radio navigator or smart radio multimedia navigator MODEL 454.0 except CODE ...

Remove/install cover on instrument panel

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3606 · Applies to: 453 · AR: AR68.10-P-1190FF, AR82.60-P-7502FG, AR82.60-P-7502FF, AR46.10-P-0100FF, AR46.10-P-0200FF (+5 more)

AR68.10-P-1190FF

center section 1.2 Remove radio On vehicles with code (C28) smart radio five or with code (C25) smart radio six Remove/install radio For vehicles with code (C28) smart radio five AR82.60-P-7502FG

On vehicles with code (C25) smart radio six AR82.60-P-7502FF 2 Remove steering wheel On vehicles without code (I49) Multifunction steering wheel Remove/install steering wheel AR46.10-P-0100FF

3 Remove spiral contact coil (A45) On vehicles without code (I49) Multifunction steering wheel Remove/install clock spring contact AR46.10-P-0200FF

4 Remove instrument cluster (A1) On vehicles without code (C18) Onboard computer (FFO) Remove/install instrument cluster AR54.30-P-6015FF

5 Remove right front seat Remove/install front seat AR91.10-P-1000FF

6 Remove footwell trim from right A-pillar Remove/install paneling in footwell AR68.30-P-4010FF

7 Remove right-hand side entrance strip Remove/install door sill molding AR68.30-P-4100FF

8 Remove control unit bracket Remove/install control unit bracket AR54.21-P-0001-01FF

9 Remove antenna cable Remove/install antenna cable On vehicles without code (C20) smart CD AR82.62-P-1200FF

changer and without code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) On vehicles with code (C20) smart CD AR82.62-P-1200FG changer and with code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) On vehicles with code (C20) smart CD AR82.62-P-1200FH changer On vehicles with code (C27) Telephone AR82.62-P-1200FI preparation incl. fastener and antenna (DFO/ FFO) Install

10 Retrofit new antenna wiring harness (2) AZ82.70-P-0002-01FG Cover plugs and connectors on fiber optic cable before installing new antenna wiring harness (2) with protective covers. Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 11 Retrofit adapter wiring harness (1) for smart On vehicles without code (C25) smart radio AZ82.60-P-0003-01FF radio navigator (A2/56) or smart radio six with code (C20) smart CD changer or with multimedia navigator (A40/3) code (C27) Telephone preparation incl. fastener and antenna (DFO/FFO) 12 Retrofit and connect GPS antenna (A2/23) AZ82.61-P-0003-02FF 13 Install control unit bracket Remove/install control unit bracket AR54.21-P-0001-01FF

14 Install headliner On vehicles with code (E55) Glass roof with sun protection (FFO) Fix headliner in place with the left grab handles and the rear interior lamp only. Install edge guards in area of headliner on left front and rear door cutout. Remove/install headliner AR68.30-P-4300FF

15 Position headliner and install edge guards in area of headliner on right front and rear door cutout 16 Install edge guard of headliner in area of On vehicles with code (V29) electric glass electric glass sliding roof sliding roof (FFO) 17 Install paneling on right B-pillar Remove/install paneling on B-pillar AR68.30-P-4700FF

18 Install grab handles on right of roof Remove/install handle on roof AR68.30-P-4330FF

19 Install sun visors Remove/install sun visor AR68.60-P-5480FF

20 Install paneling on right A-pillar Remove/install paneling on A-pillar AR68.30-P-4050FF

Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.85-p-2003fg, Install navigation unit MODEL 454.0 except CODE (C26) smart radio multimedia navigator with CODE (V33) ESP Retrofitting smart radio navigator or smart radio multimedia navigator with CD changer MODEL ...

Removal

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3610 · Applies to: 453 · AR: AR68.10-P-1190FF, AR82.60-P-7502FG, AR82.60-P-7502FF, AR46.10-P-0100FF, AR46.10-P-0200FF (+5 more)

Notes on avoiding damage to electronic AH54.00-P-0001-01A

components due to electrostatic discharge 1.1 Remove cover on center part of instrument On vehicles without code (C25) smart radio panel six or without code (C28) smart radio five Remove/install cover on instrument panel AR68.10-P-1190FF

center section 1.2 Remove radio On vehicles with code (C28) smart radio five or with code (C25) smart radio six Remove/install radio For vehicles with code (C28) smart radio five AR82.60-P-7502FG

On vehicles with code (C25) smart radio six AR82.60-P-7502FF 2 Remove steering wheel On vehicles without code (I49) Multifunction steering wheel Remove/install steering wheel AR46.10-P-0100FF

3 Remove spiral contact coil (A45) On vehicles without code (I49) Multifunction steering wheel Remove/install clock spring contact AR46.10-P-0200FF

4 Remove instrument cluster (A1) On vehicles without code (C18) Onboard computer (FFO) Remove/install instrument cluster AR54.30-P-6015FF

5 Remove right front seat Remove/install front seat AR91.10-P-1000FF

6 Remove footwell trim from right A-pillar Remove/install paneling in footwell AR68.30-P-4010FF

7 Remove right-hand side entrance strip Remove/install door sill molding AR68.30-P-4100FF

8 Remove control unit bracket Remove/install control unit bracket AR54.21-P-0001-01FF

9 Remove antenna cable Remove/install antenna cable On vehicles without code (C20) smart CD AR82.62-P-1200FF

changer and without code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) On vehicles with code (C20) smart CD AR82.62-P-1200FG changer and with code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) On vehicles with code (C20) smart CD AR82.62-P-1200FH changer On vehicles with code (C27) Telephone AR82.62-P-1200FI preparation incl. fastener and antenna (DFO/ FFO) 10 Remove radio antenna On vehicles without code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) or without code (C30) Hands-free system Remove/install antenna AR82.70-P-8951FF

Install

11 Retrofit radio/telephone antenna (A2/21) On vehicles without code (C27) Telephone AZ82.85-P-0001-14FF preparation incl. fastener and antenna (DFO/ FFO) or without code (C30) Hands-free system 12 Retrofit new antenna wiring harness (3) AZ82.70-P-0002-01FG Cover plugs and connectors on fiber optic cable before installing new antenna wiring harness (3) with protective covers. Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 13 Retrofit adapter wiring harness (2) for smart On vehicles without code (C25) smart radio AZ82.60-P-0003-01FF radio navigator (A2/56) or smart radio six with code (C20) smart CD changer or with multimedia navigator (A40/3) code (C27) Telephone preparation incl. fastener and antenna (DFO/FFO) or with code (C30) Hands-free system 14 Install control unit bracket Remove/install control unit bracket AR54.21-P-0001-01FF

15 Retrofit and connect GPS antenna (A2/23) AZ82.61-P-0003-02FF 16 Install headliner On vehicles with code (E55) Glass roof with sun protection (FFO) Page 2 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.85-p-2003fh, Install navigation unit MODEL 454.0 except CODE (C26) smart radio multimedia navigator with CODE (V33) ESP Retrofitting smart radio navigator or smart radio multimedia navigator with hands-free system ...

Fix headliner in place with the left grab

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3611 · Applies to: 453 · AR: AR68.30-P-4300FF, AR68.30-P-4700FF, AR68.30-P-4330FF, AR68.60-P-5480FF, AR68.30-P-4050FF (+5 more)

handles and the rear interior lamp only. Install edge guards in area of headliner on left front and rear door cutout. Remove/install headliner AR68.30-P-4300FF

17 Position headliner and install edge guards in area of headliner on right front and rear door cutout 18 Install edge guard of headliner in area of On vehicles with code (V29) electric glass electric glass sliding roof sliding roof (FFO) 19 Install paneling on right B-pillar Remove/install paneling on B-pillar AR68.30-P-4700FF

20 Install grab handles on right of roof Remove/install handle on roof AR68.30-P-4330FF

21 Install sun visors Remove/install sun visor AR68.60-P-5480FF

22 Install paneling on right A-pillar Remove/install paneling on A-pillar AR68.30-P-4050FF

23 Retrofit hands-free system microphone (B25) On vehicles without code (C27) Telephone AZ82.70-P-0005-08FF preparation incl. fastener and antenna (DFO/ FFO) or without code (C30) Hands-free system 24.1 Retrofit frame (7) and overhead control panel On vehicles without code (C27) Telephone AZ82.20-P-0100FF (6) for hands-free system preparation incl. fastener and antenna (DFO/ FFO) or without code (C30) Hands-free system or without code (V29) Electric glass sliding roof (FFO) 24.2 Install front overhead control panel (6) On vehicles with code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) or with code (C30) Hands-free system or with code (V29) Electric glass sliding roof (FFO) Remove/install front overhead control panel AR82.20-P-1100FF

25 Retrofit central gateway control unit (N93) On vehicles without code (C25) smart radio AZ54.21-P-0001FF six or without code (C28) smart radio five 26 Retrofit UPCI [UHI] portable CTEL holder On vehicles without code (C30) Hands-free AZ82.70-P-0005-02FG (A34/15) with hands-free system wiring system harness (1) 27 Install glove compartment Remove/install glove compartment AR68.10-P-1400FF

28 Remove protective covers from fiber optic cable of new antenna wiring harness (3) Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 29 Connect combination plug (9) to smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) 30 Connect radio antenna plug (10) and GPS antenna plug (11) to smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) 31 Insert smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) into radio recess and tighten with the bolts (12) 32 Install upper control panel control module Remove/install upper control panel control AR54.21-P-1262FF

unit 33.1 Install telephone console (5) On vehicles with code (C10) Telephone console (DFO) Remove and install bracket for portable CTEL AR82.70-P-8918FG

33.2 Retrofit telephone console (5) On vehicles without code (C10) Telephone AZ82.70-P-0010FF console (DFO) 34 Install new clock spring contact (A45) For modification to code (I49) Multifunction steering wheel Remove/install clock spring contact AR46.10-P-0200FF

35 Install multifunction steering wheel (4) For modification to code (I49) Multifunction steering wheel When retrofitting a multifunction steering wheel (4), the airbag unit must also be exchanged. Remove/install steering wheel AR46.10-P-0100FF

36 Install new instrument cluster (A1) with For modification to code (C18) Onboard onboard computer computer (FFO) Remove/install instrument cluster AR54.30-P-6015FF

Page 3 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.85-p-2003fh, Install navigation unit MODEL 454.0 except CODE (C26) smart radio multimedia navigator with CODE (V33) ESP Retrofitting smart radio navigator or smart radio multimedia navigator with hands-free system ...

Install right door sill molding

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3612 · Applies to: 453 · AR: AR68.30-P-4100FF, AR68.30-P-4010FF, AR82.70-P-7010FF, AR91.10-P-1000FF

37 Install right door sill molding Remove/install door sill molding AR68.30-P-4100FF

38 Install footwell trim at right A-pillar Remove/install paneling in footwell AR68.30-P-4010FF

39.1 Retrofit Universal Portable CTEL Interface On vehicles without code (C27) Telephone AZ82.70-P-0005-04FG (UPCI [UHI]) control unit (N123/1) preparation incl. fastener and antenna (DFO/ FFO) or without code (C30) Hands-free system 39.2 Install Universal Portable CTEL Interface On vehicles with code (C27) Telephone (UPCI [UHI]) control unit (N123/1) preparation incl. fastener and antenna (DFO/ FFO) or with code (C30) Hands-free system Remove/install Universal Portable CTEL AR82.70-P-7010FF

Interface control unit 40 Clip corresponding portable CTEL holder into When retrofitting code (C30) Hands-free UPCI [UHI] portable CTEL holder (A34/15) system Portable CTEL holder depends on the particular mobile phone. 41 Install right front seat Remove/install front seat AR91.10-P-1000FF

42 Use STAR DIAGNOSIS to enable the Universal Portable CTEL Interface (UPCI [UHI]) control unit (N123/1) in the audio gateway control unit menu with the help of a MOST ring query Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory 43 Code instrument cluster (A1) in control unit For modification to code (C18) Onboard adaptations menu using onboard computer computer (FFO) and and multifunction steering wheel (4) via STAR CODE (I49) Multifunction steering wheel DIAGNOSIS Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory 44 Read out fault memory, delete if necessary and activate smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) via STAR DIAGNOSIS Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory 45 Enter special equipment in the vehicle data At workshops without DMS Autoline 8.0 card and in the vehicle's online data card dealer system. Code (C26) smart radio multimedia navigator or code (C29) smart radio navigator with code (C27) Telephone preparation incl. fastener and antenna (DFO/FFO) and code (C30) Hands-free system and depending on conversion scope Add code (C18) Onboard computer (FFO) and code (I49) multifunction steering wheel. Parts ordering notes Part no. Designation Quantity Design group 82 (see smart radio navigator EPC) Design group 82 (see CD-ROM navigation system with code (C29) smart radio navigator EPC) or Design group 82 (see smart radio multimedia navigator EPC) Design group 82 (see DVD-ROM navigation system with code (C26) smart radio multimedia navigator EPC) In combination with Design group 82 (see Antenna line wiring harness EPC) Design group 82 (see GPS amplifier (GPS antenna) EPC) Depending on vehicle equipment Design group 82 (see Adapter line EPC) Design group 54 (see Central gateway control unit (CGW [ZGW]) EPC) Design group 54 (see Instrument cluster with code (C18) Onboard computer (FFO) EPC) Design group 54 (see Sensor for steering wheel functions (clock spring contact) with code (I49) Multifunction steering wheel EPC) Page 4 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.85-p-2003fh, Install navigation unit MODEL 454.0 except CODE (C26) smart radio multimedia navigator with CODE (V33) ESP Retrofitting smart radio navigator or smart radio multimedia navigator with hands-free system ...

Removal

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3615 · Applies to: 453 · AR: AR68.10-P-1190FF, AR82.60-P-7502FG, AR82.60-P-7502FF, AR46.10-P-0100FF, AR46.10-P-0200FF (+5 more)

Notes on avoiding damage to electronic AH54.00-P-0001-01A

components due to electrostatic discharge 1.1 Remove cover on center part of instrument On vehicles without code (C25) smart radio panel six or without code (C28) smart radio five Remove/install cover on instrument panel AR68.10-P-1190FF

center section 1.2 Remove radio On vehicles with code (C28) smart radio five or with code (C25) smart radio six Remove/install radio For vehicles with code (C28) smart radio five AR82.60-P-7502FG

On vehicles with code (C25) smart radio six AR82.60-P-7502FF 2 Remove steering wheel On vehicles without code (I49) Multifunction steering wheel Remove/install steering wheel AR46.10-P-0100FF

3 Remove spiral contact coil (A45) On vehicles without code (I49) Multifunction steering wheel Remove/install clock spring contact AR46.10-P-0200FF

4 Remove instrument cluster (A1) On vehicles without code (C18) Onboard computer (FFO) Remove/install instrument cluster AR54.30-P-6015FF

5 Remove right front seat Remove/install front seat AR91.10-P-1000FF

6 Remove footwell trim from right A-pillar Remove/install paneling in footwell AR68.30-P-4010FF

7 Remove right-hand side entrance strip Remove/install door sill molding AR68.30-P-4100FF

8 Remove control unit bracket Remove/install control unit bracket AR54.21-P-0001-01FF

9 Remove antenna cable Remove/install antenna cable On vehicles without code (C20) smart CD AR82.62-P-1200FF

changer and without code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) On vehicles with code (C20) smart CD AR82.62-P-1200FG changer and with code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) On vehicles with code (C20) smart CD AR82.62-P-1200FH changer On vehicles with code (C27) Telephone AR82.62-P-1200FI preparation incl. fastener and antenna (DFO/ FFO) 10 Remove radio antenna On vehicles without code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) or without code (C30) Hands-free system Remove/install antenna AR82.70-P-8951FF

Install

11 Retrofit radio/telephone antenna (A2/21) On vehicles without code (C27) Telephone AZ82.85-P-0001-14FF preparation incl. fastener and antenna (DFO/ FFO) or without code (C30) Hands-free system 12 Retrofit new antenna wiring harness (3) AZ82.70-P-0002-01FG Cover plugs and connectors on fiber optic cable before installing new antenna wiring harness (3) with protective covers. Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 13 Retrofit adapter wiring harness (2) for smart On vehicles without code (C25) smart radio AZ82.60-P-0003-01FF radio navigator (A2/56) or smart radio six with code (C20) smart CD changer or with multimedia navigator (A40/3) code (C27) Telephone preparation incl. fastener and antenna (DFO/FFO) or with code (C30) Hands-free system 14 Install control unit bracket Remove/install control unit bracket AR54.21-P-0001-01FF

15 Retrofit and connect GPS antenna (A2/23) AZ82.61-P-0003-02FF 16 Install headliner On vehicles with code (E55) Glass roof with sun protection (FFO) Page 2 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.85-p-2003fi, Install navigation unit MODEL 454.0 except CODE (C26) smart radio multimedia navigator with CODE (V33) ESP Retrofitting smart radio navigator or smart radio multimedia navigator with CD changer and ...

Fix headliner in place with the left grab

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3616 · Applies to: 453 · AR: AR68.30-P-4300FF, AR68.30-P-4700FF, AR68.30-P-4330FF, AR68.60-P-5480FF, AR68.30-P-4050FF (+5 more)

handles and the rear interior lamp only. Install edge guards in area of headliner on left front and rear door cutout. Remove/install headliner AR68.30-P-4300FF

17 Position headliner and install edge guards in area of headliner on right front and rear door cutout 18 Install edge guard of headliner in area of On vehicles with code (V29) electric glass electric glass sliding roof sliding roof (FFO) 19 Install paneling on right B-pillar Remove/install paneling on B-pillar AR68.30-P-4700FF

20 Install grab handles on right of roof Remove/install handle on roof AR68.30-P-4330FF

21 Install sun visors Remove/install sun visor AR68.60-P-5480FF

22 Install paneling on right A-pillar Remove/install paneling on A-pillar AR68.30-P-4050FF

23 Retrofit hands-free system microphone group On vehicles without code (C27) Telephone AZ82.70-P-0005-08FF (B25) preparation incl. fastener and antenna (DFO/ FFO) or without code (C30) Hands-free system 24.1 Retrofit frame (8) and overhead control panel On vehicles without code (C27) Telephone AZ82.20-P-0100FF (7) for hands-free system preparation incl. fastener and antenna (DFO/ FFO) or without code (C30) Hands-free system or without code (V29) Electric glass sliding roof (FFO) 24.2 Install front overhead control panel (7) On vehicles with code (C27) Telephone preparation incl. fastener and antenna (DFO/ FFO) or with code (C30) Hands-free system or with code (V29) Electric glass sliding roof (FFO) Remove/install front overhead control panel AR82.20-P-1100FF

25 Retrofit central gateway control unit (N93) On vehicles without code (C25) smart radio AZ54.21-P-0001FF six or without code (C28) smart radio five 26 Retrofit UPCI [UHI] portable CTEL holder On vehicles without code (C30) Hands-free AZ82.70-P-0005-02FG (A34/15) with hands-free system wiring system harness (1) 27 Install glove compartment Remove/install glove compartment AR68.10-P-1400FF

28 Remove protective covers from fiber optic cable of new antenna wiring harness (3) Notes on avoiding damage to fiber optic AH82.60-P-0001-05AK cables during repair work 29 Connect combination plug (9) to smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) 30 Connect radio antenna plugs (10) and GPS antenna plug (11) to smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) 31 Insert smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) into radio recess and tighten with the bolts (12) 32 Install upper control panel control module Remove/install upper control panel control AR54.21-P-1262FF

unit 33.1 Install telephone console (6) On vehicles with code (C10) Telephone console (DFO) Remove and install bracket for portable CTEL AR82.70-P-8918FG

33.2 Retrofit telephone console (6) On vehicles without code (C10) Telephone AZ82.70-P-0010FF console (DFO) 34 Install new clock spring contact (A45) For modification to code (I49) Multifunction steering wheel Remove/install clock spring contact AR46.10-P-0200FF

35 Install multifunction steering wheel (4) For modification to code (I49) Multifunction steering wheel When retrofitting a multifunction steering wheel (4), the airbag unit must also be exchanged. Remove/install steering wheel AR46.10-P-0100FF

36 Install new instrument cluster (A1) with For modification to code (C18) Onboard onboard computer computer (FFO) Page 3 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.85-p-2003fi, Install navigation unit MODEL 454.0 except CODE (C26) smart radio multimedia navigator with CODE (V33) ESP Retrofitting smart radio navigator or smart radio multimedia navigator with CD changer and ...

AP83.00-P-8384S

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3669 · Applies to: 453 · AR: AR68.30-P-1340SR

Replace combination filter 15.07.2014 MODEL 453 1 Passenger-side footrest 2 Cover 3 Activated charcoal dust filter P83.00-2402-06 Remove

1 Remove passenger-side footrest (1) AR68.30-P-1340SR

2 Unlock retainer (arrow) on cover (2) and remove cover (2) 3 Remove activated charcoal dust filter (3) from air conditioner housing Clean

4 Clean area surrounding air conditioner housing Install

5 Push new activated charcoal dust filter (3) Observe installation position of activated

into air conditioner housing charcoal dust filter (3). 6 Install cover (2) and lock retainer (arrow) on cover (2) 7 Install passenger-side footrest (1) AR68.30-P-1340SR

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap83.00-p-8384s, Replace combination filter MODEL 453

Collect escaping coolant in a suitable

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3684 · Applies to: 453 · AR: AR88.00-P-2792FF, AR20.00-P-1142FF, AR20.00-P-1142FG, AR68.10-P-1400FF

container. 12 Remove the sealing rings from the coolant pipes (16, 17) 13 Take off clamp (14) 14 Remove the coolant pipe (15) from the heat Collect escaping coolant in a suitable exchanger (18) container. 15 Remove the sealing ring from the coolant pipe (15) Install

16 Insert the coolant pipe (15) with sealing ring Replace sealing ring. and secure it with a clamp (14) to the heat Make sure that the clamp (14) is properly exchanger seated on the heat exchanger (18). 17 Insert the coolant pipes (16, 17) with sealing Replace sealing rings. rings into the heat exchanger (18) and secure Make sure that the clamps (12, 13) are them with clamps (12, 13) to the heat properly seated on the heat exchanger (18) exchanger (16) and the coolant pipe (15) and the coolant pipe (15). 18 Position the cover (11) and fasten it in place with the screw (10) 19 Install the bracket (6) and fasten it in place Make sure that the bracket (6) is properly with the screw (5) seated. 20 Install the accelerator pedal (4) and fasten it Replace self-locking nuts (2). with the nuts (2) *BA29.10-P-1004-02E

21 Remove the clamp pliers from the coolant hoses (1) 22 Install covering on center section in front of AR88.00-P-2792FF windshield 23 Fill in coolant and check the cooling system See: for leaks in the area of the coolant pipes (15, 16, 17) Drain coolant, pour in Engines 134.910, 135.930/950 AR20.00-P-1142FF Engine 639.939 AR20.00-P-1142FG 24 Install the trim panel (9) and reposition the floor covering (8) in the vehicle 25 Install glove compartment (7) AR68.10-P-1400FF Pedals, bearing bracket

Number Designation Model 454.0 BA29.10-P-1004-02E Nut, accelerator pedal to splash wall Nm 7 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar83.20-p-1300ff, Remove/install coolant pipe sealing rings for the heat exchanger MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle

Remove accelerator pedal sensor (B37) and

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3686 · Applies to: 453 · AR: AR68.10-P-1400FF, AR88.00-P-2792FF, AR20.00-P-1142FF, AR20.00-P-1142FG

5 Remove accelerator pedal sensor (B37) and place aside with plug (3) still connected 6 Remove bolt (5) and remove bracket (6) 7 Remover glove compartment (7) AR68.10-P-1400FF 8 Fold back floor covering (8) and remove panel (9) 9 Remove bolt (10) and place cover (11) aside 10 Remove clamps (12, 13) 11 Pull coolant pipe (14) out of the heating Carefully press coolant pipes (14, 15) to system heat exchanger (16) and coolant pipe the rear to avoid damaging the coolant pipes (15) out of the coolant pipe (18) and press (14, 15). toward the rear Collect the escaping coolant in a suitable container. 12 Remove sealing rings on the coolant pipes (14, 15) 13 Pull heating system heat exchanger (16) out of the heater/A/C housing 14.1 Remove coolant pipe (18) with sealing ring When installing a new heating system heat and clamp (17) from the heating system heat exchanger (16). exchanger (16) Install

15.1 Insert coolant pipe (18) with new sealing ring When installing a new heating system heat into the heating system heat exchanger (16) exchanger (16). and secure using clamp (17) Install a new clamp (17) for the coolant pipe (18). 16 Insert heating system heat exchanger (16) Carefully press coolant pipes (14, 15) to into the heater/A/C housing the rear to avoid damaging the coolant pipes (14, 15). 17 Insert coolant pipe (14) with new sealing ring Install a new clamp (12) for the coolant into the heating system heat exchanger (16) pipe (14). and secure using clamp (12) 18 Insert coolant pipe (15) with new sealing ring Install a new clamp (13) for the coolant into the coolant pipe (18) and secure using pipe (15). clamp (13) 19 Position cover (11) and screw in bolt (10) 20 Position bracket (6) and screw in bolt (5) Ensure bracket (6) is seated correctly. 21 Position accelerator pedal sensor (B37) and Replace self-locking nuts (2). screw on nuts (2) *BA29.10-P-1004-02E

22 Remove pliers from the coolant hoses (1) 23 Install covering on center section in front of AR88.00-P-2792FF windshield 24 Top up coolant and check cooling system for See: leaks in the vicinity of the coolant pipes (14, 15, 18) Drain/fill with coolant Engines 122.9, 134.9, 135.9 AR20.00-P-1142FF Engine 639.9 AR20.00-P-1142FG 25 Install panel (9) and position floor covering (8) in the vehicle 26 Install glove compartment (7) AR68.10-P-1400FF Pedals, bearing bracket

Number Designation Model 454.0 BA29.10-P-1004-02E Nut, accelerator pedal to splash wall Nm 7 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar83.20-p-1100ff, Remove/install heat exchanger MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle

Position the cover (7) and fasten it in place

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3688 · Applies to: 453 · AR: AR88.00-P-2792FF, AR20.00-P-1142FF, AR20.00-P-1142FG, AR68.10-P-1400FF

14 Position the cover (7) and fasten it in place with the screw (6) 15 Install bracket (5) Make sure that the bracket (5) is properly seated. 16 Remove the clamp pliers from the coolant hoses (1) 17 Install covering on center section in front of AR88.00-P-2792FF windshield 18 Fill in coolant and check the cooling system See: for leaks in the area of the coolant pipes (9) Drain coolant, pour in Engine 134.910/135.930/950 AR20.00-P-1142FF Engine 639.939 AR20.00-P-1142FG 19 Install the trim panel (4) and reposition the floor covering (3) in the vehicle 20 Install glove compartment (2) AR68.10-P-1400FF Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar83.20-p-1100fg, Remove/install heat exchanger MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle

P83.20-2276-08

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3692 · Applies to: 453 · AR: AR68.10-P-1400FF, AR68.10-P-1520FF

Shown on vehicle with Code (LHD) Left- hand drive vehicle 7 Control cable 9 Cover 11 Retaining clamp 8 Bolt 10 Expansion clip 12 Lever 13 Eye Remove/install

1 Set air distribution switch of operating unit (1) to top position and heater valve switch of the operating unit (1) to the left stop 2.1 Remove glove compartment On vehicles with code (LHD) Left-hand drive AR68.10-P-1400FF vehicle 2.2 Remove cover below right instrument panel On vehicles with code (RHD) right-hand drive AR68.10-P-1520FF vehicle 3 Unscrew bolts (3) at left and right on operating unit (1) 4 Unclip catch hook (2, 4) on operating unit (1) and route operating unit (1) carefully downwards until the Bowden cable (7) is accessible 5 Unclip retaining clamp (6) of Bowden cable (7) on the operating unit (1) and unhook eyelet (5) of Bowden cable (7) on the relay lever of the operating unit (1) 6.1 Fold over floor covering until the spreader clip On vehicles with code (LHD) Left-hand drive (10) of the cover (9) is accessible vehicle 7.1 Remove bolts (8) On vehicles with code (LHD) Left-hand drive vehicle 8.1 Remove expansion clip (10). On vehicles with code (LHD) Left-hand drive vehicle 9.1 Take off cover (9) On vehicles with code (LHD) Left-hand drive vehicle Observe installation position for cover (9). 10 Unhook Bowden cable (7) from retaining clamp (11) 11 Release catch hook of lever (12) and unhook Do not damage catch hook, as otherwise eyelet (13) of Bowden cable (7) the Bowden cable (7) can then no longer be locked. 12 Pull Bowden cable (7) out of instrument panel and remove 13 Install in the reverse order 14 Perform functional check on operating unit (1) Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar83.20-p-1400ff, Remove/install heater control cable MODEL 454.0 with CODE (I01) Air conditioning Plus

Install covering on center section in front of

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3699 · Applies to: 453 · AR: AR88.00-P-2792FF, AR20.00-P-1142FF, AR20.00-P-1142FG, AR68.10-P-1400FF

15 Install covering on center section in front of AR88.00-P-2792FF windshield 16 Fill up coolant and check cooling system for See: leaks in the vicinity of the coolant pipes (9) Drain/fill with coolant Engines 122.9, 134.9, 135.9 AR20.00-P-1142FF Engine 639.9 AR20.00-P-1142FG 17 Install panel (4) and position floor covering (3) in the vehicle 18 Install glove compartment (2) AR68.10-P-1400FF Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar83.20-p-1300fg, Removing/installing sealing rings for coolant pipes of heating system heat exchanger MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle

Control cable

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3703 · Applies to: 453 · AR: AR68.20-P-2350FG, AR68.10-P-1500FF, AR68.10-P-1400FF, AR83.10-P-1400FF

6 Control cable 8 Control cable 14 Electrical connectors N22 AAC [KLA] control and operating unit P83.20-2253-11 Remove/install

1 Set switch of AAC [KLA] control and operating This sets the levers (5, 9) for the air flaps unit (N22) to uppermost position to the rear stop. 2 Remove cover (2) on the front center console AR68.20-P-2350FG 3.1 Remove cover (1) below instrument panel on On vehicles with code (LHD) Left-hand drive AR68.10-P-1500FF left vehicle 3.2 Remove glove compartment On vehicles with code (RHD) right-hand drive AR68.10-P-1400FF vehicle 4 Unhook Bowden cable (6) from retaining Installation:

Push lever (5) back to rear clamp (10) stop and lock Bowden cable (6) into the retaining clamp (10). 5 Unhook Bowden cable (8) from retaining Installation:

Push lever (9) back to rear clamp (7) stop and lock Bowden cable (8) into the retaining clamp (7). 6 Release locking catch (4) of levers (5, 9) and Do not damage locking catch (4), as unhook Bowden cables (6, 8) otherwise it may not be possible to lock the Bowden cables (6, 8) anymore. 7 Undo screws (12) at right and left on the AAC [KLA] control and operating unit (N22) 8 Unclip catch hook (11, 13) on the AAC [KLA] control and operating unit (N22) and move AAC [KLA] control and operating unit (N22) slightly forward 9 Tilt AAC [KLA] control and operating unit (N22) onto left side and route downwards 10 Route AAC [KLA] control and operating unit (N22) on its left side slightly to the rear and on the right side slightly forward 11 Carefully remove the AAC [KLA] control and operating unit (N22), downwards, by the left side first, until the electrical connectors (14) are accessible 12 Separate electrical connectors (14) Observe safety and securing clips for electrical connectors (14). 13 Remove AC operating and control unit (N22) Observe installation position of Bowden cable (6, 8). 14.1 Remove air distribution cable When replacing the AAC [KLA] control and AR83.10-P-1400FF operating unit (N22). 15 Install in the reverse order 16 Perform function check on AAC [KLA] control and operating unit (N22) Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar83.25-p-1124ff, Remove and install air conditioning pushbutton control unit MODEL 454.0 with CODE (I01) Air conditioning Plus

Model 454

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3724 · Applies to: 453 · AR: AR61.30-P-1001SM, AR83.30-P-8085RR, AR83.30-P-8085FF, AP83.00-P-8384RR, AP83.00-P-8384FF

2 Spray probe 3 Control lever P83.30-4658-06 Removing

Risk of explosion caused by welding or Never perform welding work on or near a AS83.00-Z-0001-01A Danger!

soldering work on closed air conditioning closed air conditioning system. No smoking or system. Risk of poisoning caused by open flames. Wear safety glasses and inhaling overheated refrigerant vapors. Risk protective gloves. Work only in well ventilated of injury to skin and eyes caused by contact areas. Carry out repair work on the air with liquid refrigerant. conditioning system circuit only after the system has been discharged. Procedure for a damaged or leaky air AH83.30-N-0004-01A conditioning system 1 Open engine hood and remove luggage Model 452.3/4 compartment tray (4) 2 Remove front underfloor paneling Model 450.3/4 AR61.30-P-1001SM 3 Close air recirculation flap 4 Switch off ignition, blower and air conditioning 5 Remove evaporator temperature sensor Model 452.3/4 AR83.30-P-8085RR Type 454.0 AR83.30-P-8085FF 6 Remove combination filter Model 452.3/4 AP83.00-P-8384RR Model 454.0 with code (I01) Air conditioning AP83.00-P-8384FF Plus 7.1 Expose condensation drain (5) and place Model 452.3/4 suitable collecting pan underneath 7.2 Place suitable collecting pan under vehicle in Model 450.3/4 and 454.0 area of condensation drain (5) 8 Fill disinfection cleaner into disinfection On model 452.3/4 and model 450.3/4, use cleaning equipment with connected spray short spray probe (2). probe (2) On model 454.0, use long spray probe (2). 9 Connect disinfection cleaning equipment to compressed air hose and adjust pressure up to 10 bar Cleaning the evaporator

10.1 Insert spray probe (2) through opening of Model 452.3/4 and 454.0 evaporator temperature sensor into evaporator housing 10.2 Insert spray probe (2) through opening into air Model 450.3/4 recirculation unit (1) 11 Cover opening of combination filter slot Model 452.3/4 and 454.0 No disinfection cleaner must enter the interior. 12 Place thumb on plate on spray probe (2) This sets the spray direction of the spray probe (2). On models 452.3/4 and 454.0, when spraying through the evaporator temperature sensor opening, the plate on the spray probe (2) must point towards the vehicle interior. Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar83.30-p-5555sm, Cleaning the evaporator MODEL 450.3 /4 with CODE (I01) Air conditioning Plus with CODE (I29) Air conditioning Plus (with combination filter and outside temperature indicator), smart & passion MODEL 452.3 /4 with ...

Model 453.3/4 with engine 281, 780

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3765 · Applies to: 453 · AR: AR88.20-P-2000SRA, AR62.10-P-1020SR, AR83.30-P-6521SR

AR88.20-P-2000SRA with code I01 (Air conditioning Plus) Model 453.3/4 with engine 281, 780 with code I77 (Air conditioning, manual) 3 Remove the CMS Front AR62.10-P-1020SR 4 Unclip air duct segment (1) and take off 5 Remove bolts (6) BA83.30-P-1015-01G Bolt/nut, low-pressure line to condenser BA83.30-P-1003-01G Bolt, high-pressure line to condenser 6 Remove refrigerant lines (2) and close off with Installation: Install new seals.

stop plugs *129589009100 Record plug 7 Detach condenser (4) from the catches (3) and remove from retaining clamps (5) in direction of arrow (A) 8 Remove desiccant cartridge AR83.30-P-6521SR Installation: The desiccant cartridge must

be replaced after every opening of the refrigerant circuit. 9 Install in the reverse order Air conditioning Number Designation Model 453 BA83.30-P-1003-01G Bolt, high-pressure line to condenser Nm 8 Air conditioning Number Designation Model 453 BA83.30-P-1015-01G Bolt/nut, low-pressure line to condenser Nm 8 129 589 00 91 00 Record plug Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar83.30-p-6540sr, Remove/install condenser Model 453 with engine 281, 780 with code I01 (Air conditioning Plus) Model 453 with engine 281, 780 with code I77 (Air conditioning, manual)

AZ83.70-P-0030FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3835 · Applies to: 453 · AR: AZ83.70-P-0030FF, AR68.10-P-1500FF, AR68.30-P-4010FF

Retrofit auxiliary heater timer 15.11.11 MODEL 454.0## 1# with ENGINE 639.9 with CODE (I58) Stationary heater, diesel with CODE (LHD) Left-hand drive vehicle MODEL 454.0## 1# with ENGINE 134.9, 135.9 with CODE (I60) Stationary heater, gasoline with CODE (LHD) Left-hand drive vehicle P83.70-4920-09 1 Instrument panel 4 Bore 7 Digital timer 2 Template 5 Wiring harness 8 Cover 3 Bore 6 Receiver 9 Self-adhesive felt P83.70-4934-07 6 Receiver 10 Wiring harness 11 Connector Before attaching the digital timer (7),

coordinate the installation location with the customer first. Remove

1 Remove left cover under the dashboard Remove/install cover below instrument panel AR68.10-P-1500FF

(left) 2 Remove paneling in left footwell Remove/install paneling in footwell AR68.30-P-4010FF

Install

3 Attach template (2) to desired position on The template (2) is included in the digital dashboard (1). timer's package contents (7). 4 Drill bore (3) dia. 10 mm and bore (4) dia. 2.5 When drilling, make sure that the mm to match the template (2). concealed components are not damaged. *450589017000

Wet/dry vacuum cleaner gotis://P_00.12_06.0 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az83.70-p-0030ff, Retrofit auxiliary heater timer MODEL 454.0## 1# with ENGINE 639.9 with CODE (I58) Stationary heater, diesel with CODE (LHD) Left-hand drive vehicle MODEL 454.0## 1# with ENGINE 134.9, 135.9 with CODE (I60) ...

Cordless drill/driver, cordless drill

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3836 · Applies to: 453 · AR: AR68.10-P-1500FF, AR68.30-P-4010FF, AR83.70-P-0017FF

gotis://G_58.0_01.1 5 Remove template (2) from the dashboard (1). 6 Trace wiring harness (10) from receiver (6) back to the plug (11) and expose 7 Connect wiring harness (5) of digital timer (7) Route wiring harness (5) and fasten such to plug (11), route upwards through bore dia. that chafing will not cause any noise or 10 mm (3) into the dashboard (1) and fasten damage. using cable ties to suitable points 8 Stick the self-adhesive felt (9) included in the package contents to the rear of the digital timer (7). 9 Connect 4-pin connector of wiring harness (5) to digital timer (7) 10 Position digital timer (7) onto dashboard (1) and screw together through the hole (arrow) using the bolt included in the package contents. 11 Clip cover (8) onto digital timer (7). When clipping cover (8) in, do not press on the display of the digital timer (7) as otherwise it will be destroyed. 12 Route wiring harnesses (5, 10) into receiver Route wiring harnesses (5, 10) and fasten (6) area and fasten to suitable points using such that chafing will not cause any noise or cable ties damage. 13 Install left-hand cover under the dashboard Remove/install cover below instrument panel AR68.10-P-1500FF

(left) 14 Install paneling in left footwell Remove/install paneling in footwell AR68.30-P-4010FF

15 Perform test run of stationary heater; in the Stationary heater diagnostic tool: event of malfunction connect stationary heater Order number: Q002 1664 V000 000000 diagnostic tool and troubleshoot. Finally, delete the fault memory Connect diagnostic tool to auxiliary heater AR83.70-P-0017FF

(water heater) 450 589 01 70 00 Twist drill bit set Parts ordering notes Part no. Designation Quantity DG 99 (see EPC) Stationary heater time switch 1 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az83.70-p-0030ff, Retrofit auxiliary heater timer MODEL 454.0## 1# with ENGINE 639.9 with CODE (I58) Stationary heater, diesel with CODE (LHD) Left-hand drive vehicle MODEL 454.0## 1# with ENGINE 134.9, 135.9 with CODE (I60) ...

AZ83.70-P-0009FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3837 · Applies to: 453 · AR: AZ83.70-P-0009FF, AR68.10-P-1500FF, AR68.30-P-4010FF, AR68.30-P-4050FF, AR83.70-P-0017FF

Retrofitting Telestart receiver 16.2.06 MODEL 454.0## 1# with ENGINE 639.9 with CODE (I58) stationary heater, diesel with CODE (LHD) Left-hand drive vehicle MODEL 454.0## 1# with ENGINE 134.9, 135.9 with CODE (I60) stationary heater, gasoline with CODE (LHD) Left-hand drive vehicle 16 Receiver P83.70-4959-04 Remove/install

1 Remove cover below instrument panel Remove/install cover below instrument panel AR68.10-P-1500FF

(left) 2 Remove paneling in left footwell Remove/install paneling in footwell AR68.30-P-4010FF

3 Remove paneling from left A-pillar Remove/install paneling on A-pillar AR68.30-P-4050FF

4 Retrofit Telestart receiver and Telestart AZ83.70-P-0020-03FG antenna *452589029900

5 Install in the reverse order Operation steps 3, 2, 1, 6 Perform new teach-in for all new telestart handheld transmitters Teach-in Telestart transmitter AR83.70-P-0003-03FF

7 Perform test run of stationary heater; in the Stationary heater diagnostic tool: event of malfunction connect stationary heater Order number: Q002 1664 V000 000000 diagnostic tool and troubleshoot. Finally, delete the fault memory Connect diagnostic tool to auxiliary heater AR83.70-P-0017FF

(water heater) 452 589 02 99 00 Wiring harness repair kit Parts ordering notes Part no. Designation Quantity Design group 99 (see Stationary heater remote control 1 EPC) Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, az83.70-p-0009ff, Retrofitting Telestart receiver MODEL 454.0## 1# with ENGINE 639.9 with CODE (I58) stationary heater, diesel with CODE (LHD) Left-hand drive vehicle MODEL 454.0## 1# with ENGINE 134.9, 135.9 with CODE (I60) ...

AR88.00-P-1014FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3853 · Applies to: 453 · AR: AR88.00-P-1014FF

Remove/install company sign 29.7.05 MODEL 454.0 Front company sign 1 Company sign 2 CBS front center section Dimensions a 390 mm b 25 mm P88.00-2304-06 Remove

1 Carefully loosen company sign (1) from CBS Carefully loosen company sign (1) to front center section (2) with snap-release tool prevent scratching the CBS front center and remove section (2). *452589016300

Install

2 Clean CBS front center section (2) in area of The CBS front center section (2) must be company sign (1) free of dust and grease in the area of the company sign (1). 3 Determine position of company sign (1) according to dimensions (a, b) and mark with suitable adhesive tape. 4 Remove rear protective foil from company Ensure that individual parts of company sign (1) sign (1) are not loosened from front carrier foil 4 Align company sign (1) according to markings on adhesive tape and press on to CBS front center section (2) 5 Press on company sign (1) and remove front carrier foil 6 Remove adhesive 452 589 01 63 00 Snap-release tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.00-p-1014ff, Remove/install company sign MODEL 454.0 Front company sign

AR88.00-P-1014FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3854 · Applies to: 453 · AR: AR88.00-P-1014FG

Remove/install company sign 29.7.05 MODEL 454.0 Rear company sign 1 Rear window 2 Company sign 3 Handle strip 4 Adhesive tape Dimensions a 627.5 mm b 38 mm P88.00-2303-06 Remove

1 Carefully loosen company sign (2) from rear Carefully loosen company sign (2) to window (1) and remove prevent scratching rear window (1). *452589016300

Install

2 Clean rear window (1) in area of company The rear window (1) must be free of dust sign (2) and grease in area of company sign (2). 3 Determine vertical position of company sign Measure dimension (b) on bottom of (1) according to dimension (b) and mark with handle strip (3) suitable adhesive tape (4). 4 Determine horizontal position of company sign (2) according to dimension (a) and mark with suitable adhesive tape (4). 5 Remove rear protective foil from company Ensure that individual parts of company sign (2) sign (2) are not loosened from front carrier foil 6 Align company sign (2) in relation to adhesive tape (4) and bottom right point of letter "n" in relation to marking of adhesive tape (4) and press onto rear window (1). 7 Press on company sign (2) and remove front carrier foil 8 Remove adhesive tape (4). 452 589 01 63 00 Snap-release tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.00-p-1014fg, Remove/install company sign MODEL 454.0 Rear company sign

AR88.00-P-1200SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3855 · Applies to: 453 · AR: AR88.00-P-1200SRA, AR88.20-P-2000SRA, AR88.10-P-1000SRA, AR72.18-P-1000SRA, AR88.70-P-9040SR (+3 more)

Remove/install fresh up 15.09.2016 Model 453.3/4 P88.00-2569-08 Shown on model 453.30 1 Maintenance flap 5 Left outside mirror paneling 9 Fuel filler flap (model 453.34/35/36/44/45/46) 2 Front bumper 6 Rear bumper 10 Right door paneling 3 Left fender 7 Outside trim of liftgate 11 Right fender 4 Left door paneling 8 Rear spoiler 12 Right outside mirror paneling Remove/install

1 Remove maintenance flap (1) Installation: All detachable parts not

present on the replacement part must be transferred. 2 Remove front bumper (2) AR88.20-P-2000SRA Installation: All detachable parts not

present on the replacement part must be transferred. 3 Remove left fender (3) and right fender (11) AR88.10-P-1000SRA Installation: All detachable parts not

present on the replacement part must be transferred. 4 Remove left door paneling (4) and right door AR72.18-P-1000SRA paneling (10) Installation: All detachable parts not

present on the replacement part must be transferred. 5 Remove left outside mirror (5) and right AR88.70-P-9040SR outside mirror paneling (12) Installation: All detachable parts not

present on the replacement part must be transferred. 6 Remove rear bumper (6) AR88.20-P-2200SRA Installation: All detachable parts not

present on the replacement part must be transferred. 7 Remove outer paneling from liftgate (7) AR72.20-P-1016SRA Installation: All detachable parts not

present on the replacement part must be transferred. 8 Remove rear spoiler (8) Model 453.3 AR72.20-P-4000SRA Installation: All detachable parts not

present on the replacement part must be transferred. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.00-p-1200sra, Remove/install fresh up Model 453.3/4

Remove fuel filler flap (9)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3856 · Applies to: 453 · AR: AR88.60-P-2000SR

9 Remove fuel filler flap (9) Model 453.34/35/36/44/45/46 AR88.60-P-2000SR Installation: All detachable parts not

present on the replacement part must be transferred. 10 Remove cover for power outlet socket Model 453.391/491 11 Install in the reverse order Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.00-p-1200sra, Remove/install fresh up Model 453.3/4

AR88.00-P-1010FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3857 · Applies to: 453 · AR: AR88.00-P-1010FF

Remove/install front CBS 8.1.07 MODEL 454.0 P88.00-2295-08 Shown on vehicle with code (22Y) Headlamp cleaning system 1 CBS front end 4 Retaining clamps (with code (22Y) E6/1 Left turn signal lamp 2 Bolt Headlamp cleaning system) E6/2 Right turn signal lamp 3 Hose (with code (22Y) Headlamp 5 Expansion clip cleaning system) P88.00-2259-08 1 CBS front end 6 Engine hood seal 8 Guide 7 Bolts P88.00-2260-08 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.00-p-1010ff, Remove/install front CBS MODEL 454.0

Guide

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3858 · Applies to: 453 · AR: AR88.80-P-1050FF, AR61.20-P-1105FF

8 Guide 9 Guide On model 454.034 or on vehicles with code (E58) Front spoiler, Brabus (DFO) 10 BRABUS front spoiler 11 Counterholder 12 Bolt P88.30-2369-03 Remove/install

1.1 Remove left and right side sill protective Except model 454.034 or on vehicles without AR88.80-P-1050FF molding code (E71) side skirts, BRABUS 1.2 Loosen left and right side skirts, BRABUS in On model 454.034 or on vehicles with code AR88.80-P-1050-01FB front area until bolts (2) are accessible (E71) side skirts, BRABUS 2 Remove lower engine compartment paneling AR61.20-P-1105FF 3 Remove bolts (2) 4 Remove expansion clip (5) in front area of Installation: Replace damaged

fender liner. expansion clips (5). 5 Unscrew bolt (12) on left and right from front On model 454.034 or on vehicles with code spoiler BRABUS (10) and remove (E58) Front spoiler Brabus (DFO) counterholder (11). 6 Lower vehicle 7 Unclip CBS front (1) on left and right side in Carefully unclip CBS front end (1) to marked areas (arrows) with clip remover prevent damage by breakage or scratching. *452589016300

8 Open engine hood 9 Unscrew bolts (7) in area of engine hood seal The bolts (7) are shown with engine hood (6) seal (6) removed for better illustration. 10 Unlock retaining clip (4) from hose (3) On vehicles with code (22Y) Headlamp cleaning system 11 Pull off hose (3) and close opening on washer On vehicles with code (22Y) Headlamp fluid reservoir with suitable stop plug. cleaning system Collect escaping window washer fluid in suitable container. 12 Loosen CBS front end (1) and guide forward Treat CBS front (1) carefully to prevent with aid of helper until electrical connector on damaging paint left turn signal lamp (E6/1) and right turn signal lamp (E6/2) is accessible. Lift CBS front end (1) over guides (8) and lightly pull toward outside in areas of rocker panels. Installation: Ensure that CBS front end

(1) is seated correctly in guides (8, 9). 13 Disconnect electrical connector from left turn signal lamp (E6/1) and right turn signal lamp (E6/2) 14 Disconnect electrical connector from left front On vehicles with code (V07) front fog lamps fog lamp and right front fog lamp (FFO) The left front fog lamp is integrated into the left turn signal lamp (E6/1) and the right front fog lamp is integrated into the right turn signal lamp (E6/2) Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.00-p-1010ff, Remove/install front CBS MODEL 454.0

AR88.00-P-1100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3860 · Applies to: 453 · AR: AR88.00-P-1100FF, AR88.30-P-0505FF, AR88.00-P-1010FF, AR88.10-P-1000FF

Remove/install front center section 22.10.03 MODEL 454.0 1 Front fender 2 CBS front center section 3 Lower front grille P88.00-2261-04 Remove/install

1.1 Remove BRABUS front spoiler On model 454.034 or on vehicles with code AR88.30-P-0505FF (E58) BRABUS front spoiler (DFO) 2 Remove CBS front end AR88.00-P-1010FF 3 Remove left and right front fender (1) from AR88.10-P-1000FF CBS front center section (2) 4.1 Remove license plate When replacing CBS front center section (2). 5.1 Unclip lower front grille (3) from CBS front When replacing CBS front center section (2). center section (2) 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.00-p-1100ff, Remove/install front center section MODEL 454.0

AR88.00-P-2115FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3861 · Applies to: 453 · AR: AR88.00-P-2115FF, AR88.00-P-1010FF

Remove/install front grille 8.1.07 MODEL 454.0 P88.00-2300-09 1 CBS front end 3 Lower front grille (standard) 5 Lower front grille (BRABUS) 2 Upper front grille (standard) 4 Upper front grille (BRABUS) Shown on vehicle with code (Y22) Headlamp cleaning system 1 CBS front end 2 Upper front grille (standard) 3 Lower front grille (standard) 6 Hose bracket (with code (22Y) Headlamp cleaning system) 7 Hoses (with code (22Y) Headlamp cleaning system) P88.00-2299-06 Remove/install

1 Remove CBS front end (1) and lay down on AR88.00-P-1010FF suitable subsurface Upper front grille 2 Unclip upper front grille (2 or 4) from inside from CBS front end (1) (arrows A) 3 Disassemble upper front grille (4) On vehicles with upper front grille (4). The upper front grille (4) and the integrated carrier are connected with six retaining clamps. 4 Unclip carrier of upper front grille (2) from On vehicles with upper front grille (2). CBS front end (1), unhook and remove toward front Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.00-p-2115ff, Remove/install front grille MODEL 454.0

AR88.00-P-1011FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3863 · Applies to: 453 · AR: AR88.00-P-1011FF

Remove/install model badge 29.7.05 MODEL 454.0 forfour lettering P88.00-2302-09 1 Rear-end door 3 Adhesive tape Dimensions 2 Model badge 4 Adhesive tape a 40 mm b 13 mm Remove

1 Open rear-end door (1) and arrest at suitable working height with wire 2 Carefully loosen model badge (2) from rear- Carefully loosen model badge (2) to end door (1) with snap-release tool and prevent scratching rear-end door (1). remove *452589016300

Install

3 Clean rear-end door (1) in area of model The rear-end door (1) must be free of dust badge (2) and grease in the area of the model badge (2). 4 Determine vertical position of model badge (2) Measure dimension (b) on bottom of rear- according to dimension (b) and mark with end door (1) suitable adhesive tape (4). 5 Determine horizontal position of model badge Measure dimension (a) at cutting point (2) according to dimension (a) and mark with (arrow A) on rear-end door (1) and on suitable adhesive tape (4). adhesive tape (4). 6 Position adhesive tape (3) on marking on adhesive tape (4) and glue on upward vertically. 7 Remove rear protective foil from model badge Ensure that the individual parts of the (2) model badge (2) are not detached from the front carrier foil 8 Align model badge (2) in relation to adhesive tape (4) and bottom left point of letter "f" in relation to cutting edge (arrow B) or right edge of adhesive tape (3) and press onto rear-end door (1). 9 Press on model badge (2) and remove front carrier foil 10 Remove adhesive tapes (3, 4) 11 Remove arrest on rear-end door (1) and close rear-end door (1) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.00-p-1011ff, Remove/install model badge MODEL 454.0 forfour lettering

AR88.00-P-1011FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3865 · Applies to: 453 · AR: AR88.00-P-1011FG

Remove/install model badge 29.7.05 MODEL 454.0 Engine lettering P88.00-2301-09 1 Model badge 3 Adhesive tape Dimensions 2 Rear-end door 4 Adhesive tape a 40 mm b 13 mm Remove

1 Open rear-end door (2) and arrest at suitable working height with wire 2 Carefully loosen model badge (1) from rear- Carefully loosen model badge (1) to end door (2) with snap-release tool and prevent scratching rear-end door (2). remove *452589016300

Install

3 Clean rear-end door (2) in area of model The rear-end door (2) must be free of dust badge (1) and grease in the area of the model badge (1). 4 Determine vertical position of model badge (1) Measure dimension (b) on bottom of rear- according to dimension (b) and mark with end door (2) suitable adhesive tape (4). 5 Determine horizontal position of model badge Measure dimension (a) at cutting point (1) according to dimension (a) and mark with (arrow B) on tailgate (2) and adhesive tape. suitable adhesive tape (4). 6 Position adhesive tape (3) on marking of adhesive tape (4) and glue on upward vertically. 7 Remove rear protective foil from model badge Ensure that the individual parts of the (1) model badge (1) are not detached from the front carrier foil 8 Align model badge (1) in relation to adhesive tape (4) and rearmost model badge (1) in relation to cutting edge (arrow A) or to left edge of adhesive tape (3) and press onto rear-end door (2) 9 Press on model badge (1) and remove front carrier foil 10 Remove adhesive tapes (3, 4) 11 Remove arrest on rear-end door (2) and close rear-end door (2) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.00-p-1011fg, Remove/install model badge MODEL 454.0 Engine lettering

AR88.00-P-2792FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3867 · Applies to: 453 · AR: AR88.00-P-2792FF, AR82.30-P-6951FF, AP82.35-P-8252FF

Remove/install paneling on center section of windshield 13.8.03 MODEL 454.0 P88.00-2245-09 1 Paneling 3 Water hose 5 Bracket 2 Bolt 4 Left wiper arm Remove/install

1 Remove left wiper arm (4) AR82.30-P-6951FF 2 Open engine hood 3 Remove water hose (3) from distribution Remove only water hose (3) coming from element windshield washer reservoir from distribution element 4 Unscrew bolt (2) on left and right on paneling (1) 5 Cover left wiper arm shaft (4) Cover shaft to prevent damaging cover (1) during removal. 6 Pull paneling (1) toward rear and loosen from brackets (5) on left and right 7 Remove paneling (1) between windshield and Carefully loosen paneling (1) to prevent engine hood damaging paint. Helper required Check bracket (5), replace if necessary 8.1 Unclip spray nozzles of windshield washer Only when replacing paneling (1). system from paneling (1) and remove with wash fluid hose. 9 Install in the reverse order 10 Check spray nozzle of windshield washer system for proper function, adjust spray nozzles if necessary. Windshield wipers, windshield washer system AP82.35-P-8252FF

• Function check Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.00-p-2792ff, Remove/install paneling on center section of windshield MODEL 454.0

AR88.00-P-1300FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3868 · Applies to: 453 · AR: AR88.00-P-1300FF, AR88.30-P-0502FF, AR88.20-P-1900FF, AR88.10-P-1100FF

Remove/install rear center section 22.10.03 MODEL 454.0 1 Rear fender 2 Rear center section 3 Plastic nuts P88.00-2250-03 Remove/install

1.1 Remove BRABUS rear apron On model 454.034 or on vehicles with code AR88.30-P-0502FF (E78) smart BRABUS rear apron (DFO) 2 Remove CBS rear end AR88.20-P-1900FF 3 Remove rear fender (1) AR88.10-P-1100FF 4.1 Remove license plate When replacing rear center section (2). 5.1 Remove plastic nuts (3) from rear center When replacing rear center section (2). section (2) 6.1 Unclip cap from tow hook and remove When replacing rear center section (2). 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.00-p-1300ff, Remove/install rear center section MODEL 454.0

AN88.00-P-0004FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3869 · Applies to: 453 · AR: AN88.00-P-0004FF, AR88.00-P-1010FF

Retrofit BRABUS front grille 4.8.05 MODEL 454.0 (except 454.034) P88.00-2300-09 1 CBS front end 3 Lower front grille 5 BRABUS lower front grille 2 Upper front grille 4 BRABUS upper front grille Shown on vehicles with code (V43) Headlamp cleaning system (FFO) 1 CBS front end 2 Upper front grille 3 Lower front grille 6 Brackets (with code (V43) Headlamp cleaning system (FFO) 7 Hoses (with code (V43) Headlamp cleaning system (FFO) P88.00-2299-06 Remove

1 Remove CBS front end (1) and lay down on suitable subsurface Remove/install CBS front end AR88.00-P-1010FF

2.1 Unhook hoses (7) on headlamp cleaning On vehicles with code (V43) Headlamp system from brackets (6) of lower front grille cleaning system (FFO) (3). 3 Unclip lower front grille (3) from CBS front end (1) (arrows B) and remove toward rear. 4 Unclip upper front grille (2) from CBS front end (1) (arrows A) and remove toward front Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, an88.00-p-0004ff, Retrofit BRABUS front grille MODEL 454.0 (except 454.034)

Unclip carrier of upper front grille (2) from

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3870 · Applies to: 453 · AR: AR88.00-P-1010FF

5 Unclip carrier of upper front grille (2) from CBS front end (1), unhook and remove toward front Install

6 Assemble two-piece upper front grille Retaining clamps are included in scope of BRABUS (4) and fasten with retaining clamps. delivery. 7 Clip upper front grille BRABUS (4) from front into CBS front end (1). 8 Clip lower front grille BRABUS (5) from rear into CBS front end (1). 9.1 Fasten hoses (7) on headlamp cleaning Only on vehicles with code (V43) Headlamp system in brackets (6). cleaning system (FFO) Fasten brackets (6) in center area directly to CBS front end (1). 10 Install CBS front end (1) Remove/install CBS front end AR88.00-P-1010FF

Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, an88.00-p-0004ff, Retrofit BRABUS front grille MODEL 454.0 (except 454.034)

AR88.10-P-1300FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3878 · Applies to: 453 · AR: AR88.10-P-1300FF, AR32.25-P-1017FF

Remove/install fender liner in front fender 14.8.03 MODEL 454.0 1 Front fender 2 Suspension strut 3 Front rocker panel 4 Expansion clip 5 Fender liner 6 Expansion clip 7 Lower engine compartment paneling P88.10-2122-06 Removal/installation

1 Remove front suspension strut (2) AR32.25-P-1017FF 2 Remove expansion clips (6) from bottom engine compartment paneling (7) in area of fender liner (5) 3 Remove expansion clips (4) from front rocker panel (3) in area of fender liner (5) 4 Remove all expansion clips from fender liner (5) 5 Detach fender liner (5) in area of front rocker 452589016300 Clip remover panel (3) and bottom engine compartment paneling (7) with clip remover 6 Detach fender liner (5) from front fender (1) Observe installation position of ABS line. with clip remover and remove. 452589016300 Clip remover 7 Install in the reverse order 452 589 01 63 00 Clip remover Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.10-p-1300ff, Remove/install fender liner in front fender MODEL 454.0

AR88.10-P-1300SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3879 · Applies to: 453 · AR: AR88.10-P-1300SRA

Remove/install fender liner in front fender 13.09.2018 Model 453.3/4 Shown on removed front wheel 1 Fender liner 2 Plastic clip 3 Plastic clip 4 Bolts P88.10-2302-06 Remove/install

Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. 1 Lift vehicle on vehicle lift 2 Remove plastic clips (2) 452589016300 Clip remover 3 Remove plastic clips (3) 452589016300 Clip remover 4 Turn steering on front wheel 5 Unscrew bolts (4) 6 Pull outer edge of fender liner (1) toward inside out of wheel arch lip and remove fender liner (1) downward 7 Install in the reverse order 452 589 01 63 00 Clip remover Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.10-p-1300sra, Remove/install fender liner in front fender Model 453.3/4

AR88.10-P-1400FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3880 · Applies to: 453 · AR: AR88.10-P-1400FF

Remove/install fender liner in rear fender 14.8.03 MODEL 454.0 1 Fender liner 2 Nuts 3 Clip P88.10-2118-05 Remove/Install

Risk of death Danger! cased by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A toppling off of the lifting platform. hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. 1 Raise vehicle. 2 Remove clips (3) Installation:

Check clips (2), replace if necessary 3 Unscrew nuts (2) 4 Remove fender liner (1) 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.10-p-1400ff, Remove/install fender liner in rear fender MODEL 454.0

AR88.10-P-1400SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3881 · Applies to: 453 · AR: AR88.10-P-1400SRA, AR40.10-P-1100SR

Remove/install fender liner in rear fender 13.09.2018 Model 453.3/4 Shown on left side of vehicle 1 Fender liner 2 Plastic clip 3 Screw 4 Expansion rivet P88.10-2303-06 Remove/install

1 Remove relative rear wheel AR40.10-P-1100SR 2 Remove plastic clips (2) Mounting version can vary.

*452589016300 Clip remover 3 Unscrew bolts (3) Mounting version can vary.

4 Remove expansion rivet (4) Mounting version can vary.

*452589016300 Clip remover 5 Pull outer edge of fender liner (1) toward inside out of wheel arch lip and remove fender liner (1) downward 6 Install in the reverse order 452 589 01 63 00 Clip remover Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar88.10-p-1400sra, Remove/install fender liner in rear fender Model 453.3/4

AR88.10-P-1000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3882 · Applies to: 453 · AR: AR88.10-P-1000FF, AR88.30-P-0505FF, AR88.00-P-1010FF, AR82.10-P-4725FF, AR82.10-P-1835FF (+1 more)

Remove/install front fenders 8.1.07 MODEL 454.0 P88.10-2192-08 1 Front fender 3 Engine hood seal 5 Upper front grille 2 CBS front center section 4 Carrier 6 Lower front grille P88.10-2193-08 1 Front fender 7 Telescopic nozzle (with code (22Y) 11 Hose (with code (22Y) Headlamp Headlamp cleaning system) cleaning system) 2 CBS front center section 8 Retaining bracket 12 Halter (with code (22Y) Headlamp 4 Carrier cleaning system) 9 Bolt 5 Upper front grille 13 Cover 10 Halter (with code (22Y) Headlamp 6 Lower front grille cleaning system) 14 Retaining clamp Remove/install

1 Remove BRABUS front spoiler On model 454.034 or on vehicles with code AR88.30-P-0505FF (E58) BRABUS front spoiler (DFO) 2 Remove front CBS AR88.00-P-1010FF 3.1 Remove left and right turn signal lamp On vehicles without code (V07) Front fog AR82.10-P-4725FF lamps (FFO) 3.2 Remove left and right front fog lamp On vehicles with code (V07) front fog lamps AR82.10-P-1835FF (FFO) 4 Remove engine hood seal (3) 5 Unclip upper front grille (5) and remove 6 Unclip carrier (4) from CBS front end and On vehicles without BRABUS front grille remove 7 Unscrew bolts (9) from left and right fender (1). 8 Remove telescoping nozzle (7) with hose (11) On vehicles with code (22Y) Headlamp AR82.15-P-6100FF connected from left and right front fender (1). cleaning system 9 Loosen hose (11) on telescoping nozzle (7) On vehicles with code (22Y) Headlamp from brackets (10, 12) cleaning system Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.10-p-1000ff, Remove/install front fenders MODEL 454.0

AR88.10-P-1000SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3884 · Applies to: 453 · AR: AR88.10-P-1000SRA, AR88.10-P-1300SRA, AR88.20-P-2000SRA

Remove/install front fenders 17.12.15 Model 453.3/4 P88.10-2319-09 Shows on model 453.3 1 Front fender 6 Screw 11 Screw 2 Mounting clip 7 Expansion rivet 12 Front bumper 3 Cover 8 Screw 13 Headlamp guide 4 Bolts 9 Fender liner E22/1 Left additional turn signal lamp 5 Mirror cover 10 Expansion rivet E22/2 Right additional turn signal lamp Remove/install

1 Detach fender liner (9) from front fender (1) AR88.10-P-1300SRA 2 Loosen front bumper (12) in front fender (1) AR88.20-P-2000SRA 3 Pull front bumper (12) toward front and unscrew bolts (11) 4 Unclip retaining clip (2) and remove cover (3) *452589016300 Clip remover 5 Unclip left additional turn signal lamp (E22/1) Installation: Guide bulb holder with bulb

or right turn signal lamp (E22/2) and unscrew through cutout when positioning front fender bulb holder with bulb (1). Otherwise the bulb holder with bulb is not easily accessible. 6 Open front door 7 Remove expansion rivet (7) 452589016300 Clip remover 8 Unclip mirror cover (5) and remove 452589016300 Clip remover 9 Remove screw/bolts (4, 6, 8) Installation: Adjust gap dimensions on

front fender (1). Fender to maintenance flap BE60.00-P-1007-01CA Fender to A-pillar BE60.00-P-1008-01CA Fender to front door BE60.00-P-1012-01CA 129589032100 Feeler gauge 10 Remove expansion rivet (10) *452589016300 Clip remover 11 Guide front fender (1) in direction of arrow out

of headlamp guide (13) and remove Carefully guide front fender (1) out of headlamp guide (13). Otherwise the left front lamp unit (E1) or right front lamp unit (E2) can be damaged. 12 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.10-p-1000sra, Remove/install front fenders Model 453.3/4

AR88.10-P-1100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3886 · Applies to: 453 · AR: AR88.10-P-1100FF, AR88.20-P-1900FF

Remove/install rear fender 22.10.03 MODEL 454.0 1 Rear fender 2 Rear center section 3 Bolt 4 Retaining brackets P88.10-2116-06 Remove

1 Remove CBS rear end AR88.20-P-1900FF 2.1 Loosen BRABUS rear apron from rear fender On model 454.034 or on vehicles with code AR88.30-P-0502-02FF (1) to be removed (E78) smart BRABUS rear apron (DFO) 3 Release tension on retaining brackets(4) on left and right rear fender (1) with suitable pliers and remove 4 Unscrew bolts (3) from left and right rear fender (1) 5 Loosen left and right rear fender (1) from rear center section (2) and remove Install

6.1 Prepare BRABUS rear apron On model 454.034 or on vehicles with code AR88.30-P-0502-02FF (E78) smart BRABUS rear apron (DFO) Repair kit *BR00.45-Z-1094-02A 7 Position left and right rear fender (1) on rear center section (2) and arrest in guides on rear center section (2). 8 Tighten bolts (3) on left and right rear fender (1) 9 Install retaining brackets (4) on left and right rear fender (1) with suitable pliers 10 Install CBS rear end AR88.20-P-1900FF 11.1 Raise vehicle On model 454.034 or on vehicles with code (E78) smart BRABUS rear apron (DFO) 12.1 Fasten BRABUS rear apron to left and right On model 454.034 or on vehicles with code AR88.30-P-0502-02FF rear fender (1) (E78) smart BRABUS rear apron (DFO) 13.1 Lower vehicle On model 454.034 or on vehicles with code (E78) smart BRABUS rear apron (DFO) Repair materials Number Designation Order number BR00.45-Z-1094-02A Repair kit A 454 899 00 98 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.10-p-1100ff, Remove/install rear fender MODEL 454.0

AR88.20-P-2050SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3887 · Applies to: 453 · AR: AR88.20-P-2050SRA

Disassemble/assemble front bumper 17.12.15 Model 453.3/4 P88.20-4368-08 Shown with code V07 (Front fog lamp (FFO)) and code 252 (COLLISION PREVENTION ASSIST) 1 Front bumper 20 Electrical connector E5/1 Left front fog lamp cover (with codeV07 (Front fog lamps (FFO)) 2 Electrical wiring harness 21 Electrical connector (with code V07 E5/2 Right front fog lamp cover (with (Front fog lamp, (FFO))) code V07 (Front fog lamps (FFO)) 5 Screw 22 Electrical connector (with code 252 (COLLISION PREVENTION ASSIST)) P88.20-4365-08 Shown except code V07 (Front fog lamp (FFO)) and except code 252 (COLLISION PREVENTION ASSIST) 1 Front bumper 7 Towing eye cover 16 Front spoiler 3 Bolts 9 Retaining clamp E6/1 Left turn signal lamp 4 Radiator grille 13 Lower front compartment cover E6/2 Right turn signal lamp 5 Screw 14 Center wind deflector 6 Cover 15 Retaining clamp Page 1 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, ar88.20-p-2050sra, Disassemble/assemble front bumper Model 453.3/4

P88.20-4367-08

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3888 · Applies to: 453 · AR: AR88.20-P-2000SRA, AR88.40-P-4001SRA

Shown except code V07 (Front fog lamp (FFO)) 1 Front bumper 10 Retaining clips 12 Rivet 8 Retaining clips 11 Bottom radiator panel 13 Lower front compartment cover Remove

1 Remove front bumper (1) and lay down on AR88.20-P-2000SRA suitable subsurface Disassemble/assemble

2 Remove license plate and license plate brackets 3 Disconnect electrical connectors (20) 4 Disconnect electrical connectors (21) Model 453.3/4 with code V07 (Front fog lamps (FFO)) 5 Disconnect electrical connection (22) Model 453.3/4 with code 252 (COLLISION PREVENTION ASSIST) 6 Expose electrical wiring harness (2) and Installation: Observe line routing.

remove *452589016300 Clip remover 7 Unscrew bolts (3) and remove left turn signal lamp (E6/1) and right turn signal lamp (E6/2) 8 Remove radiator grille (4) AR88.40-P-4001SRA 9.1 Unscrew bolts (5) and remove covers (6) in Model 453.3/4 direction of arrow except code V07 (Front fog lamps (FFO)) 9.2 Unscrew bolts (5) and remove left front fog Model 453.3/4 lamp (E5/1) and right front fog lamp (E5/2) in with code V07 (Front fog lamps (FFO)) direction of arrow 10 Press barb on towing eye cover (7) together and remove towing eye cover (7) 11 Unclip retaining clips (8) 12 Unclip retaining clips (9) 13 Unclip retaining clips (10) and remove lower radiator grille (11) 14 Drill off heads of rivets (12)

Do not drill out rivet heads of rivets (12) too far. Otherwise the lower front compartment cover (13) can be damaged and must be replaced. Use 7 mm dia. bit.

15 Unclip lower front compartment cover (13) 110589035900 Mounting wedge and remove 16 Unclip center wind deflector (14) and remove 17 Unclip retaining clips (15) 18 Unclip front spoiler (16) 110589035900 Mounting wedge 19 Remove rests of rivet from rivets (12) 20 Assemble in the reverse order Page 2 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, ar88.20-p-2050sra, Disassemble/assemble front bumper Model 453.3/4

Install

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3889 · Applies to: 453 · AR: AR88.20-P-2000SRA

21 Install front bumper (1) AR88.20-P-2000SRA 452 589 01 63 00 110 589 03 59 00 Clip remover Mounting wedge Page 3 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, ar88.20-p-2050sra, Disassemble/assemble front bumper Model 453.3/4

AR88.20-P-1900FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3890 · Applies to: 453 · AR: AR88.20-P-1900FF, AR82.10-P-5161FF, AR88.80-P-1050FF

Remove/install CBS rear end 14.8.03 MODEL 454.0 P88.20-2534-07 1 CBS rear end 2 Reflector 3 Retaining clamp P88.20-2843-09 1 CBS rear end 5 Edge guard 7 Expansion clip 4 Expansion clip 6 Bolt 8 Bolt Remove/install

1 Remove license plate lamps AR82.10-P-5161FF 2.1 Remove left and right rear side sill protective Except model 454.034 or on vehicles without AR88.80-P-1050FF molding code (E71) BRABUS side skirts 2.2 Loosen left and right BRABUS side skirts in On model 454.034 or on vehicles with code AR88.80-P-1050-01FB rear area until bolt (6) is accessible (E71) BRABUS side skirts Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A

toppling off of the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 3 Raise vehicle 4 Unclip retaining clamp (3) from left and right reflector (2) with suitable screwdriver 5 Remove left and right reflector (2) from outside 6 Unscrew bolt (8) behind left and right reflectors (2) 7 Remove expansion clips (4, 7) on left and On model 454.034 or on vehicles with right from CBS rear end (1) code (E71) BRABUS side skirts, expansion clips (4) eliminated. Installation:

Replace damaged expansion clips (4, 7) 8 Unscrew bolt (6) from CBS rear end (1) on left and right Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.20-p-1900ff, Remove/install CBS rear end MODEL 454.0

AR88.20-P-1950SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3892 · Applies to: 453 · AR: AR88.20-P-1950SR, AR88.20-P-2200SR, AR88.20-P-2200SRA, AR88.20-P-1925SR

Remove/install CMS rear end 15.09.2016 Model 453.0/3/4 P88.20-4322-08 Show here is model 453.0 1 CMS rear end 2 Bolts 3 Heat shield Remove/install

1 Remove rear bumper Model 453.0 AR88.20-P-2200SR Model 453.3/4 AR88.20-P-2200SRA 2 Remove heat shield (3) Model 453.0 (except 453.091) AR88.20-P-1925SR 3 Unscrew screws/bolts (2) *BA64.20-P-1001-01B Screw/bolt, CMS rear end to drive module 4 Remove CMS rear end (1) 5 Install in the reverse order CMS rear end Number Designation Model 453 BA64.20-P-1001-01B Screw/bolt, CMS rear end to drive module Nm 39 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.20-p-1950sr, Remove/install CMS rear end Model 453.0/3/4

AR88.20-P-2000SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3893 · Applies to: 453 · AR: AR88.20-P-2000SRA

Remove/install front bumper 11.08.2017 Model 453.3/4 Shown on model 453.3 with code V07 (Front fog lamp (FFO)) 1 Front bumper 5 Electrical connector P88.20-4363-06 P88.20-4364-09 1 Front bumper 3 Bolts 2 Bolts 4 Screw Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.20-p-2000sra, Remove/install front bumper Model 453.3/4

AR88.20-P-1925SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3896 · Applies to: 453 · AR: AR88.20-P-1925SRA, AR88.20-P-2200SRA

Remove/install heat shield 15.09.2016 Model 453.3 (except 453.391), 453.4 (except 453.491) 1 Heat shield 2 Rivets P88.20-4359-06 Remove/install

1 Remove rear bumper AR88.20-P-2200SRA 2 Set rear bumper down on suitable base 3 Drill out rivet heads on rivets (2) Risk of injury Always wear protective gloves when working Danger ! caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. 4 Remove heat shield (1) from rear bumper 5 Press out any pieces of rivets remaining in the rear bumper 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar88.20-p-1925sra, Remove/install heat shield Model 453.3 (except 453.391), 453.4 (except 453.491)

AR88.20-P-2200SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3897 · Applies to: 453 · AR: AR88.20-P-2200SRA, AR72.20-P-1020SRC, AR72.20-P-1020SRA

Remove/install rear bumper 15.07.2016 Model 453.3/4 Modification notes 06.07.2016 Step 6 added P88.20-4344-09 Shown on model 453.3 with code 220 (Rear parking assist) 1 Bolts 3 Rear bumper 2 Bolts 4 Electrical connector (with code 220 (rear parking assist) or code V52(Combination code for rear parking assist and reversing camera)) Check

1 Remove lower liftgate Model 453.4 AR72.20-P-1020SRC Model 453.3 AR72.20-P-1020SRA Risk of death Danger ! caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. 2 Lift vehicle with lifting platform 3 Mask left and right sidewall to prevent paint damage in area of rear bumper (3) 4 Remove bolts (1) 5 Secure rear bumper (3) so it cannot fall and remove bolts (2) 6 Unscrew bolts at side of upper fender liner 7 Removal: Unclip rear bumper (3) at sides

Carefully unclip rear bumper (3). Otherwise the rear bumper (3) can be damaged. 8 Pull rear bumper (3) toward rear and Model 453.3/4 with code 220 (Rear parking assist) disconnect electrical connector (4) Model 453.3/4 with code V52 (Combination code for rear parking aid and reversing camera) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.20-p-2200sra, Remove/install rear bumper Model 453.3/4

AZ88.20-P-0006SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3901 · Applies to: 453 · AR: AZ88.20-P-0006SR, AR88.20-P-2200SRA

Retrofit rear apron 12.04.2016 Model 453.3/4 Shown on exhaust system with one exhaust end pipe 1 Rear apron P88.30-2912-12 12 Reflector 13 Screw 14 Cover 15 Retaining clips 16 Rear bumper P88.30-2923-06 Remove

1 Remove rear bumper (16) AR88.20-P-2200SRA

2 Unclip reflectors (12) Install

3 Use only paints approved by Daimler AG: Paint rear apron (1)

http://xentryportal.mercedes-benz.com Risk of injury Always wear protective gloves when working Danger ! caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. 4 Retrofit rear apron (1) AZ88.20-P-0006-01SR Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az88.20-p-0006sr, Retrofit rear apron Model 453.3/4

Information on preventing damage to

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3902 · Applies to: 453 · AR: AR88.20-P-2200SRA, AZ88.20-P-0006SR

Model 453.3/4 AH54.00-P-0001-01A

with code 220 (Rear parking assist) electronic components due to electrostatic discharge Model 453.3/4 with code V52 (Combination code for rear parking aid and reversing camera) Cleaner *BR00.45-Z-1025-04A 5 Install rear bumper (16) AR88.20-P-2200SRA

6 Tighten bolts (13) 7 Insert covers (14) and fasten with retaining clips (15) 8 Clip in reflectors (12) Update Vehicle Documentation (VeDoc) 9 Attach note "Rear apron retrofitted according to AZ88.20-P-0006SR" to field organization texts for design group 88 Repair materials Number Designation Order number BR00.45-Z-1025-04A Cleaner A 005 989 19 71 Parts ordering note Part no. Designation Quantity KG 98 (siehe EPC) Rear apron parts kit 1 KG 88 (siehe EPC) PARKTRONIC system mount parts kit 1 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az88.20-p-0006sr, Retrofit rear apron Model 453.3/4

AZ88.20-P-0010SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3903 · Applies to: 453 · AR: AZ88.20-P-0010SR, AR88.20-P-2050SRA

Retrofit spoiler on front bumper 18.03.2020 Model 453.3/4 up to 1/19/20 1 Front spoiler 2 Front spoiler lip P88.30-2910-12 1 Front spoiler 2 Front spoiler lip 5 Screw P88.30-2911-12 Remove

1 Remove front spoiler (1) installed at factory AR88.20-P-2050SRA

Factory-installed front spoiler (1) is

eliminated part. Install

2 Paint front spoiler (1) and front spoiler lip (2)

Also paint front spoiler (1) and front spoiler lip (2) in area of bonding surfaces. Proper bonding cannot be ensured on an unpainted surface. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az88.20-p-0010sr, Retrofit spoiler on front bumper Model 453.3/4 up to 1/19/20

Use only paints approved by Daimler AG:

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3904 · Applies to: 453 · AR: AR88.20-P-2050SRA, AZ88.20-P-0010SR

http://xentryportal.mercedes-benz.com 3 Retrofit front spoiler lip (2) on new front spoiler AZ88.20-P-0010-02SR (1)

When pressing on, ensure that the pressure is applied directly on the adhesive strips. The maximum adhesive strength is only reached after approx. 72 h at 20 °C. Avoid any contact with moisture (e.g. rain, fog, frost, carwash) or any mechanical stress within the first 24 h. Otherwise adhesion problems may occur. Cleaner *BR00.45-Z-1025-04A 4 Install new front spoiler (1) AR88.20-P-2050SRA

Insert bolts (5) so that the shackles of the

wheel well paneling and the shackles (arrows) on the front spoiler (1) are bolted. Update Vehicle Documentation (VeDoc) 5 Attach note "Front spoiler retrofitted according to AZ88.20-P-0010SR" field organization texts for design group 88 Repair materials Number Designation Order number BR00.45-Z-1025-04A Cleaner A 005 989 19 71 Parts ordering note Part no. Designation Quantity KG 98 (siehe EPC) Parts kit Front spoiler 1 A 453 989 01 00 Bonding kit 1 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, az88.20-p-0010sr, Retrofit spoiler on front bumper Model 453.3/4 up to 1/19/20

PE88.30-P-2000BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3907 · Applies to: 453 · AR: PE88.30-P-2000BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Electric wiring diagram for rear luggage carrier 12.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code E12 (Preinstallation for rear-end carrier) Electric wiring diagram for rear luggage carrier PE88.30-P-2000-97BBA Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe88.30-p-2000bba, Electric wiring diagram for rear luggage carrier Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code E12 (Preinstallation for rear-end carrier)

AR88.30-P-0505FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3908 · Applies to: 453 · AR: AR88.30-P-0505FF

Remove/install front spoiler 10.8.05 MODEL 454.0 (except 454.034) with CODE (E58) Front spoiler, Brabus (DFO) MODEL 454.034 P88.30-2371-08 1 BRABUS front spoiler 4 Covering 7 Masking tape 2 CBS front end 5 Gluing surface 8 Adhesive strips 3 Expansion clip 6 Bracket 9 Lugs 1 BRABUS front spoiler 10 Bolt 11 Counterholder P88.30-2375-03 Remove

Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A

toppling off of the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 1 Raise vehicle. 2 Unclip expansion clips (3) from BRABUS front spoiler (1) 3 Unscrew bolt (1) on BRABUS front spoiler (10) on left and right and remove counterholder (11). 4 Carefully loosen BRABUS front spoiler (1) from CBS front end (2) in area of adhesive strips (8) with suitable blade. 5 Unhook BRABUS front spoiler (1) from Aid of helper required bracket (6) and remove Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.30-p-0505ff, Remove/install front spoiler MODEL 454.0 (except 454.034) with CODE (E58) Front spoiler, Brabus (DFO) MODEL 454.034

AR88.30-P-0502FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3910 · Applies to: 453 · AR: AR88.30-P-0502FF

Remove/install rear apron 4.8.05 MODEL 454.0 (except 454.034) with CODE (E78) Rear apron, smart BRABUS (DFO) MODEL 454.034 1 BRABUS rear apron 2 CBS rear end 3 Bore 4 Guide 5 Lugs 6 Adhesive strips P88.20-2573-06 Remove

Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A

toppling off of the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 1 Raise vehicle. 2 Loosen clamps (arrows) from BRABUS rear apron (1) and CBS rear end (2) with suitable tool and remove 3 Carefully loosen BRABUS rear apron (1) on Aid of helper required left and right in area of adhesive strips (6) from CBS rear end (2) with suitable blade and remove. 4 Remove glue residues on adhesive strips (6) from parts to be reused. Install

5.1 Check that BRABUS rear apron spoiler (1) fits When replacing BRABUS rear apron (1). precisely and then paint. 6.1 Clean gluing surfaces of adhesive strips (6) When reusing removed BRABUS rear apron on left and right on BRABUS rear apron (1) (1). Bonding surface must be free of dust and grease. 7.1 Mask BRABUS rear apron (1) in area of When reusing removed BRABUS rear apron gluing surfaces with masking tape, coat with (1). primer and allow to air-dry for at least 5 minutes. Thoroughly remove primer from painted surfaces not to be glued to prevent damage. Primer is included in the repair kit in the form of an impregnated non-woven cloth. Repair kit BR00.45-Z-1094-02A 8 Clean gluing surfaces on CBS rear end (2). Bonding surface must be free of dust and grease. 9 Mask CBS rear end (2) in area of gluing Thoroughly remove primer from painted surfaces with masking tape, coat with primer surfaces not to be glued to prevent damage. and allow to air-dry for at least 5 minutes. Primer is included in the repair kit in the form of an impregnated non-woven cloth. Repair kit BR00.45-Z-1094-02A 10.1 Glue adhesive strips (6) to BRABUS rear When reusing removed BRABUS rear apron apron (1) (1). Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.30-p-0502ff, Remove/install rear apron MODEL 454.0 (except 454.034) with CODE (E78) Rear apron, smart BRABUS (DFO) MODEL 454.034

AR88.30-P-0500FB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3912 · Applies to: 453 · AR: AR88.30-P-0500FB, AR88.30-P-0500FF

Remove/install rear spoiler 8.8.05 MODEL 454.0 (except 454.034) with CODE (E79) Rear spoiler, smart BRABUS (DFO) MODEL 454.034 1 BRABUS rear spoiler 2 Rear spoiler E21 Center high-mounted stop lamp P88.50-2612-11 Remove/install

1 Remove rear spoiler (2) AR88.30-P-0500FF It is not possible to remove the BRABUS rear spoiler (1) separately.Replace with rear spoiler (2) if necessary. 2 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.30-p-0500fb, Remove/install rear spoiler MODEL 454.0 (except 454.034) with CODE (E79) Rear spoiler, smart BRABUS (DFO) MODEL 454.034

AR88.30-P-0500FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3913 · Applies to: 453 · AR: AR88.30-P-0500FF

Remove/install rear spoiler 14.8.03 MODEL 454.0 P88.30-2261-07 1 Rear-end door 4 Washer fluid hose 6 Electrical connector 2 Rear spoiler 5 Hose connector 3 Nuts E21 Center high-mounted stop lamp Remove/install

1 Mask roof edge over entire length along rear spoiler (2). 2 Open rear-end door (1) 3 Unscrew nuts (3) 4 Unclip rear spoiler (2) with snap-release tool Carefully unclip rear spoiler (2) to prevent damaging paint. Installation: Check retaining clamps on rear spoiler (2), replace if necessary. *452589016300

5 Separate washer fluid hose (4) from hose coupling (5) 6 Disconnect electrical connector (6) from center high-mounted stop lamp (E21) 7 Remove rear spoiler (2) The BRABUS rear spoiler installed on 454.034 or on vehicles with code (E79) smart BRABUS rear spoiler (DFO), cannot be removed from the rear spoiler (2); it must also be replaced when replacing the rear spoiler (2). 8.1 Remove center high-mounted stop lamp When replacing rear spoiler (2). (E21) and spraying nozzle on windshield washer system. 9 Install in the reverse sequence 10 Check center high-mounted stop lamp (E21) and spray nozzle for proper function. 11.1 Check that BRABUS rear spoiler fits precisely On model 454.034 or when replacing rear and then paint spoiler (2) on vehicles with code (E79) smart BRABUS rear spoiler (DFO) 12.1 Glue on BRABUS rear spoiler On model 454.034 or when replacing rear AR88.30-P-0500-01FB spoiler (2) on vehicles with code (E79) smart BRABUS rear spoiler (DFO) 452 589 01 63 00 Snap-release tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.30-p-0500ff, Remove/install rear spoiler MODEL 454.0

AR88.40-P-3020FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3914 · Applies to: 453 · AR: AR88.40-P-3020FF, AR88.00-P-2792FF, AR88.40-P-3200FF

Adjust engine hood 16.10.03 MODEL 454.0 P88.40-2426-08 1 Engine hood 3 Bolts 5 Bolts 2 Upper section of engine hood catch 4 Engine hood hinge 6 Stop buffer Adjust Risk of injury Danger! to fingers being jammed or When moving components, ensure that no AS00.00-Z-0011-01A

pinched when Remove/install or aligning body parts or limbs are within the operating hoods, doors, trunk lid/tailgate or sliding roof. range of moving parts. 1 Remove paneling from center section in front AR88.00-P-2792FF of windshield 2 Remove engine hood lock top section (2) AR88.40-P-3200FF Adjustment in transverse direction 3 Loosen bolts (3) on both engine hood hinges (4) and close engine hood (1) 4 Center gaps of engine hood (1), if necessary AR60.00-P-0700-01FF align engine hood (1) *BE60.00-P-1001-01M 5 Open engine hood (1) and tighten bolts (3) Adjust height 6 Close engine hood (1) and lay down on stop buffers (6) 7 Check transition from engine hood (1) to CBS front, if necessary loosen nuts (arrows) and adjust height of stop buffers (6) 8 Open engine hood (1) 9 Loosen bolts (5) on both engine hood hinges (4) 10 Close engine hood (1) and align height of engine hood (1) in relation to fender 11 Open engine hood (1) and tighten bolts (5) 12 Install engine hood lock upper section (2) AR88.40-P-3200FF 13 Install paneling on center section in front of AR88.00-P-2792FF windshield Test and adjustment values Number Designation Model 454.0 Dimension "A" 5.0 ( 2.5) Size of gap CBS front end to headlamps mm BE60.00-P-1001-01M 5.0 ( 1.5) CBS front to front engine hood Dimension"B" mm 8.0 ( 1.5) CBS front to side engine hood Dimension"C" mm Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.40-p-3020ff, Adjust engine hood MODEL 454.0

Proceed with step 4.

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3917 · Applies to: 453 · AR: AR88.20-P-2000SRA

If cutouts (arrows) are present. Proceed with step 5. Remove/install

4 Rework service cover (1) SM88.40-P-0015-02A Fabricate template for changing engine cover WF58.50-P-8840-01A

5 Replace right and left locks (2) Remove/install front bumper AR88.20-P-2000SRA

Remove front bumper.

6 Install in the reverse order Parts ordering note Part no. Designation Quantity A 453 751 22 00 Maintenance flap unlocking 2 A 453 991 01 32 Blind rivet 2 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, sm88.40-p-0015a, Check service cover (code: 1602P88A43) Model 453.3

AR88.40-P-3000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3918 · Applies to: 453 · AR: AR88.40-P-3000FF, AR88.40-P-3020FF, AZ88.40-P-0002FF

Remove/install engine hood 16.10.03 MODEL 454.0 1 Engine hood 2 Bolts P88.40-2419-05 Remove/install

Risk of injury Danger! caused by fingers being When moving components, ensure that no AS00.00-Z-0011-01A

jammed or pinched when removing, body parts or limbs are within the operating installing or aligning hoods, doors, trunk lid/ range of moving parts. rear-end door or sliding roof. 1 Open engine hood (1) 2 Unscrew bolts (2) from engine hood (1) Before loosening bolts (2) mark installation position. Installation:

Ensure that engine hood (1) fits properly, if necessary: Adjust engine hood (1) AR88.40-P-3020FF 3 Remove engine hood (1) Helper required 4 Install in the reverse order 5.1 Install air intake grate When replacing engine hood (1) on vehicles up to production date 5.6.05 or on customer request on vehicles as of production date 6.6.05. Retrofit air inlet grate AZ88.40-P-0002FF

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.40-p-3000ff, Remove/install engine hood MODEL 454.0

AR88.40-P-3060FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3919 · Applies to: 453 · AR: AR88.40-P-3060FF, AR88.40-P-3000FF, AR88.00-P-2792FF

Remove/install engine hood hinge 16.10.03 MODEL 454.0 1 Engine hood hinge 2 Bolts P88.40-2423-11 Remove/Install

1 Remove engine hood AR88.40-P-3000FF 2 Remove paneling from center section in front AR88.00-P-2792FF of windshield 3 Mark installation position of engine hood hinge (1) in relation to spring strut dome 4 Unscrew bolts (2) and remove engine hood hinge (1) 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.40-p-3060ff, Remove/install engine hood hinge MODEL 454.0

AR88.40-P-3200FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3920 · Applies to: 453 · AR: AR88.40-P-3200FF, AR88.40-P-3020FF

Remove/install engine hood lock 16.10.03 MODEL 454.0 1 Engine hood 2 Upper section of engine hood catch 3 Bolts 4 Lower section of engine hood catch 5 Bolt 6 Hood cable P88.40-2424-06 Remove

1 Open engine hood (1) See Operating Instructions 2 Mark installation position of engine hood lock top section (2) in relation to engine hood (1) 3 Unscrew bolts (3) 4 Remove engine hood lock top section (2) 5 Unclip engine hood control cable (6) from engine hood lock top section (4) and unhook 6 Mark installation position of engine hood lock bottom section (4) in relation to upper frame cross member 7 Unscrew bolts (5) 8 Remove engine hood lock bottom section (4) Install

9 Insert engine hood lock bottom section (4) Align engine hood lock bottom section (4) in relation to marked upper frame cross member 10 Screw tight bolts (5) 11 Hook engine hood control cable (4) into engine hood lock bottom section (4) 12 Close engine hood lock bottom section (4) manually and unlock from release lever in passenger compartment 13 Position engine hood lock top section (2) Align engine hood lock top section (2) in relation to marked engine hood (1) 14 Tighten bolts (3) 15 Check engine hood fit If necessary, Adjust engine hood (1) AR88.40-P-3020FF 16 Check engine hood lock and safety hook for To do thus, close the engine hood (1), proper function unlock and check engagement on upper frame crossmember. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.40-p-3200ff, Remove/install engine hood lock MODEL 454.0

AR88.40-P-3100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3921 · Applies to: 453 · AR: AR88.40-P-3100FF, AR88.00-P-1010FF, AR68.30-P-4010FF

Remove/install pull cable for engine hood 7.10.03 MODEL 454.0 P88.40-2407-09 1 Hood cable 4 Clip 6 Grommet 2 Engine hood lock 5 Fender liner 7 Bracket 3 Front end crossmember 1 Hood cable 8 Bolt 9 Actuation handle 10 Carrier plate P88.40-2416-06 Remove/Install

1 Remove front CBS AR88.00-P-1010FF 2 Unhook engine hood control cable (1) from engine hood lock (2) 3 Loosen engine hood control cable (1) from lock carrier (3) and pull out front section of engine hood control cable (1) at side 4 Loosen engine hood control cable (1) from brackets (7) 5 Remove clips (4) and carefully press fender liner (5) downward 6 Remove paneling in footwell AR68.30-P-4010FF Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.40-p-3100ff, Remove/install pull cable for engine hood MODEL 454.0

AR88.40-P-4001SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3923 · Applies to: 453 · AR: AR88.40-P-4001SRA, AR88.20-P-2000SRA

Remove/install radiator grille 17.12.15 Model 453.3/4 Shown with code 252 (COLLISION PREVENTION ASSIST) 1 Radiator grille 2 Screw 3 Handle 4 Electrical connector (with code 252 (COLLISION PREVENTION ASSIST)) 5 Radiator grille substructure 6 Rivet 7 Retaining clips B92 Front radar sensor (with code 252 (COLLISION PREVENTION ASSIST)) P88.40-3186-06 Remove/install

1 Remove front bumper AR88.20-P-2000SRA 2 Unscrew bolts (2) and remove handle fittings (3) 3 Disconnect electrical connector (4) from front Model 453.3/4 radar sensor (B92) with code 252 (COLLISION PREVENTION ASSIST) The front radar sensor (B92) must not be

removed from the radiator grille substructure (5). 4 Drill rivet heads on rivets (6) off of radiator

grille (1) Do not drill out rivet heads of rivets (6) too far. Otherwise the front bumper can be damaged and must be replaced. Use 7 mm dia. bit.

5 Remove rests of rivet from rivets (6) 6 Remove retaining clamps (7) 7 Unclip radiator grille (1) from front bumper 110589035900 Mounting wedge 8 UNclip company sign When replacing radiator grille (1). 110589035900 Mounting wedge 9 Unclip radiator grille substructure (5) from When replacing radiator grille (1). radiator grille (1) *110589035900 Mounting wedge 10 Install in the reverse order 110 589 03 59 00 Mounting wedge Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar88.40-p-4001sra, Remove/install radiator grille Model 453.3/4

AR88.60-P-1002SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3927 · Applies to: 453 · AR: AR88.60-P-1002SR

Actuate emergency release of fuel filler flap 06.08.2014 MODEL 453 P88.60-2434-07 Shown on MODEL 453.0 1 Emergency release operating M14/10 Tank cap central locking actuator A Actuation direction lever Run 1 Open liftgate 2 Remove cargo area floor covering 3 Remove engine compartment flap 4 Actuate emergency release operating lever The tank cap center locking actuator

(1) on tank cap center locking actuator (M14/10) can be reached through the engine (M14/10) in direction of arrow (A) compartment. 5 Open fuel filler flap Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.60-p-1002sr, Actuate emergency release of fuel filler flap MODEL 453

AR88.60-P-6023FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3928 · Applies to: 453 · AR: AR88.60-P-6023FF

Remove/install fuel filler flap 14.8.03 MODEL 454.0 1 Fuel filler flap 2 Lock bolt 3 Bolt 4 Filler cap 5 Fuel tank filler neck 6 Lip 7 Guide P88.60-2113-06 Remove/install

Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by fuel igniting, AS47.00-Z-0001-01A risk of poisoning Pour fuels only into suitable and appropriately caused by inhaling and swallowing fuel as well as risk of injury marked containers. to eyes and skin caused by contact with fuel. Wear protective clothing when handling fuel. 1 Open fuel filler flap cover (1) 2 Unscrew filler cap (4) When replacing fuel filler flap (1) unclip catch strap from filler cap (4) 3 Unscrew bolt (3) 4 Pull lip (6) over fuel tank filler neck (5) Install lip (6) carefully to prevent tearing. 5 Turn fuel filler flap (1) to right until lock bolt (2) is disengaged 6 Loosen fuel filler flap (1) and remove Installation:

Ensure that guide (7) is installed correctly. When installing fuel filler flap (1) insert uniformly in area of fuel tank filler neck (5) and guide (7) 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.60-p-6023ff, Remove/install fuel filler flap MODEL 454.0

AR88.60-P-2000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3929 · Applies to: 453 · AR: AR88.60-P-2000SR, AR88.10-P-1400SR, AR88.10-P-1400SRA

Remove/install tank recess 15.09.2016 Model 453.04/05/06/34/35/36/44/45/46 P88.60-2420-09 Shown on model 453.04 1 Tank filling recess 4 Tank flap lock 7 Fuel tank cap 2 Fuel filler flap 5 Cable 3 Bolts 6 Unlocking opening Risk of explosion No fires, sparks, open flames or smoking. Danger ! caused by fuel igniting, risk AS47.00-Z-0001-01A

of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Remove/install

1 Remove right rear fender liner Model 453.04/05/06 AR88.10-P-1400SR Model 453.34/35/36/44/45/46 AR88.10-P-1400SRA 2 Remove drain hose from tank filling recess (1) 3 Open fuel filler flap (2) 4 Unscrew bolts (3) 5 Unclip fuel filer flap lock (4) and remove from 452589016300 Clip remover cable (5) 6 Remove cable (5) downward 7 Unscrew tank cap (7) and hook into tank filling recess (1) 8 Loosen filler necks from tank filling recess (1) 9 Unclip tank filler recess (1) at bottom from 452589016300 Clip remover rear side wall 10 Close fuel filler flap (2) and remove tank filling recess (1) 11 Unlock fuel filler flap (2) through release When replacing tank filling recess (1). opening (6) and remove from hinge lever on tank filling recess (1) in direction of arrow (arrow A) 12 Remove tank cap (7) from hinge lever on tank When replacing tank filling recess (1). filling recess (1) 13 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar88.60-p-2000sr, Remove/install tank recess Model 453.04/05/06/34/35/36/44/45/46

AR88.70-P-9000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3931 · Applies to: 453 · AR: AR88.70-P-9000FF

Remove/install complete outside mirror 13.8.03 MODEL 454.0 with CODE (V21) Electrically adjustable and heated outside mirrors (FFO) P88.70-2332-08 Shown on vehicle with code (C22) Sound H4/33 Left tweeter (with code (C22) M21/2 Right electrically adjustable and package (FFO) Sound package (FFO)) heated outside mirror H4/34 Right tweeter (with code (C22) M21/2x1 Right electrically adjustable and Sound package (FFO)) heated outside mirror connector 1 Catch hook M21/1 Left electrically adjustable and S50 Outside mirror adjustment 2 Mirror triangle paneling heated outside mirror switch 3 Retaining clip M21/1x1 Left electrically adjustable and 4 Lock tab heated outside mirror connector 5 Bolts Remove/Install

1 Unclip retaining clips (3) from mirror triangle Check retaining clips (3), replace if paneling (2) in upper rear and loosen catch necessary hook (1) 2 Disconnect electrical connector from outside mirror switch (S50) 3.1 Disconnect electrical connector from left On vehicles with code (C22) Sound package tweeter (H4/33) and right tweeter (H4/34) (FFO) 4 Remove mirror triangle paneling (2) 5 Carefully pull wiring harness for left electrically adjustable and heated outside mirror (M21/1)and right electrically adjustable and heated outside mirror (M21/2) upward out of door paneling until electrical connector for left electrically adjustable and heated outside mirror (M21/1x1) and right electrically adjustable and heated outside mirror (M21/2x1) are accessible 6 Lift lock tab (4) and disconnect left electrically adjustable and heated outside mirror (M21/1x1) and right electrically adjustable and heated outside mirror (M21/2x1) from door wiring harness 7 Unscrew bolts (5) 8 Remove left electrically adjustable and heated Installation:

Slightly slide left electrically outside mirror (M21/1) and right electrically adjustable and heated outside mirror (M21/1) adjustable and heated outside mirror (M21/2) and right electrically adjustable and heated while guiding left electrically adjustable and outside mirror (M21/2) below rubber seal in heated outside mirror (M21/1x1) and right front area electrically adjustable and heated outside mirror (M21/2x1) toward outside through opening in tubular frame. 9 Install in the reverse order 10 Perform function check Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.70-p-9000ff, Remove/install complete outside mirror MODEL 454.0 with CODE (V21) Electrically adjustable and heated outside mirrors (FFO)

AR88.70-P-9000FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3932 · Applies to: 453 · AR: AR88.70-P-9000FG

Remove/install complete outside mirror 12.1.04 MODEL 454.0 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO) P88.70-2331-09 1 Outside mirrors 4 Nut 7 Catch hook 2 Mirror triangle paneling 5 Outside mirror adjustment 8 Bolts 3 Grommet 6 Retaining clip 9 Wiring harness Removal/installation

1 Detach grommet (3) The grommet (3) is held by the nut (4) 2 Unscrew nut (4) 3 Unclip retaining clips (6) from mirror triangle Check retaining clips (6), replace if paneling (2) in upper rear and loosen catch necessary hook (7) 4.1 Disconnect electrical connector from left On vehicles with code (C22) Sound package tweeter and right tweeter (FFO) 5 Remove mirror triangle paneling (2) Installation: Ensure that outside mirror is seated properly. 6 Carefully pull wiring harness (9) for outside mirror upward out of paneling until electrical connector is accessible 7 Disconnect electrical connector from wiring harness (9) 8 Remove bolts (8) 9 Remove outside mirror (1) while guiding Installation:

Slightly slide outside mirror wiring harness (9) and outside mirror (5) (1) below rubber seal in front area toward outside through opening in tubular frame. 10 Install in the reverse order 11 Perform function check Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.70-p-9000fg, Remove/install complete outside mirror MODEL 454.0 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO)

AR88.70-P-9000SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3933 · Applies to: 453 · AR: AR88.70-P-9000SRA

Remove/install complete outside mirror 17.12.15 Model 453.3/4 Shown except code V21 (Electrically adjustable and heated outside mirror (FFO)) 1 Exterior rearview mirrors 2 Bolts 3 Door rubber seal P88.70-2728-11 Shown with code V21 (Electrically adjustable and heated outside mirror (FFO)) 1 Exterior rearview mirrors 2 Bolts 3 Door rubber seal 4 Electrical connector (with code V21 (Electrically adjustable and heated outside mirror (FFO))) P88.70-2727-11 Remove/install

1 Remove mirror triangle paneling 2 Disconnect electrical connector from tweeter Model 453.3/4 with code 810 (Sound system) 3 Detach door rubber seal (3) 4 Disconnect electrical connector (4) from Model 453.3/4 outside mirror (1) with code V21 (Electrically adjustable and heated outside mirrors (FFO)) 5 Unscrew bolts (2) and remove outside mirror (1) 6 Install in the reverse order Check

7 Check outside mirror (1) for proper function Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.70-p-9000sra, Remove/install complete outside mirror Model 453.3/4

AR88.70-P-9060FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3934 · Applies to: 453 · AR: AR88.70-P-9060FF, AR88.70-P-9020FF

Remove/install glass adjustment drive 14.8.03 MODEL 454.0 with CODE (V21) Electrically adjustable and heated outside mirrors (FFO) P88.70-2309-08 1 Bolt 2 Glass adjustment drive 3 Wiring connector Remove/Install

1 Remove mirror glass AR88.70-P-9020FF 2 Remove bolts (1) 3 Lift glass adjustment drive (2) until electrical connector (3) is accessible 4 Disconnect electrical connection (3) 5 Remove mirror adjustment motor (2) 6 Install in the reverse order 7 Perform function check Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.70-p-9060ff, Remove/install glass adjustment drive MODEL 454.0 with CODE (V21) Electrically adjustable and heated outside mirrors (FFO)

AR88.70-P-9020FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3935 · Applies to: 453 · AR: AR88.70-P-9020FF

Remove/install mirror glass 14.8.03 MODEL 454.0 P88.70-2300-08 Shown on vehicle with code (V21) Electrically adjustable and 2 Mirror glass heated outside mirror 3 Catch hook 4 Electrical connections (with code (V21) Electrically 1 Outside mirror adjustable and heated outside mirror (FFO)) 5 Bracket Remove/Install

1 Unclip catch hook (3) for mirror glass (2) from Carefully unclip catch hook (3) to prevent bracket (5) damaging mirror glass (2) Move behind mirror glass (2) in marked area (arrow) and unclip carefully 2.1 Separate electrical connections (4) Only on vehicles with code (V21) Electrically adjustable and heated outside mirror (FFO) 3 Remove mirror glass (2) 4 Install in the reverse order 5.1 Perform function check Only on vehicles with code (V21) Electrically adjustable and heated outside mirror (FFO) Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.70-p-9020ff, Remove/install mirror glass MODEL 454.0

AR88.70-P-9020SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3936 · Applies to: 453 · AR: AR88.70-P-9020SR

Remove/install mirror glass 06.08.2014 MODEL 453 Shown on MODEL 453.0 without CODE V21 (Electrically adjustable and heated outside mirror) 1 Exterior rearview mirrors 2 Mirror glass 3 Catch hook P88.70-2718-05 Shown on MODEL 453.0 with CODE V21 (Electrically adjustable and heated outside mirror) 1 Exterior rearview mirrors 2 Mirror glass 3 Catch hook 4 Electrical connectors P88.70-2719-05 Risk of injury Danger ! caused by irritation of the skin, Wear protective gloves and safety glasses. AS60.00-Z-0008-01R

eyes and respiratory system through contact or inhalation of substances contained in the mirror lens. Remove/install

1 Unclip mirror glass (2) from outside mirror (1) Installation: Ensure that catch hook (3)

arrests completely. 2 Disconnect electrical connector (4) from MODEL 453 outside mirror (1) with CODE V21 (Electrically adjustable and heated door mirrors) 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar88.70-p-9020sr, Remove/install mirror glass MODEL 453

AR88.70-P-9040FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3937 · Applies to: 453 · AR: AR88.70-P-9040FF, AR88.70-P-9020FF

Remove/install outside mirror cover 14.8.03 MODEL 454.0 with CODE (V21) Electrically adjustable and heated outside mirrors (FFO) P88.70-2301-07 1 Outside mirror cover 2 Catch hook 3 Bracket Remove

1 Remove mirror glass AR88.70-P-9020FF 2 Move glass adjustment drive to uppermost Glass adjustment drive is not shown for position until all catch hooks (2) are better illustration of catch hooks (2) accessible 3 Fold outside mirror toward front 4 Unclip bracket (3) with suitable tool 5 Move outside mirror to center position Fold outside mirror in carefully so that bracket (3) does not arrest. 6 Unclip catch hook (2) Catch hook (2) shown with glass adjustment drive removed and outside mirror folded toward front for better illustration 7 Fold outside mirror completely toward rear Fold in outside mirror carefully so that catch hooks (2) and bracket (3) do not arrest 8 Remove outside mirror paneling (1) Install

9 Carefully position outside mirror paneling (1) and arrest catch hook (2) and bracket (3) 10 Move outside mirror to center position 11 Install mirror lens AR88.70-P-9020FF Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.70-p-9040ff, Remove/install outside mirror cover MODEL 454.0 with CODE (V21) Electrically adjustable and heated outside mirrors (FFO)

AR88.70-P-9040SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3938 · Applies to: 453 · AR: AR88.70-P-9040SR, AR88.70-P-9020SR

Remove/install outside mirror trim 06.08.2014 MODEL 453 P88.70-2720-07 Shown on MODEL 453.0 without CODE V21 (Electrically adjustable and heated outside mirror) 1 Exterior rearview mirrors 3 Catch hook 2 Mirror glass 4 Outside mirror trim Remove/install

1 Remove mirror glass (2) from outside mirror AR88.70-P-9020SR (1) 2 Loosen catch hook (3) in outside mirror (1)
*110589035900 Mounting wedge 3 Remove outside mirror paneling (4) 4 Install in the reverse order 110 589 03 59 00 Mounting wedge Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.70-p-9040sr, Remove/install outside mirror trim MODEL 453

PE88.79-P-2055BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3946 · Applies to: 453 · AR: PE88.79-P-2055BBA

Electrical function schematic for mirror heater 19.09.2016 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) with code V21 (Electrically adjustable and heated outside mirrors (FFO)) except code I01 (Automatic air conditioning) Electrical function diagram for mirror heater PE88.79-P-2055-97BBA Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe88.79-p-2055bba, Electrical function schematic for mirror heater Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) with code V21 (Electrically adjustable and heated outside mirrors (FFO)) except code I01 (Automatic air ...

PE88.79-P-2055BBB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3947 · Applies to: 453 · AR: PE88.79-P-2055BBB

Electrical function schematic for mirror heater 19.09.2016 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) with code I01 (Automatic air conditioning) with code V21 (Electrically adjustable and heated outside mirrors (FFO)) Electrical function diagram for mirror heater PE88.79-P-2055-97BBB Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe88.79-p-2055bbb, Electrical function schematic for mirror heater Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) with code I01 (Automatic air conditioning) with code V21 (Electrically adjustable and heated outside mirrors (FFO))

PE88.79-P-2051BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3948 · Applies to: 453 · AR: PE88.79-P-2051BBA

Electrical function schematic for mirror lens adjustment 19.09.2016 Model 453.0/3/4 with code V21 (Electrically adjustable and heated outside mirrors (FFO)) Electrical function schematic for mirror lens PE88.79-P-2051-97BBA adjustment Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe88.79-p-2051bba, Electrical function schematic for mirror lens adjustment Model 453.0/3/4 with code V21 (Electrically adjustable and heated outside mirrors (FFO))

GF88.79-P-9996KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3949 · Applies to: 453 · AR: GF88.79-P-9996KJ

Overview of system components for electric mirror 01.06.2017 Model 453.0/3/4 with code V21 (Electrically adjustable and heated outside mirrors (FFO)) Model 453.0/3/4 with code V35 (Automatically dimming interior mirror) P88.79-2366-79 Shown on model 453.4 A1 Instrument cluster M21/2m1 Horizontal inclination adjustment actuator motor, right A40/3 Smart Radio Multimedia Navigator (Vehicles with code M21/2m2 Vertical inclination adjustment actuator motor, right 535 (smart Media-System)) A52n1 Soft top control unit (model 453.4) M21/2r1 Right mirror heater A67 Inside rearview mirror N3/10 ME-SFI control unit (except model 453.091/391/491) A67h1 Mirror dimming forward light sensor (vehicles with code N10/10 Center SAM control unit V35 (inside rearview mirror automatically dimmable)) A67h2 Mirror dimming rear light sensor (vehicles with code N15/5 Electronic selector lever module control unit (only with V35 (inside rearview mirror automatically dimmable)) code 429 (twinamic) or on model 453.091/391/491) A67h3 Inside rearview mirror dimming (vehicles with code V35 N20 Climate control unit (Vehicles with code I01 (Automatic (inside rearview mirror automatically dimmable)) air conditioning)) F2 Vehicle interior fuse and relay module N20s1 Rear window heater button (Vehicles with code I01 (Automatic air conditioning)) F2k1 Heated rear window/outside mirrors relay N20s4 Defroster button (Vehicles with code I01 (Automatic air conditioning)) L5 Crankshaft position sensor N22/1 Climate control unit (Vehicles with code I01 (Automatic air conditioning)) M14/6s1 Driver door central locking system microswitch N23 Air conditioning control and operating unit (vehicles without code I01 (Automatic air conditioning)) M21/1 Left electrically adjustable and heated outside mirror N23s1 Rear window heater button (vehicles without code I01 (Automatic air conditioning)) M21/1m1 Horizontal inclination adjustment actuator motor, left N93/1 Audio gateway control unit M21/1m2 Vertical inclination adjustment actuator motor, left N127 Electric drive control unit (only model 453.091/391/491) M21/1r1 Left mirror heater S2 Ignition lock M21/2 Right electrically adjustable and heated outside mirror S29/5 Backup lamp activation/idle recognition switch (only with code 410 (5-speed manual transmission)) M21/2b1 Outside air temperature (Vehicles with code I01 S50 Outside mirror adjustment switch (Automatic air conditioning)) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, gf88.79-p-9996kj, Overview of system components for electric mirror Model 453.0/3/4 with code V21 (Electrically adjustable and heated outside mirrors (FFO)) Model 453.0/3/4 with code V35 (Automatically dimming interior mirror)

AR88.79-P-3470FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3951 · Applies to: 453 · AR: AR88.79-P-3470FF

Remove/install outside mirror adjustment switch 14.8.03 MODEL 454.0 with CODE (V21) Electrically adjustable and heated outside mirrors (FFO) P88.79-2118-07 1 Mirror triangle paneling 2 Wiring connector S50 Outside mirror adjustment switch Remove/Install

1 Unclip outside mirror adjustment switch (S50) from mirror triangle paneling (1) in marked area (arrows) with suitable tool 2 Remove outside mirror adjustment switch Do not damage catch lugs, otherwise the (S50) and disconnect electrical connector (2) electrical connector (2) does no longer lock. Installation:

Ensure that electrical connector (2) arrests properly. 3 Remove outside mirror adjustment switch (S50) 4 Install in the reverse order 5 Perform function check Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.79-p-3470ff, Remove/install outside mirror adjustment switch MODEL 454.0 with CODE (V21) Electrically adjustable and heated outside mirrors (FFO)

AR88.79-P-3470SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3952 · Applies to: 453 · AR: AR88.79-P-3470SR

Remove/install outside mirror adjustment switch 06.08.2014 MODEL 453 with CODE V21 (Electrically adjustable and heated door mirrors) Shown on MODEL 453.0 1 Door trim S50 Outside mirror adjustment button group P88.79-2367-05 Remove/install

1 Unclip outside mirror adjustment button group (S50) from door trim (1) 2 Disconnect electrical connector from outside mirror adjustment button group (S50) 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.79-p-3470sr, Remove/install outside mirror adjustment switch MODEL 453 with CODE V21 (Electrically adjustable and heated door mirrors)

GF88.79-P-0996KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3953 · Applies to: 453 · AR: GF88.79-P-0996KJ, GF88.79-P-0006KJ, GF88.79-P-2000KJ, GF88.79-P-2008KJ, GF68.49-P-2000KJ (+1 more)

Table of contents for function description of electric mirrors 16.08.2017 Model 453.0/3/4 with code V21 (Electrically adjustable and heated outside mirrors (FFO)) Model 453.0/3/4 with code V35 (Automatically dimming interior mirror) Electric mirror, function GF88.79-P-0006KJ Heat left/right outside rearview mirrors function Model 453.0/3/4 GF88.79-P-2000KJ with code V21 (Electrically adjustable and heated outside mirrors (FFO)) Mirror lens adjustment left/right outside mirror, Model 453.0/3/4 GF88.79-P-2008KJ function with code V21 (Electrically adjustable and heated outside mirrors (FFO)) Automatic dimming inside rearview mirror, Model 453.0/3/4 GF68.49-P-2000KJ function with code V35 (Automatically dimming interior mirror) Overview of system components for electric GF88.79-P-9996KJ mirror Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf88.79-p-0996kj, Table of contents for function description of electric mirrors Model 453.0/3/4 with code V21 (Electrically adjustable and heated outside mirrors (FFO)) Model 453.0/3/4 with code V35 (Automatically dimming interior mirror)

PE88.79-P-2000BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3954 · Applies to: 453 · AR: PE88.79-P-2000BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of outside mirrors 12.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code V21 (Electrically adjustable and heated outside mirrors (FFO)) Wiring diagram of outside mirrors PE88.79-P-2000-97BBA Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe88.79-p-2000bba, Wiring diagram of outside mirrors Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code V21 (Electrically adjustable and heated outside mirrors (FFO))

PE88.79-P-2000ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3955 · Applies to: 453 · AR: PE88.79-P-2000ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram of outside mirrors 16.12.03 MODEL 454 up to 2.4.06 PE88.79-P-2000-99ZA Wiring diagram of outside mirrors PE88.79-P-2000-99ZA PE88.79-P-2000-60ZA Legend of wiring diagram for outside rearview PE88.79-P-2000-60ZA mirrors OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Arrangement and assignment of the wiring GF00.19-P-1000ZA and plug connectors GF00.19-P-2000ZA Arrangement and assignment of ground GF00.19-P-2000ZA points GF00.19-P-3000ZA Arrangement and assignment of Z connector GF00.19-P-3000ZA sleeves (wiring connections in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE67.00-P-1100ZA Further wiring diagrams PE67.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe88.79-p-2000za, Wiring diagram of outside mirrors MODEL 454 up to 2.4.06

PE88.79-P-2000ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3956 · Applies to: 453 · AR: PE88.79-P-2000ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram of outside mirrors 8.3.06 MODEL 454 as of 3.4.06 PE88.79-P-2000-99ZB Wiring diagram of outside mirrors PE88.79-P-2000-99ZB PE88.79-P-2000-60ZB Legend of wiring diagram for outside mirrors PE88.79-P-2000-60ZB OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Location and assignment of line and plug GF00.19-P-1000ZA connectors GF00.19-P-2000ZA Location and assignment of ground points GF00.19-P-2000ZA GF00.19-P-3000ZA Location and assignment of Z connector GF00.19-P-3000ZA sleeves (line connectors in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE67.00-P-1100ZA Further wiring diagrams PE67.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe88.79-p-2000zb, Wiring diagram of outside mirrors MODEL 454 as of 3.4.06

AN88.80-P-0010FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3957 · Applies to: 453 · AR: AN88.80-P-0010FF, AR88.80-P-1050FF

Install Brabus side skirts 18.2.04 MODEL 454.0 (except 454.034) P88.80-2091-08 1 Standard side sill protective molding 3 Clip 4 Lugs 2 BRABUS side skirts Remove

Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A

toppling off of the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 1 Raise vehicle. 2 Remove left and right standard side sill protective molding (1) Remove/install side sill protective molding AR88.80-P-1050FF

Install

3 Check that BRABUS side skirts (2) is matched correctly and then paint 4 Clean gluing surface on BRABUS side skirts Bonding surface must be free of dust and (2) grease. 5 Fit BRABUS side skirts (2) to vehicle and fasten with clips (3) on left and right 6 Clip in expansion clips (arrows) from bottom 7 Remove protective foil from BRABUS side Carefully remove protective foil from lugs skirts (2) (4) in horizontal direction to prevent lugs (4) from being torn off prematurely 8 Press on BRABUS side skirts (2) Ensure that BRABUS side skirts (2) is seated properly. 9 Lower vehicle 10 Place certificate in vehicle Certificate included in scope of delivery 11.1 Add special equipment to the vehicle data At workshops without DMS Autoline 8.0 card and to the online vehicle data card dealer system. Code (E71) BRABUS side skirts Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, an88.80-p-0010ff, Install Brabus side skirts MODEL 454.0 (except 454.034)

AR88.80-P-1050FB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3958 · Applies to: 453 · AR: AR88.80-P-1050FB

Remove/install side sill protective molding 9.3.05 MODEL 454.0 (except 454.034) with CODE (E71) Side skirts, BRABUS MODEL 454.034 P88.80-2115-08 1 BRABUS side skirts 3 Expansion clip 4 Expansion clip 2 Expansion clip Remove/install

Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A

toppling off of the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 1 Raise vehicle 2 Remove expansion clips (3) in left and right Installation:

Replace damaged front fender liner. expansion clips (3). 3 Remove expansion clips (4) in left and right Installation: Replace damaged rear fender liner. expansion clips (4). 4 Remove expansion clips (2) in lower area of Installation: Replace damaged

BRABUS side skirts (1) expansion clips (2). 5 Remove BRABUS side skirts (1) from Carefully remove BRABUS side skirts (1) longitudinal member outer shell. from longitudinal member outer shell to prevent damaging paint. Installation: Check retaining clamps in BRABUS side skirts (1), replace if necessary. 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.80-p-1050fb, Remove/install side sill protective molding MODEL 454.0 (except 454.034) with CODE (E71) Side skirts, BRABUS MODEL 454.034

AR88.80-P-1050FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3959 · Applies to: 453 · AR: AR88.80-P-1050FF

Remove/install side sill protective molding 14.8.03 MODEL 454.0 (except 454.034) except CODE (E71) Side skirts, BRABUS P88.80-2122-09 1 Front rocker panel 3 Expansion clip 5 Bracket 2 Rear rocker panel 4 Expansion clip Remove/install

Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A

toppling off of the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 1 Raise vehicle 2 Remove expansion clips (4) from front rocker Installation: Replace damaged panel (1) or rear rocker panel (2). expansion clips (4). 3 Remove expansion clips (3) from front rocker Installation:

Replace damaged panel (1) or rear rocker panel (2) in area of expansion clips (3). fender liner. 4.1 Lightly pull front rocker panel (1) away from When removing front rocker panel (1). vehicle and pull off toward front Carefully remove front rocker panel (1) to prevent paint damage Installation:

Position front rocker panel (1) with brackets (5) inserted and press on 5.1 Lightly pull rear rocker panel (2) away from When removing rear rocker panel (2). vehicle and pull off toward rear Carefully remove rear rocker panel (2) to prevent paint damage Installation:

Position rear rocker panel (2) with brackets (5) inserted and press on 6 Unscrew bracket (5) from longitudinal Installation:

Check bracket (5) for member damage, replace if necessary. Insert bracket (5) into front rocker panel (1) or rear rocker panel (2) 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar88.80-p-1050ff, Remove/install side sill protective molding MODEL 454.0 (except 454.034) except CODE (E71) Side skirts, BRABUS

Notes on paintwork repairs

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4150 · Applies to: 453 · AR: AR88.20-P-2200SRA, AR82.10-P-4731SR, AR88.60-P-2000SR, AR88.60-P-0005SRE, AR72.20-P-1020SRA (+3 more)

AH98.00-P-9408-02MCC

Mask off and cover in paint stage 2/3 1.1 Unfasten rear bumper
Paint stage 2 AR88.20-P-2200SRA 1.2 Remove rear bumper
Paint stage 3 AR88.20-P-2200SRA 2 Remove rear lamp unit
AR82.10-P-4731SR 3 Remove tank flap Paint stage 2 on right side of vehicle. Model 453.34/35/36 AR88.60-P-2000SR 4 Remove socket flap Model 453.391 Paint stage 2 on right side of vehicle. 5 Mask off tank filler recess Paint stage 2 on right side of vehicle. http://xentryportal.i.daimler.com

under category "Guidelines for paint technology" 6 Mask off socket recess Paint stage 2 on right side of vehicle. http://xentryportal.i.daimler.com

under category "Guidelines for paint technology" 7 Remove tank filler recess Paint stage 3 on right side of vehicle. Model 453.34/35/36 AR88.60-P-2000SR 8 Remove socket recess Paint stage 3 on right side of vehicle. Model 453.391 AR88.60-P-0005SRE 9 Install fuel filler flap, mask off inside of fuel Model 453.34/35/362 filler flap and close tank filler recess
Paint stage 2 on right side of vehicle. 10 Install socket flap, mask off inside of socket Model 453.391 flap and close socket recess Paint stage 2 on right side of vehicle. 11 Mask off all openings using masking tape
http://xentryportal.i.daimler.com

under category "Guidelines for paint technology" 12 Mask off rear fender all way round
http://xentryportal.i.daimler.com

under category "Guidelines for paint technology" 13 Cover areas of the vehicle not to be painted http://xentryportal.i.daimler.com

with foil under category "Guidelines for paint technology" Mask off and cover in paint stage1E 14 Remove rear bumper
AR88.20-P-2200SRA 15 Remove rear cross member under the bumper

16 Remove bracket for rear bumper
17 Remove liftgate AR72.20-P-1020SRA 18 Remove gas-filled strut from liftgate
AR72.20-P-2832SR 19 Remove edge guard for liftgate cutout in area of rear fender
20 Remove rear lamp unit
AR82.10-P-4731SR 21 Remove fender liner in rear fender
AR88.10-P-1400SRA 22 Remove tank filler recess On right side of vehicle. Model 453.34/35/36 AR88.60-P-2000SR 23 Remove socket recess
On right side of vehicle. Model 453.391 AR88.60-P-0005SRE 24 Remove front door AR72.10-P-0500SRA 25 Remove edge guard for door cutout of front door
26 Detach floor covering
27 Mask off all openings using masking tape http://xentryportal.i.daimler.com

under category "Guidelines for paint technology" 28 Mask off rear fender all way round
http://xentryportal.i.daimler.com

under category "Guidelines for paint technology" 29 Cover areas of the vehicle not to be painted http://xentryportal.i.daimler.com

with foil under category "Guidelines for paint technology" Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar98.00-p-0207sr, Assembly and covering work when painting the rear fender Model 453.3

Notes on paintwork repairs

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4152 · Applies to: 453 · AR: AR88.20-P-2200SRA, AR82.10-P-4731SR, AR88.60-P-2000SR, AR88.60-P-0005SRE, AR72.20-P-1020SRC (+2 more)

AH98.00-P-9408-02MCC

Mask off and cover in paint stage 2/3 1.1 Unfasten rear bumper Paint stage 2 AR88.20-P-2200SRA 1.2 Remove rear bumper Paint stage 3 AR88.20-P-2200SRA 2 Remove rear lamp unit AR82.10-P-4731SR 3 Remove tank flap Paint stage 2 on right side of vehicle. Model 453.44/45/46 AR88.60-P-2000SR 4 Remove socket flap Model 453.491 Paint stage 2 on right side of vehicle. 5 Mask off tank filler recess Model 453.44/45/46 Paint stage 2 on right side of vehicle. http://xentryportal.i.daimler.com

Section "Guidelines for paint technology" 6 Mask off socket recess Model 453.491 Paint stage 2 on right side of vehicle. http://xentryportal.i.daimler.com

Section "Guidelines for paint technology" 7 Remove tank filler recess Paint stage 3 on right side of vehicle. Model 453.44/45/46 AR88.60-P-2000SR 8 Remove socket recess Paint stage 3 on right side of vehicle. Model 453.491 AR88.60-P-0005SRE 9 Install tank filler flap, mask off inside of tank Model 453.44/45/46 filler flap and close tank filler recess Paint stage 2 on right side of vehicle. 10 Install socket flap, mask off inside of socket Model 453.491 flap and close socket recess Paint stage 2 on right side of vehicle 11 Mask off all openings using masking tape http://xentryportal.i.daimler.com

Section "Guidelines for paint technology" 12 Mask off rear fender all way round http://xentryportal.i.daimler.com

Section "Guidelines for paint technology" 13 Cover areas of the vehicle not to be painted http://xentryportal.i.daimler.com

with foil Section "Guidelines for paint technology" Mask off and cover in paint stage1E 14 Remove rear bumper AR88.20-P-2200SRA 15 Remove liftgate AR72.20-P-1020SRC 16 Remove edge guard for liftgate cutout in area of rear fender 17 Remove rear lamp unit AR82.10-P-4731SR 18 Remove fender liner in rear fender AR88.10-P-1400SRA 19 Remove tank filler recess On right side of vehicle. Model 453.44/45/46 AR88.60-P-2000SR 20 Remove socket recess On right side of vehicle. Model 453.491 AR88.60-P-0005SRE 21 Remove front door AR72.10-P-0500SRA 22 Remove edge guard for door cutout of front door 23 Detach floor covering 24 Mask off all openings using masking tape http://xentryportal.i.daimler.com

Section "Guidelines for paint technology" 25 Mask off rear fender all way round http://xentryportal.i.daimler.com

Section "Guidelines for paint technology" 26 Cover areas of the vehicle not to be painted http://xentryportal.i.daimler.com

with foil Section "Guidelines for paint technology" Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar98.00-p-0207src, Assembly and covering work when painting the rear fender Model 453.4