453 — fortwo / forfour (2014-2024) — Brakes

Workshop and reference excerpts for 453 — fortwo / forfour (2014-2024) in the Brakes system.

152 excerpts from 1 sources.

2014-2024 Smart Fortwo 453 Workshop Manual.pdf

Parking brake indicator switch

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 133 · Applies to: 453 · AR: PE42.20-P-2000BBA, PE54.30-P-2101BBA, PE54.18-P-2300BBB, PE54.21-P-2127BBC, PE80.20-P-2000BBA (+5 more)

S12 Parking brake indicator switch Model 453.0 (except 453.091), 453.3 (except PE42.20-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 S12 Parking brake indicator switch Model 453.0 (except 453.091), 453.3 (except PE54.30-P-2101BBA 453.391), 453.4 (except 453.491) up to model year 2020 S15/1 Trunk lid/liftgate release switch 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 S15/1 Trunk lid/liftgate release switch Model 453.0 (except 453.091), 453.3 (except PE54.21-P-2127BBC 453.391), 453.4 (except 453.491) up to model year 2020 N10/10, plug S2 P1, P2 S15/1 Trunk lid/liftgate release switch 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 S15/1 Trunk lid/liftgate release switch 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 S15/3 Driver trunk lid/liftgate control button Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2600BBA 453.391), 453.4 (except 453.491) up to model year 2020 S15/3 Driver trunk lid/liftgate control button 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 S15/3 Driver trunk lid/liftgate control button Model 453.0 (except 453.091), 453.3 (except PE54.21-P-2127BBC 453.391), 453.4 (except 453.491) up to model year 2020 N10/10, plug S2 P1, P2 S2 Ignition lock Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBB 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AA S2 Ignition lock Model 453.0 (except 453.091), 453.3 (except PE54.21-P-2135BBA 453.391), 453.4 (except 453.491) up to model year 2020 S2/3 Engine start/stop button Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2600BBA 453.391), 453.4 (except 453.491) up to model year 2020 S2/3 Engine start/stop button 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 S2/3 Engine start/stop button Model 453.0 (except 453.091), 453.3 (except PE15.00-P-2103BBA 453.391), 453.4 (except 453.491) up to model year 2020 S2/3 Engine start/stop button Model 453.0 (except 453.091), 453.3 (except PE54.21-P-2127BBA 453.391), 453.4 (except 453.491) up to model year 2020 N10/11 S20/1 Power window switch group, driver side Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2600BBA 453.391), 453.4 (except 453.491) up to model year 2020 S20/1 Power window switch group, driver side 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 S20/1 Power window switch group, driver side Model 453.0 (except 453.091), 453.3 (except PE72.29-P-2001BBC 453.391), 453.4 (except 453.491) up to model year 2020 with code 584 (Power windows with convenience feature and reversing function) except code 583 (Power windows) S21/2 Right power window switch Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2600BBA 453.391), 453.4 (except 453.491) up to model year 2020 S29/5 Backup light activation/idle recognition switch Model 453.0/3/4 with transmission 700.4 up to PE27.19-P-2102BBA model year 2020 with code 429 (twinamic) S29/5 Backup light activation/idle recognition switch Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBB 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AA S29/5 Backup light activation/idle recognition switch 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 S29/5 Backup light activation/idle recognition switch Model 453.0 (except 453.091), 453.3 (except PE54.21-P-2127BBB 453.391), 453.4 (except 453.491) up to model year 2020 N10/10, plug S1 S29/5 Backup light activation/idle recognition switch Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 S4 Combination switch Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBB 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AA S4 Combination switch Model 453.0 (except 453.091), 453.3 (except PE54.25-P-2250BBA 453.391), 453.4 (except 453.491) up to model year 2020 Page 23 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

L6/4

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 174 · Applies to: 453 · AR: PE42.45-P-2000BEA, PE00.19-P-2600BEA, PE54.15-P-2001BEC, PE72.29-P-2001BEA, PE72.29-P-2001BEB (+5 more)

right rear rpm sensor Model 453.091/391/491 up to model year PE42.45-P-2000BEA 2020 LHD Left-hand drive vehicle Model 453.091/391/491 up to model year PE00.19-P-2600BEA 2020 M10/3 Left power window motor Model 453.091/391/491 up to model year PE54.15-P-2001BEC 2020 F2 Plug AB-AE M10/3 Left power window motor 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) M10/3 Left power window motor 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)) M10/3 Left power window motor 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) M10/4 Right power window motor Model 453.091/391/491 up to model year PE54.15-P-2001BEC 2020 F2 Plug AB-AE M10/4 Right power window motor 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) M10/4 Right power window motor 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)) M10/4 Right power window motor 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) M12 Folding roof drive unit Model 453.091 up to model year 2020 PE77.20-P-2200BEA M12/7 Left soft top drive Model 453.491 up to model year 2020 PE77.39-P-2202BEA M12/8 Right soft top drive Model 453.491 up to model year 2020 PE77.39-P-2202BEA M14/10 Fuel filler flap CL [ZV] motor Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK M14/10 Fuel filler flap CL [ZV] motor Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version M14/31 Trunk lid/liftgate locking element Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK M14/31 Trunk lid/liftgate locking element Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version M14/4 Charge socket lock Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) M14/4 Charge socket lock Model 453.091/391/491 up to model year PE54.21-P-2154BEB 2020 with code 908 (22 kW on-board charger) M14/5 Right door CL [ZV] motor Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK M14/5 Right door CL [ZV] motor Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version M14/5 Right door CL [ZV] motor Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) M14/6 Left door CL [ZV] motor Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK M14/6 Left door CL [ZV] motor Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version M14/6 Left door CL [ZV] motor Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) M14/7 Rear-end door CL [ZV] motor Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 M14/7 Rear-end door CL [ZV] motor Model 453.391/491 up to model year 2020
PE68.49-P-2200BEA with code 494 (USA version) M14/7 Rear-end door CL [ZV] motor Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK M14/7 Rear-end door CL [ZV] motor Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version M14/7 Rear-end door CL [ZV] motor Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) Page 9 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

N30/4

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 178 · Applies to: 453 · AR: PE42.45-P-2000BEA, PE83.70-P-2102BEA, PE54.15-P-2001BEB, PE54.65-P-2101BEA, PE43.05-P-2000BEA (+5 more)

Electronic Stability Program control unit Model 453.091/391/491 up to model year PE42.45-P-2000BEA 2020 N33/5 High-voltage PTC heater Model 453.091/391/491 up to model year PE83.70-P-2102BEA 2020 N49 Steering angle sensor Model 453.091/391/491 up to model year PE42.45-P-2000BEA 2020 N49 Steering angle sensor Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA N62 Parking system control unit Model 453.091/391/491 up to model year PE54.65-P-2101BEA 2020 with code 220 (Rear parking assist) N65/3 Brake booster vacuum pump control unit Model 453.091/391/491 up to model year PE43.05-P-2000BEA 2020 N68 Steering assist control unit Model 453.091/391/491 up to model year PE00.19-P-2150BEA 2020 Interior compartment and suspension N68 Steering assist control unit Model 453.091/391/491 up to model year PE15.00-P-2101BEA 2020 N68 Steering assist control unit Model 453.091/391/491 up to model year PE46.35-P-2000BEA 2020 N68 Steering assist control unit Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA N70/1 Sliding roof control unit Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA N70/1 Sliding roof control unit Model 453.091/391/491 up to model year PE54.15-P-2001BEC 2020 F2 Plug AB-AE N70/1 Sliding roof control unit Model 453.091 up to model year 2020 PE77.20-P-2200BEA N76/1 Blower regulator Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA N76/1 Blower regulator 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) N82/2 Battery management system control unit Model 453.091/391/491 up to model year PE54.10-P-2104BEA 2020 N83 Onboard charger 3kW Engine 780.997 in model 453.091/391/491 up PE08.00-P-2000BEA to model year 2020 N83 Onboard charger 3kW Engine 780.997 in model 453.091/391/491 up PE08.10-P-2002BEA to model year 2020 N83 Onboard charger 3kW Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) N83 Onboard charger 3kW Model 453.091/391/491 up to model year PE54.21-P-2154BEB 2020 with code 908 (22 kW on-board charger) N83/1 DC/DC converter control unit Model 453.091/391/491 up to model year PE00.19-P-2131BEA 2020 N83/1 DC/DC converter control unit Engine 780.997 in model 453.091/391/491 up PE08.00-P-2000BEA to model year 2020 N83/1 DC/DC converter control unit Model 453.091/391/491 up to model year PE15.00-P-2101BEA 2020 N83/1 DC/DC converter control unit Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 N83/1 DC/DC converter control unit Model 453.091/391/491 up to model year PE54.10-P-2003BEA 2020 N83/1 DC/DC converter control unit Model 453.091/391/491 up to model year PE54.10-P-2104BEA 2020 N83/1 DC/DC converter control unit Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) N83/1 DC/DC converter control unit Model 453.091/391/491 up to model year PE54.21-P-2154BEB 2020 with code 908 (22 kW on-board charger) N83/1 DC/DC converter control unit Model 453.091/391/491 up to model year PE83.55-P-2000BEA 2020 N83/1 DC/DC converter control unit Model 453.091/391/491 up to model year PE83.70-P-2102BEA 2020 N83/10 Onboard charger 22 kW Engine 780.997 in model 453.091/391/491 up PE08.00-P-2000BEA to model year 2020 N83/10 Onboard charger 22 kW Engine 780.997 in model 453.091/391/491 up PE08.10-P-2002BEA to model year 2020 N83/10 Onboard charger 22 kW Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 N83/10 Onboard charger 22 kW Model 453.091/391/491 up to model year PE54.10-P-2109BEA 2020 N83/10 Onboard charger 22 kW Model 453.091/391/491 up to model year PE54.21-P-2154BEB 2020 with code 908 (22 kW on-board charger) N83/2 Charge monitoring control unit Model 453.091/391/491 up to model year PE00.19-P-2131BEA 2020 N83/2 Charge monitoring control unit Engine 780.997 in model 453.091/391/491 up PE08.00-P-2000BEA to model year 2020 Page 13 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

To be performed by the

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 474 · Applies to: 453 · AR: AP42.00-P-4290MCC, AP18.00-P-0101SS, AP40.10-P-4051EW, AP82.10-P-8252EW, AP82.10-P-8250EW

Service Advisor (where market- specific conditions require). Fully process all acceptance items and the maintenance items listed in the service sheet, only then is the service scope completely performed. Brake system Perform brake test and enter the result in the table AP42.00-P-4290MCC Vehicle interior Replace activated charcoal particle filter Vehicles with air conditioning AP83.00-P-8384S Engine compartment Check all visible parts in engine compartment for damage and leaks AP00.20-P-0055S Replace air filter element AP09.10-P-0980S Engine: Change oil and oil filter Engine 281.910 AP18.00-P-0101S Engine 281.920 AP18.00-P-0101SS Underside of vehicle Check condition of steering and tie rods AP46.00-P-4651S Check condition of front axle and front axle ball joints AP33.10-P-3358S Check condition of rear axle and rear axle ball joints AP35.20-P-3552S Check condition of suspension struts or shock absorbers and springs AP32.25-P-3255S Check poly-V-belt in visible area for signs of wear AP13.22-P-1352S Check tires for damage and crack formation and enter result in table AP40.10-P-4051EW Tires Customer package Correct tire pressure and enter set tire pressure in table AP40.15-P-4061C Vehicle exterior Customer package Check exterior lights for proper operation AP82.10-P-8252EW Check operation of headlamp range adjustment AP82.10-P-8250EW Front flap Customer package Windshield washer system: Check/correct fluid level AP82.35-P-8210S When using cleaning

compounds for summer/winter, and depending on the ambient temperature, observe the mixing ratio. Vehicle interior Customer package Check lamps in the instrument cluster and interior illumination for proper operation AP54.30-P-5453S Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-1240sm, OVERVIEW for service sheet, USA Model 453 (except 453.09/39/49)

Front

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 488 · Applies to: 453 · AR: AR42.20-P-0540FF, AP82.35-P-8252FF, AP00.20-P-0042FF, AP31.11-P-3121FF, AP31.11-P-3130FF (+5 more)

Rear Parking brake Left Right Check free travel of hand brake, adjust if Adjust subject to a separate repair order. AR42.20-P-0540FF

necessary Check bodywork for paintwork damage Without dismantling parts. Check painted outer surfaces, body edges and chipping-prone areas for damage, if necessary repair vehicle paintwork against a separate order. Check horn for proper operation Check indicator lamps and Interior illumination for proper operation Check electrical consumers for proper Operate consumer switch operation depending on the vehicle and check whether the indicator lamp lights up equipment: or the adjustment motor starts. Heated seats, rear window heater, power windows, mirror adjustment and glass sliding roof Check controls of heater and ventilation for proper operation and ease of movement Check windshield wiper for condition and AP82.35-P-8252FF windshield washer system for proper operation and spray pattern Check rear window wiper for condition and AP82.35-P-8252FF rear window washer system for proper operation and spray pattern Reset maintenance interval display in AP00.20-P-0042FF instrument cluster Additional operations Scope must be marked by service advisor Completed skid mounting points

Every year Lubricate trailer hitch with detachable ball AP31.11-P-3121FF on vehicles with code (E50) Trailer hitch

neck and check for function Every year Clean trailer hitch with detachable ball neck AP31.11-P-3130FF on vehicles with code (E50) Trailer hitch

after testing Annually or every 10,000 km, if oil change is carried out outside the regular service scope Engine oil and filter change AP18.00-P-0101FB on 130 kW BRABUS engine Every 2 years Replace battery in vehicle key See vehicle operating instructions Document change of battery in service booklet. Annually or every 20,000 km (gasoline engines and diesel engines with mineral oil filling) Annually or 25,000 km (diesel engines with synthetic oil filling) Engine oil and filter change AP18.00-P-0101FF on gasoline engine except 130 kW BRABUS engine AP18.00-P-0101FB on 130 kW BRABUS engine AP18.00-P-0101FG on diesel engines

Every 40,000 km Replace spark plugs AP15.10-P-1580FB on 130 kW BRABUS engine AP15.10-P-1580FF on gasoline engine M134 or M135 Every 40,000 km Check valve clearance, set if necessary AP05.30-P-0560FF on 90 kW-gasoline engine For the first time after 80,000 km, then every 40,000 km Remove brake drums and check adjusting AR42.10-P-1010FF

On vehicles without code (30Y) disk mechanism of drum brake for damage as well brakes on rear axle as boots of wheel brake cylinder for leaks Every 3 years or at 60,000 km Replace coolant AP20.00-P-2080FG on diesel engines

Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-0001ff, SERVICE SHEET for Active Service System (ASSYST) MODEL 454.0

AP00.20-P-0081B

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 492 · Applies to: 453 · AR: AP42.00-P-4290SM, AP42.00-P-4290MCC, AP42.00-P-4290RR, AP42.00-P-4290FF

Spring Inspection 11.04.2017 Model 450, 451, 452, 453, 454 Spring inspection P00.20-2874-11 Customer Order number VIN/license plate number Current mileage Completion time/date Notes/explanations The following activities are hereby confirmed: - Completion of relevant service operations Signature S Input condition not OK: Completed

Brake system Perform brake test and enter the result in the table Model 450.3/4 AP42.00-P-4290SM Model 451.3/4, 453 AP42.00-P-4290MCC Model 452.3/4 AP42.00-P-4290RR Model 454.0 AP42.00-P-4290FF Vehicle exterior Check condition of vehicle exterior Model 450, 451, 452, 453, 454 Model 453 AP60.00-P-0050S Check condition of windshield AP67.10-P-6750A Check condition of wiper blades Model 450, 451, 452, 453, 454 Model 453 AP82.30-P-8253G Front flap Brake system: Check fluid level Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-0081b, Spring Inspection Model 450, 451, 452, 453, 454

Model 450.3/4

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 493 · Applies to: 453 · AR: AP42.10-P-4210SM, AP42.10-P-4210MCC, AP42.10-P-4210RR, AP42.10-P-4210FF, AP20.00-P-2010SM (+5 more)

AP42.10-P-4210SM Model 451.3/4 AP42.10-P-4210MCC Model 452.3/4 AP42.10-P-4210RR Model 453 AP42.10-P-4210S Model 454.0 AP42.10-P-4210FF Check coolant level Model 450, 451, 452, 453, 454 Model 450.3, 450.4 (except 450.418) AP20.00-P-2010SM with engine 660.940 Model 450.3/4 with engine 160.910/920 Model 451.3/4 with engine 132.9, AP20.00-P-2010MCC 660.9 Model 451.391/491 with engine AP20.00-P-2010MEV 780.009 Model 452.3/4 with engine AP20.00-P-2010RR 160.921/922/923 Model 453 with engine 281 AP20.30-P-2050S Model 454.0 with engine 122.9, AP20.00-P-2010FF 134.9, 135.9 Model 454.0 with engine 639.9 AP20.00-P-2010FG Windshield washer system: Check/correct fluid level Model 450.3, 450.4 (except 450.418) AP82.35-P-8210SM Model 451.3/4 AP82.35-P-8210MCC Model 452.3/4 AP82.35-P-8210RR Model 453 AP82.35-P-8210S Model 454.0 AP82.35-P-8210FF Use summer/winter cleaner

depending on season. Vehicle front end, vehicle rear end Check exterior lights for proper operation Model 450, 451, 452, 453, 454 Model 451.3/4 AP82.10-P-8251MCC Model 453 AP82.10-P-8252EW Vehicle interior Check the windshield wipers and windshield washer system for proper operation Model 450.3, 450.4 (except 450.418) AP82.35-P-8252SM Model 451.3/4, 453 AP82.35-P-8252MCC Model 452.3/4 AP82.35-P-8252RR Model 454.0 AP82.35-P-8252FF Check TIREFIT tire sealant Model 450.3/4 AP40.10-P-4054SM Model 451.3/4, 453 AP40.10-P-4054MCC Model 452.3/4 AP40.10-P-4054RR Model 454.0 AP40.10-P-4054FF except code R02 (Spare wheel) Enter TIREFIT expiration date here:

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If the TIREFIT expiration date has been reached. Replace TIREFIT, invoice as additional operation. Engine compartment Check all visible parts in engine compartment for damage and leaks Model 450, 451, 452, 453, 454 Model 453 AP00.20-P-0055S Check/correct engine oil level Model 450, 451, 452, 453, 454 Model 451 with engine 132, 660 AP18.00-P-1811MS Model 453 with engine 281 Underside of vehicle Check condition of vehicle underside Model 450, 451, 452, 453, 454 Model 451, 453 AP60.00-P-0051S Tires, wheels Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-0081b, Spring Inspection Model 450, 451, 452, 453, 454

AP00.20-P-0080B

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 495 · Applies to: 453 · AR: AP42.00-P-4290MCC, AP42.10-P-4247US, AP20.00-P-2010MCC, AP20.00-P-2010MEV

Travel inspection 11.04.2017 Model 451, 453 Travel inspection P00.20-2874-11 Customer Order number VIN/license plate number Current mileage Completion time/date Notes/explanations The following activities are hereby confirmed: - Completion of relevant service operations Signature T Input condition not OK: Completed

Brake system Perform brake test and enter the result in the table AP42.00-P-4290MCC Vehicle exterior Check condition of windshield AP67.10-P-6750A Check condition of wiper blades Model 451, 453 Model 453 AP82.30-P-8253G Front flap Brake system: Check fluid level AP42.10-P-4247US Check coolant level Model 451.3/4 with engine 132.9, AP20.00-P-2010MCC 660.9 Model 451.391/491 with engine AP20.00-P-2010MEV 780.009 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-0080b, Travel inspection Model 451, 453

AP00.20-P-0082B

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 503 · Applies to: 453 · AR: AP42.00-P-4290SM, AP42.00-P-4290MCC, AP42.00-P-4290RR, AP42.00-P-4290FF

Winter Inspection 11.04.2017 Model 450, 451, 452, 453, 454 Winter inspection P00.20-2874-11 Customer Order number VIN/license plate number Current mileage Completion time/date Notes/explanations The following activities are hereby confirmed: - Completion of relevant service operations Signature W Input condition not OK: Completed

Brake system Perform brake test and enter the result in the table Model 450.3/4 AP42.00-P-4290SM Model 451.3/4, 453 AP42.00-P-4290MCC Model 452.3/4 AP42.00-P-4290RR Model 454.0 AP42.00-P-4290FF Vehicle exterior Check condition of vehicle exterior Model 450, 451, 452, 453, 454 Model 453 AP60.00-P-0050S Check condition of windshield AP67.10-P-6750A Check condition of wiper blades Model 450, 451, 452, 453, 454 Model 453 AP82.30-P-8253G Front flap Brake system: Check fluid level Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-0082b, Winter Inspection Model 450, 451, 452, 453, 454

Model 450.3/4

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 504 · Applies to: 453 · AR: AP42.10-P-4210SM, AP42.10-P-4210MCC, AP42.10-P-4210RR, AP42.10-P-4210FF, AP20.00-P-2010SM (+5 more)

AP42.10-P-4210SM Model 451.3/4 AP42.10-P-4210MCC Model 452.3/4 AP42.10-P-4210RR Model 453 AP42.10-P-4210S Model 454.0 AP42.10-P-4210FF Check coolant level Model 450, 451, 452, 453, 454 Model 450.3, 450.4 (except 450.418) AP20.00-P-2010SM with engine 660.940 Model 450.3/4 with engine 160.910/920 Model 451.3/4 with engine 132.9, AP20.00-P-2010MCC 660.9 Model 451.391/491 with engine AP20.00-P-2010MEV 780.009 Model 452.3/4 with engine AP20.00-P-2010RR 160.921/922/923 Model 453 with engine 281 AP20.30-P-2050S Model 454.0 with engine 122.9, AP20.00-P-2010FF 134.9, 135.9 Model 454.0 with engine 639.9 AP20.00-P-2010FG Windshield washer system: Check/correct fluid level Model 450.3, 450.4 (except 450.418) AP82.35-P-8210SM Model 451.3/4 AP82.35-P-8210MCC Model 452.3/4 AP82.35-P-8210RR Model 453 AP82.35-P-8210S Model 454.0 AP82.35-P-8210FF Use summer/winter cleaner

depending on season. Battery Check condition of battery Model 450.3/4 AR54.10-P-1129SM Model 451.3/4 AR54.10-P-1129MCC Model 452.3/4 AR54.10-P-1129RR Model 453 AR54.10-P-1129SR Model 454.0 AR54.10-P-1129FF Vehicle front end, vehicle rear end Check exterior lights for proper operation Model 450, 451, 452, 453, 454 Model 451.3/4 AP82.10-P-8251MCC Model 453 AP82.10-P-8252EW Vehicle interior Check the windshield wipers and windshield washer system for proper operation Model 450.3, 450.4 (except 450.418) AP82.35-P-8252SM Model 451.3/4, 453 AP82.35-P-8252MCC Model 452.3/4 AP82.35-P-8252RR Model 454.0 AP82.35-P-8252FF Check TIREFIT tire sealant Model 450.3/4 AP40.10-P-4054SM Model 451.3/4, 453 AP40.10-P-4054MCC Model 452.3/4 AP40.10-P-4054RR Model 454.0 AP40.10-P-4054FF except code R02 (Spare wheel) Enter TIREFIT expiration date here:

---

If the TIREFIT expiration date has been reached. Replace TIREFIT, invoice as additional operation. Engine compartment Check all visible parts in engine compartment for damage and leaks Model 450, 451, 452, 453, 454 Model 453 AP00.20-P-0055S Check/correct engine oil level Model 450, 451, 452, 453, 454 Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-0082b, Winter Inspection Model 450, 451, 452, 453, 454

AR25.20-P-0070FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1296 · Applies to: 453 · AR: AR25.20-P-0070FF, AP42.10-P-4210FF

Bleed clutch operating system 5.12.03 MODELS 454.0 with TRANSMISSION 717.470 /471 /473 /478 P25.20-2030-07 Shown on vehicle with transmission 717.471 1 Brake fluid reservoir 3 Bleed valve 5 Brake fluid receptacle 2 Cap 4 Slave cylinder Bleeding Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A

brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Unscrew cap (2) of brake fluid reservoir (1) 2 Connect brake fluid changing unit to brake Observe owner's manual of brake fluid fluid reservoir (1) and switch on replacement unit. General brake fluid Sheet 330.1 BB00.40-P-0330-01A

Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40-P-0331-00A

Brake fluid replacement unit WE58.40-Z-1001-07A 454589019100

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 below the hoist support points specified by the vehicle manufacturer. 3 Raise vehicle. 4 Remove dust cap from vent valve (3), connect hose of brake fluid receptacle (5) to vent valve (3) of slave cylinder (4) and open vent valve (3) 5 Close vent valve (3), detach hose of brake Only close the vent valve (3) when the fluid receptacle (5) and press dust cap onto brake fluid escapes free of bubbles and the vent valve (3) without contamination (brake fluid is light in color). *BA25.20-P-1005-01D

6 Lower vehicle 7 Switch off brake fluid replacement unit and Observe owner's manual of brake fluid

disconnect replacement unit. Brake fluid replacement unit WE58.40-Z-1001-07A 454589019100

8 Check brake fluid level and correct if necessary Brake system - inspect fluid level AP42.10-P-4210FF

9 Screw on cap (2) of brake fluid reservoir (1) 10 Check function of clutch operator 11 Check leaktightness of brake system AR42.10-P-0100-01FF If a test trip is carried out after a repair to the hydraulic system, the brakes are to be applied with an ABS control. Clutch mechanism Number Designation Model 454.0 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar25.20-p-0070ff, Bleed clutch operating system MODELS 454.0 with TRANSMISSION 717.470 /471 /473 /478

AR29.10-P-4597FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1459 · Applies to: 453 · AR: AR29.10-P-4597FF, AR42.10-P-0040FF

Removing and installing brake pedal 11.9.03 MODELS 454.0 P29.10-2063-08 1 Brake pedal 3 Retaining clamp 5 Bearing bushes 2 Screw 4 Pin S9/1 Stop lamp switch Removal/installation

1 Remove stop lamp switch (S9/1) and put to AR42.10-P-0040FF one side with electrical line connected 2 Unclip retaining clamp (3) from bolt (4) and pull out bolt (4) 3 Unscrew nut of bolt (2) Installation: Replace nut of bolt (2).

*BA29.10-P-1003-02E

4 Pull out bolt (2) and remove brake pedal (1) Installation:

Replace bolt (2). Pay attention to correct seat of bearing bushes (5) in the brake pedal (1). 5 Install in the reverse order Pedals, bearing bracket

Number Designation Model 454.0 BA29.10-P-1003-02E Nut, brake pedal to bearing bracket Nm 20 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar29.10-p-4597ff, Removing and installing brake pedal MODELS 454.0

Risk of injury

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1515 · Applies to: 453 · AR: AR42.20-P-0545SR, AR40.10-P-1100SR, AR42.40-P-9807SR, AR42.10-P-0023SR, AR42.10-P-0010SR (+1 more)

Danger ! caused by pinching or crushing Use only approved tensioning devices; AS00.00-Z-0001-01A

when working on springs or spring bodies that additionally screen off hazardous area if are under tension necessary. Check special tools for damage and proper operation (visual inspection). Wear protective gloves. Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Remove/install

1 Detach left and right brake cable in vehicle AR42.20-P-0545SR interior 2 Remove wheel and tire assemblies on rear AR40.10-P-1100SR axle 3 Pull left and right brake cable from guide AR42.20-P-0545SR tubes on body 4 Remove rubber grommets (6) from axle tube (5) 5 Remove rubber grommets on left rear axle AR42.40-P-9807SR rpm sensor and right rear axle rpm sensor from axle tube (5) 6 Remove bolt (3) from left and right shock *BA32.25-P-1001-03Q Bolt, shock absorber to rear axle absorber (4) and pull out 7 Detach left and right shock absorber (4) from axle tube (5) 000 588 11 62 00 Major assembly mount WS01.00-P-0092B

Installation: Use a telescopic lifter to

position each shock absorber (4) on axle tube (5). 8 Detach brake lines (7) from brake hoses (8) AR42.10-P-0023SR and detach brake hoses (8) from axle tube bracket (5) 9 Prop up axle tube (5) using telescopic lifter in area of rear axle center bearing (9) 000 588 11 62 00 Major assembly mount WS01.00-P-0092B

10 Remove screw/bolt (10) *BA35.10-P-1002-03B Bolt, rear axle tube to body 11 Lower axle tube (5) with telescopic lifter until the left and right rear axle spring (1) can be removed 000 588 11 62 00 Major assembly mount WS01.00-P-0092B

Installation:

The coil end on the rear axle spring (1) must be positioned just before the end stop (13.1) of the lower spring cup (13) when installed. Otherwise noises can occur while driving. 12 Remove left or right rear axle spring (1) When replacing a rear axle spring (1) note

the color codings on the spring coils. The color codings on the left and right rear axle spring (1) must not vary. Check

13 Check left or right rear axle spring (1), upper Installation: The assembly position of the

spring cup (12) and lower spring cup (13) for lower spring cup (13) is defined by a nipple damage (13.2), which is pressed into a hole (arrow A) on the mount. In event of any visible damage to components: Replace corresponding component. 14 Install in the reverse order 15 Bleed brake system AR42.10-P-0010SR 16 Perform wheel alignment check AR40.20-P-0200SR Rear axle shock absorber Number Designation Model 453 BA32.25-P-1001-03Q Bolt, shock absorber to rear axle Nm 105 Rear axle Number Designation Model 453 BA35.10-P-1002-03B Bolt, rear axle tube to body Nm 180 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar32.20-p-0230sr, Remove/install rear spring Model 453

Unhook brake hose (12) from bracket (14) on

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1557 · Applies to: 453 · AR: AR42.10-P-0010SR, AR40.20-P-0200SR

14 Unhook brake hose (12) from bracket (14) on suspension strut (4) 15 Remove underfloor panels 16 Turn steering to right until nut (19) is accessible 17 Unscrew nut (19) and remove associated *BA46.10-P-1003-05B Nut, steering column linkage to steering threaded pin gear 18 Fold ball joint (20) on steering gear (21) upwards 19 Disconnect electrical connection (22) 20 Position telescopic lifter with removal fixture centrally on front axle (1) 000 588 11 62 00 Major assembly mount WS01.00-P-0092B

450589026200 Removal fixture 21 Remove bolts (23) BA33.10-P-1001-02A Screw/bolt, front axle to body 22 Remove screw/bolts (24) *BA33.10-P-1001-02A Screw/bolt, front axle to body 23 Lower front axle (1) slightly until the screws/

bolts (25) of the retaining plate (26) are Make sure that the coolant hoses (29) are not accessible under tension. Otherwise coolant hoses (29) can get damaged.

Model 453 with code I01 (Air conditioning Plus) Model 453 with code I77 (Air conditioning, manual) Make sure that the refrigerant line (28) is not under tension. Otherwise refrigerant line (28) can get damaged. 24 Unscrew nut (27) of refrigerant line (28) Model 453 with code I01 (Air conditioning Plus) Model 453 with code I77 (Air conditioning, manual) 25 Unscrew screw/bolts (25) of retaining plate (26) on right and left 26 Fully lower front axle (1) Installation: Ensure that the guide pin of

the radiator is seated correctly in the rubber guides (30). 27 Install in the reverse order 28 Bleed brake system AR42.10-P-0010SR 29 Perform wheel alignment check
AR40.20-P-0200SR Suspension struts Number Designation Model 453 BA32.25-P-1001-04Q Bolt, suspension strut to body Nm 21 Front axle Number Designation Model 453 BA33.10-P-1001-02A Screw/bolt, front axle to body Nm 105 Brake lines, brake hoses Number Designation Model 453 BA42.10-P-1002-04SR Retaining screw, brake line to brake hose Nm 13 Steering wheel, steering column tube, steering shaft Number Designation Model 453 BA46.10-P-1003-05B Nut, steering column linkage to steering gear Nm 21 Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.10-p-0100sr, Remove/install front axle Model 453

Puller

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1576 · Applies to: 453 · AR: AR42.30-P-0712FF, AR40.10-P-1100FF

450589013300 Puller 12 Unscrew nuts (7) and pull out bolts (8) 13 Fold down upright (3) forwards, pull front axle With engine 122.9, 639.9. shaft and place to one side Place suitable rags between the upright (3) and front axle shaft otherwise the rubber boot may be damaged. 14 Detach flange ball joint from upright (3) AR33.20-P-0446-01FF 454589003300 Puller 15 Remove steering knuckle (3) 16 Using a suitable tool, hammer left front rpm If left front rpm sensor (L6/1) or right front rpm sensor (L6/1) or right front rpm sensor (L6/2) sensor is seized (L6/2). upwards out of upright (3) Install

17 Insert front axle shaft in the upright (3) With engine 122.9, 639.9. 18 Attach the steering knuckle (3) with nuts (7) Replace self-locking nuts (7). and bolts (8) *BA32.25-P-1002-04I

19 Mount flange ball joint on the steering knuckle AR33.20-P-0446-01FF Push transverse control arm on front axle (3) down only as far as required, as otherwise the rubber bushings in the transverse control arm may be damaged. *BA33.15-P-1002-01D

20 Mount the tie rod end on the steering knuckle AR46.40-P-0200-02FF (3) *BA46.40-P-1001-01I

21 Clean the contact surfaces of the wheel hub and clean the brake disk (6) and attach the brake disk (6) 22 Remove cable ties and attach brake caliper *BA42.10-P-1003-10A

support (5) with bolts (4) 23 Install left front rpm sensor (L6/1) or right front AR42.30-P-0712FF If the left front rpm sensor (L6/1) or right rpm sensor (L6/2) front rpm sensor (L6/2) is seized the left front rpm sensor (L6/1) or right front rpm sensor (L6/2) must be replaced. 24 Screw on nut (1) until it abuts Replace self-locking nut (1). In order to avoid damage to the thread of the front axle shaft the nut (1) should not be screwed-on using an impact wrench. The nut (1) must be screwed-on using a suitable locking handle or torque wrench. 25 Mount the left or right wheel on the front axle AR40.10-P-1100FF Do not mount wheel cover on vehicles with steel rims or cover of nut (1) on vehicles with aluminum rims. 26 Tighten nut (1) In order to avoid damage to the thread of the front axle shaft the nut (1) should not be tightened using an impact wrench. The nut (1) must be tightened using a torque wrench. *BA33.30-P-1001-07B

27.1 Mount left or right wheel cover on front axle On vehicles with steel rims. 27.2 Mount the left or right cover of the nut (1) on On vehicles with aluminum rims. the aluminum rim Suspension struts

Number Designation Model Model 454.0 454.034 except model 454.034 BA32.25-P-1002-04I Nut, spring strut to steering knuckle Nm 90 96 Trailing arms, wishbones

Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.25-p-0400ff, Remove/install steering knuckle MODEL 454.0 with ENGINE 122.9, 134.9, 135.9, 639.9

P35.10-2480-09

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1595 · Applies to: 453 · AR: AR42.10-P-0165SR, AR42.10-P-0023SR, AR35.15-P-0250SR

1 Rear axle tube 15 Rear axle crossmember 18 Rear axle center bearing 13 Screw 16 Control arm 19 Screw 14 Shock absorber 17 Rear axle shafts 20 Rear axle springs 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. Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Notes on repair work on suspension AH00.00-P-0100-01A

components Remove/install

1 Remove brake shoes at rear axle AR42.10-P-0165SR 2 Remove left and right rubber grommet (2) from brackets on rear axle tube (1) 3 Push tabs together (arrows) and pull corresponding brake cable (3) out of left and right brake cover plate (4) 4 Pull left and right brake cable (3) through the corresponding guides (5, 6) on the rear axle tube (1) 5 Remove rubber grommets (7) for electrical lines (8, 9) from bracket 6 Detach left rear axle rpm sensor electrical connection (L6/3x1) and right rear axle rpm sensor electrical connection (L6/4x1) 7 Unclip electrical connectors from brackets (10) 8 Detach brake lines (11) from brake hoses AR42.10-P-0023SR (12) and remove brake hoses (12) from bracket on rear axle tube (1) 9 Remove bolt (13) of left and right damper *BA32.25-P-1001-03Q Bolt, shock absorber to rear axle (14) and pull out 10 Remove left and right damper (14) from rear axle tube (1) 000 588 11 62 00 Major assembly mount WS01.00-P-0092B

Installation: Use a telescopic lifter to

position each damper (14) on the rear axle tube (1). 11 Lower rear axle cross member (15) until it is AR35.15-P-0250SR unstressed Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar35.10-p-0070sr, Remove/install axle tube Model 453

Tighten bolt (5)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1610 · Applies to: 453 · AR: AR42.10-P-1010SR

9 Tighten bolt (5) To tighten the bolt (5) screw two wheel

bolts into wheel hub and secure wheel hub using suitable tool. *BA35.30-P-1001-01O Bolt, rear axle shaft to wheel bearing 10 Install left or right brake drum AR42.10-P-1010SR Wheel control Number Designation MODEL 453 BA35.20-P-1001-07E Bolt, wheel bearing to rear axle tube Nm 62 Rear axle shaft Number Designation MODEL 453 BA35.30-P-1001-01O Bolt, rear axle shaft to wheel bearing Stage 1 Nm 60 ° Stage 2 70 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar35.20-p-0302sr, Remove/install wheel bearing MODEL 453

AP42.00-P-4290MCC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1701 · Applies to: 453 · AR: AP42.00-P-4290MCC

Brake test 06.02.2019 Model 451.3/4, 453 Modification notes 24.03.2014 General brake test added. General brake test (Only applies for countries without a specified brake test on the brake test stand) 1 Check braking behavior of service brake when

driving It must be ensured that the brake test when driving is performed as per the country-specific legislation and regulations. Damage can occur otherwise. Press brake pedal uniformly.

With braking deceleration fluctuations or pulsating brake pedal: Rectify problem subject to separate repair order. With a difference in the service brake performance on the wheels on a single axle: Check/correct tire pressure subject to separate repair order. If the service brake performance difference remains even after repeat brake test on the wheels on a single axle: Rectify problem subject to separate repair order. The locking limit was not reached: Subject to a separate repair order, check whether the brake values still comply with the legal regulations. The specified minimum requirements and tolerance limits for the brake system must be fulfilled on a vehicle-specific basis in accordance with the country-specific legislation. If this is not the case: Repair any complaints subject to separate repair order after performing diagnosis with the appropriate findings. 2 Check braking behavior of parking brake when

driving It must be ensured that the brake test when driving is performed as per the country-specific legislation and regulations. Damage can occur otherwise. The locking limit was not reached: Subject to a separate repair order, check whether the brake values still comply with the legal regulations. The specified minimum requirements and tolerance limits for the brake system must be fulfilled on a vehicle-specific basis in accordance with the country-specific legislation. If this is not the case: Repair any complaints subject to separate repair order after performing diagnosis with the appropriate findings. Brake test on brake test stand Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.00-p-4290mcc, Brake test Model 451.3/4, 453

AP42.00-P-4290FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1703 · Applies to: 453 · AR: AP42.00-P-4290FF, AP42.10-P-4251FG, AP42.10-P-4251FF, AR42.20-P-0540FF, AR42.10-P-0240FF (+1 more)

Brake testing on test stand 21.1.08 MODEL 454.0 Checking

Risk of death Do not insert your hand into rotating parts. Danger! caused by body parts being AS00.00-Z-0019-01A

pulled in by rotating vehicle wheels and roller Wear closed and snug-fitting work clothes. dynamometer rollers Safeguard areas with rotating vehicle parts and dynamometer rollers against unauthorized access. Safeguard roller dynamometer from unauthorized access. 1 Drive the vehicle onto the brake test stand Permissible deviation from the higher and measure and enter deceleration values value: Maximum 25 %. If the braking effect is for service brake at the front axle and rear uneven or inadequate, establish the cause axle into the maintenance sheet and eliminate against a separate order: Check lining thickness of brake pads and Model 454 except code 30Y Disk brakes on AP42.10-P-4251FG condition of brake disks rear axle Model 454 with code 30Y Disk brakes on rear AP42.10-P-4251FF axle 2 Engage parking brake, measure and note Permissible deviation from the higher deceleration values value: Maximum 25 %. If the braking effect is uneven or inadequate: Adjust parking brake AR42.20-P-0540FF

If the braking effect is uneven or inadequate, establish the cause and eliminate against a separate order: Remove brake drum or brake disk and determine or eliminate cause (e.g. replace brake pads, brake drum or brake disk): Remove/install rear axle brake disc Model 454 with code 30Y Disk brakes on rear AR42.10-P-0240FF

axle Remove/install brake drum Model 454 except code 30Y Disk brakes on AR42.10-P-1010FF

rear axle Check components of parking brake for signs of wear and damage, replace if necessary. 3 Drive vehicle off the brake test stand Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.00-p-4290ff, Brake testing on test stand MODEL 454.0

AP42.00-P-4298SM

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1704 · Applies to: 453 · AR: AP42.00-P-4298SM, AP42.00-P-4280SM, AP42.00-P-4280RR, AP42.00-P-4280FF, AP42.00-P-4280FG

Check wet boiling point of brake fluid 5.5.15 Model 450, 452, 454 1 Hinged lid 2 Pipette 3 Prism surface 4 Brake fluid meter 5 Eyepiece P42.00-2120-11 Risk of poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Notes on repairs to brake system AH42.00-P-0003-01A

Brake fluid notes AH42.50-P-0001-01A

Check

1 Open brake fluid reservoir 2 Fold up folding cover (1) on brake fluid measuring device (4) 3 Using pipette (2) coat a few droplets of brake fluid onto the prism surface (3) and carefully fold down the folding cover (1) 4 Limit of wet boiling point: Direct the brake fluid measuring device (4)

towards the bright light source and read off the At DOT4: 155 °C (279 °F) wet boiling point of the brake fluid through the At DOT4+: 168 °C (302 °F) eyepiece (5) If there are problems: Replace the brake fluid subject to a separate repair order. Model 450.3/4 AP42.00-P-4280SM Model 452.3/4 AP42.00-P-4280RR Model 454.0 AP42.00-P-4280FF with code 30Y (Disk brakes on rear axle) Model 454.0 AP42.00-P-4280FG except code 30Y (Disk brakes on rear axle) 5 Clean brake fluid measuring device (4) with water and dry 6 Dispose of used pipette (2) 7 Seal brake fluid reservoir Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.00-p-4298sm, Check wet boiling point of brake fluid Model 450, 452, 454

Proceed with operation step 10.

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1706 · Applies to: 453 · AR: AR42.20-P-0540SR, AR00.60-P-0100SR

If the setting for the parking brake according to the above-mentioned criteria is not OK. Adjust parking brake AR42.20-P-0540SR

10 Lower vehicle on vehicle lift AR00.60-P-0100SR

Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, sm42.00-p-0006a, Program Electronic Stability Program control unit and check parking brake (code: 1512P42C63) Model 453

AP42.00-P-4280FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1707 · Applies to: 453 · AR: AP42.00-P-4280FF

Replace brake fluid 13.4.06 MODEL 454.0 with CODE (30Y) Disk brakes on rear axle P42.00-2106-09 Illustrated on model 454.031 1 Cap 4 Rear brake caliper 6 Slave cylinder (on transmission 717.470/471/473/478) 2 Brake fluid reservoir 5 Brake bleeder valve 7 Bleed valve (on transmission 3 Front brake caliper 717.470/471/473/478) Replace Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Open engine hood 2 Unscrew cap (1) of brake fluid reservoir (2) 3 Connect the brake fluid change unit to the *WE58.40-Z-1001-07A Observe owner's manual of brake fluid brake fluid reservoir (2) and switch on replacement unit. General brake fluid Sheet 330.1 BB00.40-P-0330-01A

Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40-P-0331-00A

*454589019100

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. 4 Raise vehicle 5 Detach dust caps of the brake bleeder valve Only close brake bleeder valve (5) when (5), connect hose of brake fluid receptacle to brake fluid is discharged free of bubbles and brake bleeder valve (5) of right rear brake without contamination (brake fluid has light caliper (4) and open brake bleeder valve (5). color). Then have a second person depress brake pedal several times and close brake bleeder valve (5) again. *BA42.10-P-1002-12A

6 Carry out bleeding process on left rear brake Observe correct sequence. caliper (4), right rear brake caliper (3) and left front brake caliper (3) in the same way *BA42.10-P-1002-10A

*BA42.10-P-1002-12A

7.1 Remove dust cap from bleed valve (7), Only on transmission 717.470/471/473/478 connect hose of brake fluid receptacle to bleed valve (7) of slave cylinder (6) and open bleed valve (7) and close it again Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.00-p-4280ff, Replace brake fluid MODEL 454.0 with CODE (30Y) Disk brakes on rear axle

Only close the brake bleeder valve (7)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1708 · Applies to: 453 · AR: AP42.10-P-4210FF

when brake fluid escapes free of bubbles and without contamination (light color of brake fluid). 8 Press dust caps onto the brake bleeder valves Bleeder valve (7) only on transmission (5) and bleed valve (7) 717.470/471/473/478. 9 Lower vehicle 10 Disconnect brake fluid replacement unit WE58.40-Z-1001-07A Observe owner's manual of brake fluid replacement unit. 454589019100

11 Check brake fluid level, correct if necessary AP42.10-P-4210FF 12 Screw on cap (1) of brake fluid reservoir (2) 13 Check leaktightness of brake system If a test trip is carried out after a repair to the hydraulic system, the brakes are to be applied with an ABS control. Check brake system for leaks AR42.10-P-0100-01FF

Front axle floating caliper

Number Designation Model 454.0 BA42.10-P-1002-10A Brake bleeder valve to brake caliper Nm 10 Rear axle floating brake caliper

Number Designation Model 454.0 with code 30Y BA42.10-P-1002-12A Brake bleeder valve to brake caliper Nm 6 454 589 01 91 00 Adapter Workshop equipment WE58.40-Z-1001-07A Brake fluid replacement unit Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.00-p-4280ff, Replace brake fluid MODEL 454.0 with CODE (30Y) Disk brakes on rear axle

AP42.00-P-4280FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1709 · Applies to: 453 · AR: AP42.00-P-4280FG

Replace brake fluid 13.4.06 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle P42.00-2122-09 Illustrated on model 454.033 1 Cap 4 Wheel brake cylinder 6 Slave cylinder (on transmission 717.470/471/473/478) 2 Brake fluid reservoir 5 Brake bleeder valve 7 Bleed valve (on transmission 3 Front brake caliper 717.470/471/473/478) Replace Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Open engine hood 2 Unscrew cap (1) of brake fluid reservoir (2) 3 Connect the brake fluid change unit to the *WE58.40-Z-1001-07A Observe owner's manual of brake fluid brake fluid reservoir (2) and switch on replacement unit. General brake fluid Sheet 330.1 BB00.40-P-0330-01A

Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40-P-0331-00A

*454589019100

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. 4 Raise vehicle 5 Detach dust caps from the brake bleeder Only close brake bleeder valve (5) when valves (5), connect hose of the brake fluid brake fluid is discharged free of bubbles and receptacle to brake bleeder valve (5) of the without contamination (brake fluid has light right-hand wheel brake cylinder (4) and open color). brake bleeder valve (5). Then have a second person depress brake pedal several times and close brake bleeder valve (5) again. *BA42.10-P-1001-08E

6 Carry out bleeding process on left wheel Observe correct sequence. brake cylinder (4), right front brake caliper (3) and left front brake caliper (3) in the same way *BA42.10-P-1001-08E

*BA42.10-P-1002-10A

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.00-p-4280fg, Replace brake fluid MODEL 454.0 except CODE (30Y) Disk brakes on rear axle

Remove dust cap from bleed valve (7),

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1710 · Applies to: 453 · AR: AP42.10-P-4210FF

7.1 Remove dust cap from bleed valve (7), Only on transmission 717.470/471/473/478 connect hose of brake fluid-receptacle to bleed valve (7) of slave cylinder (6) and open bleed valve (7) and close it again Only close the brake bleeder valve (7) when brake fluid escapes free of bubbles and without contamination (light color of brake fluid). 8 Press dust caps onto the brake bleeder valves Bleeder valve (7) only on transmission (5) and bleed valve (7) 717.470/471/473/478. 9 Lower vehicle 10 Disconnect brake fluid replacement unit WE58.40-Z-1001-07A Observe owner's manual of brake fluid replacement unit. 454589019100

11 Check brake fluid level, correct if necessary AP42.10-P-4210FF 12 Screw on cap (1) of brake fluid reservoir (2) 13 Check leaktightness of brake system If a test trip is carried out after a repair to the hydraulic system, the brakes are to be applied with an ABS control. Check brake system for leaks AR42.10-P-0100-01FF

Front axle floating caliper

Number Designation Model 454.0 BA42.10-P-1002-10A Brake bleeder valve to brake caliper Nm 10 Brake cylinder

Number Designation Model 454.0 without code 30Y BA42.10-P-1001-08E Brake bleed valve to rear axle wheel brake cylinder Nm 6 454 589 01 91 00 Adapter Workshop equipment WE58.40-Z-1001-07A Brake fluid replacement unit Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.00-p-4280fg, Replace brake fluid MODEL 454.0 except CODE (30Y) Disk brakes on rear axle

BE42.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1714 · Applies to: 453 · AR: BE42.00-Z-9999CZ

Test and adjustment values: Smart: Brakes - hydraulic and mechanical systems 18.09.2019 MODEL all Test values for front axle floating caliper MODEL 450.3/4, 452.3/4, 454.0 BE42.10-P-1000-03B Check values for front brakepad Model 450.3/4, 451.3/4, 452.3/4 BE42.10-P-1000-05E Check values for front brakepad Model 454.0 BE42.10-P-1000-05G Check values for front brakepad Model 453 BE42.10-P-1000-05Y Test values for front brake disks MODEL 450.3/4, 451.3/4, 452.3/4, 454.0 BE42.10-P-1000-08E Test values for front brake disks Model 453 BE42.10-P-1000-08Y Test values for rear brake disks MODEL 454.0 with CODE 30Y (Disk brakes BE42.10-P-1000-09F on rear axle) Service brakes MODEL 164, 166, 167, 169, 171, 172, 190, BE42.10-P-1000-10B 203, 204, 205, 207, 212, 213, 216, 217, 218, 219, 221, 222, 230, 231, 238, 245, 246, 251, 253, 292, 293, 451 ... Drum brake MODEL 450.3/4, 451.3/4, 452.3/4 BE42.10-P-1000-12C Drum brake MODEL 454.0 without CODE 30Y (Disk BE42.10-P-1000-12D brakes on rear axle) Drum brake Model 453 BE42.10-P-1000-12E Inspection data for rear brake floating calipers MODEL 454.0 with CODE 30Y (Disk brakes BE42.10-P-1000-14C on rear axle) Check values for rear brakepad Model 454.0 (except 454.033) with code 30Y BE42.10-P-1000-15F (Disk brakes on rear axle) Parking brake for maintenance operations MODEL 451, 453 BE42.20-P-1000-02B Antilock brake system (ABS) MODEL 450.3/4 BE42.30-P-1000-01B Rpm sensor MODEL 450.3/4, 452.3/4 BE42.45-P-1000-01A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be42.00-z-9999cz, Test and adjustment values: Smart: Brakes - hydraulic and mechanical systems MODEL all

AR42.10-P-0041FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1716 · Applies to: 453 · AR: AR42.10-P-0041FF, AR68.10-P-1500FF

Adjust mechanical stop lamp switch 8.1.07 MODEL 454.0 P42.10-2395-08 Shown on vehicle with code (LHD) Left- hand drive vehicle 1 Brake pedal 2 Rubber stopper S9/1 Stop lamp switch Modification notes 27.11.06 Quality note: "The brake light switch must on no account come into contact with grease or any antifriction agent" added Adjust The brake light switch (S9/1) must on no

account come into contact with grease or any antifriction agent, as this may otherwise result in malfunctions. 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 Push brake pedal (1) down until the button of the brake light switch (S9/1) no longer makes contact with the rubber bump (2) 4 Rotate the brake light switch (S9/1) through 90° to the left and remove upwards 5 Extract button on brake light switch (S9/1) Pull out button on brake light switch (S9/1) carefully to avoid damage to the Brake light switch (S9/1). 6 Depress brake pedal (1) and retain 7 Insert brake light switch (S9/1) onto bearing bracket of brake pedal (1) and rotate through 90° to the right 8 Slowly release the brake pedal (1) 9 Connect STAR DIAGNOSIS and check signal from brake light switch (S9/1) Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory 10 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, ar42.10-p-0041ff, Adjust mechanical stop lamp switch MODEL 454.0

AP42.10-P-4256EW

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1717 · Applies to: 453 · AR: AP42.10-P-4256EW

Assess condition of brake disks 10.05.2019 Model 117, 118, 156, 164, 166, 167, 169, 171, 172, 176, 177, 190, 197, 203, 204, 205, 207, 209, 211, 212, 213, 216, 217, 218, 219, 221, 222, 230, 231, 238, 242, 245, 246, 247, 251, 253, 257, 290, 292, 293, 453, 461, 463 P42.10-2952-09 1 Steel brake disk x Crack length 2 Ceramic brake disk Perforated compound brake disk with wear bores 11 Outer wear bore 12 Center wear bore 13 Inner wear bore 14 Brake disk bores P42.10-3225-06 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.10-p-4256ew, Assess condition of brake disks Model 117, 118, 156, 164, 166, 167, 169, 171, 172, 176, 177, 190, 197, 203, 204, 205, 207, 209, 211, 212, 213, 216, 217, 218, 219, 221, 222, 230, 231, 238, 242, 245, 246, 247, 251, 253, 257, ...

AP42.10-P-4252SS

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1722 · Applies to: 453 · AR: AP42.10-P-4252SS, AR42.10-P-1010SR

Assess condition of brake linings 3.2.15 MODEL 453 at rear axle P42.10-3083-08 1 Plug 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. Remove

1 Lift vehicle on vehicle lift 2 Remove stop plug (1) from hose of brake cover plate on left and right drum brake Check

3 Evaluate lining thickness of brake shoes on If necessary, use flashlight or mirror. The

rear axle thickness of the pad backing plate can be used as a guide when assessing lining thickness. Brake lining thickness *BE42.10-P-1002-12E If, in exceptional cases, assessment by means of visual inspection is not possible: Remove brake drum and check lining thickness of brake shoes, subject to separate repair order. AR42.10-P-1010SR

4 Determine likely remaining distance of brake AP42.10-P-4253-03EW linings on rear axle

If the wear limit for the brake linings is reached, the brake linings must be replaced subject to a separate repair order. Otherwise the braking effect may be impaired and people, property and environmental damage may result. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.10-p-4252ss, Assess condition of brake linings MODEL 453 at rear axle

AR42.10-P-0010FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1724 · Applies to: 453 · AR: AR42.10-P-0010FF

Bleed brake system 20.3.06 MODEL 454.0 with CODE (30Y) Disk brakes on rear axle 1 Cap 2 Brake fluid reservoir 3 Front brake caliper 4 Rear brake caliper 5 Brake bleeder valve P42.10-2398-06 Bleeding Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Connect STAR DIAGNOSIS Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system WH58.30-Z-1048-13A 2 Open engine hood 3 Unscrew cap (1) of brake fluid reservoir (2) 4 Connect and switch on brake fluid WE58.40-Z-1001-07A Observe owner's manual of brake fluid replacement unit on brake fluid reservoir (2) replacement unit. General brake fluid Sheet 330.1 BB00.40-P-0330-01A

Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40-P-0331-00A

*454589019100

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 below the lifting platform support points specified by the vehicle manufacturer. 5 Raise vehicle Bleed primary circuit 6 Remove dust cap from brake bleeder valve Only close the brake bleeder valve (5) (5), connect hose of brake fluid receptacle to when brake fluid is discharged free of bubbles brake bleeder valve (5) of right rear brake and without contamination (the brake fluid caliper (4) and open brake bleeder valve (5). must be light in color). Then have a second person depress brake pedal several times and close brake bleeder valve (5) again. *BA42.10-P-1002-12A

7 Carry out bleeding process on left rear brake Observe correct sequence. caliper (4), right rear brake caliper (3) and left front brake caliper (3) in the same way *BA42.10-P-1002-12A

*BA42.10-P-1002-10A

Bleed secondary circuit Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0010ff, Bleed brake system MODEL 454.0 with CODE (30Y) Disk brakes on rear axle

Actuate hydraulic unit with STAR DIAGNOSIS

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1725 · Applies to: 453 · AR: AP42.10-P-4210FF

8 Actuate hydraulic unit with STAR DIAGNOSIS Assistant required as the brake pedal must be pressed every 15 seconds. By actuating the hydraulic unit in addition the secondary circuit of the brake system is bled. STAR DIAGNOSIS diagnosis system WH58.30-Z-1048-13A 9 Connect hose of brake fluid receptacle to Only close the brake bleeder valve (5) brake bleeder valve (5) of right rear brake when brake fluid is discharged free of bubbles caliper (4) and open brake bleeder valve (5). and without contamination (the brake fluid Then have a second person depress brake must be light in color). pedal several times and close brake bleeder valve (5) again. BA42.10-P-1002-12A

10 Carry out bleeding process on the left rear Observe correct sequence. brake caliper (4), right front brake caliper (3) and left front brake caliper (3) in the same way *BA42.10-P-1002-12A

*BA42.10-P-1002-10A

11 Press dust caps onto the brake bleeder valves (5) 12 Lower vehicle 13 Switch off brake fluid replacement unit and WE58.40-Z-1001-07A Observe owner's manual of brake fluid disconnect replacement unit. 454589019100

14 Check brake fluid level and correct if necessary Brake system - inspect fluid level AP42.10-P-4210FF

15 Screw on cap (1) of brake fluid reservoir (2) 16 Read out fault memory and disconnect STAR If necessary, delete DTC memory. DIAGNOSIS Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A 17 Check leaktightness of brake system AR42.10-P-0100-01FF If a road test is carried out following repair work on the hydraulic system, braking with ABS regulation must be performed. Front axle floating caliper

Number Designation Model 454.0 BA42.10-P-1002-10A Brake bleeder valve to brake caliper Nm 10 Rear axle floating brake caliper

Number Designation Model 454.0 with code 30Y BA42.10-P-1002-12A Brake bleeder valve to brake caliper Nm 6 454 589 01 91 00 Adapter Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0010ff, Bleed brake system MODEL 454.0 with CODE (30Y) Disk brakes on rear axle

AR42.10-P-0010FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1727 · Applies to: 453 · AR: AR42.10-P-0010FG

Bleed brake system 20.3.06 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle 1 Cap 2 Brake fluid reservoir 3 Front brake caliper 4 Wheel brake cylinder 5 Brake bleeder valve P42.10-2517-06 Bleeding Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Connect STAR DIAGNOSIS Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system WH58.30-Z-1048-13A 2 Open engine hood 3 Unscrew cap (1) of brake fluid reservoir (2) 4 Connect and switch on brake fluid WE58.40-Z-1001-07A Observe owner's manual of brake fluid replacement unit on brake fluid reservoir (2) replacement unit. General brake fluid Sheet 330.1 BB00.40-P-0330-01A

Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40-P-0331-00A

*454589019100

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 below the lifting platform support points specified by the vehicle manufacturer. 5 Raise vehicle Bleed primary circuit 6 Remove dust cap from brake bleeder valve Only close the brake bleeder valve (5) (5), connect hose of brake fluid receptacle to when brake fluid is discharged free of bubbles brake bleeder valve (5) of right wheel brake and without contamination (the brake fluid cylinder (4) and open brake bleeder valve (5). must be light in color). Then have a second person depress brake pedal several times and close brake bleeder valve (5) again. *BA42.10-P-1001-08E

7 Carry out bleeding process on left wheel Observe correct sequence. brake cylinder (4), right front brake caliper (3) and left front brake caliper (3) in the same way *BA42.10-P-1001-08E

*BA42.10-P-1002-10A

Bleed secondary circuit Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0010fg, Bleed brake system MODEL 454.0 except CODE (30Y) Disk brakes on rear axle

Actuate hydraulic unit with STAR DIAGNOSIS

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1728 · Applies to: 453 · AR: AP42.10-P-4210FF

8 Actuate hydraulic unit with STAR DIAGNOSIS Assistant required as the brake pedal must be pressed every 15 seconds. By actuating the hydraulic unit in addition the secondary circuit of the brake system is bled. STAR DIAGNOSIS diagnosis system WH58.30-Z-1048-13A 9 Connect hose of brake fluid receptacle to Only close the brake bleeder valve (5) brake bleeder valve (5) of right wheel brake when brake fluid is discharged free of bubbles cylinder (4) and open brake bleeder valve (5). and without contamination (the brake fluid Then have a second person depress brake must be light in color). pedal several times and close brake bleeder valve (5) again. BA42.10-P-1001-08E

10 Carry out bleeding process on left wheel Observe correct sequence. brake cylinder (4), right front brake caliper (3) and left front brake caliper (3) in the same way *BA42.10-P-1001-08E

*BA42.10-P-1002-10A

11 Press dust caps onto the brake bleeder valves (5) 12 Lower vehicle 13 Switch off brake fluid replacement unit and WE58.40-Z-1001-07A Observe owner's manual of brake fluid disconnect replacement unit. 454589019100

14 Check brake fluid level and correct if necessary Brake system - inspect fluid level AP42.10-P-4210FF

15 Screw on cap (1) of brake fluid reservoir (2) 16 Read out fault memory and disconnect STAR If necessary, delete DTC memory. DIAGNOSIS Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A 17 Check leaktightness of brake system AR42.10-P-0100-01FF If a road test is carried out following repair work on the hydraulic system, braking with ABS regulation must be performed. Front axle floating caliper

Number Designation Model 454.0 BA42.10-P-1002-10A Brake bleeder valve to brake caliper Nm 10 Brake cylinder

Number Designation Model 454.0 without code 30Y BA42.10-P-1001-08E Brake bleed valve to rear axle wheel brake cylinder Nm 6 454 589 01 91 00 Adapter Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0010fg, Bleed brake system MODEL 454.0 except CODE (30Y) Disk brakes on rear axle

AR42.10-P-0010SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1730 · Applies to: 453 · AR: AR42.10-P-0010SR

Bleed brake system 4.5.15 Model 453 P42.10-3047-09 1 Brake fluid reservoir 2 Cap 3 Bleed bottle 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 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. Risk of poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

Remove

1 Switch off ignition The ignition must remain off for the entire

duration of the bleeding process because the solenoid valves of the hydraulic unit must be in the deactivated state when bleeding. 2 Detach maintenance flap and move away from working area Clean

3 Clean area around cap (2) 4 Unscrew cap (2) of brake fluid reservoir (1) Bleeding 5 Fill with new brake fluid up to the "MAXI" mark in the brake fluid reservoir (1) Brake fluids (DOT 4 plus) BB00.40-P-0331-00A

General brake fluid BB00.40-P-0330-01A

6 Connect filler/bleeder unit on brake fluid reservoir (1) 000 588 01 82 00 Filling unit WS25.00-P-0016B

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0010sr, Bleed brake system Model 453

AP42.10-P-4210FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1732 · Applies to: 453 · AR: AP42.10-P-4210FF

Brake system - inspect fluid level 7.10.03 MODELS 454.0 1 Expansion reservoir 2 Cap P42.10-2322-04 Check Risk of poisoning Danger! from swallowing brake Pour brake fluid only into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from brake fluid coming appropriately marked containers. Wear into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Check fluid level in expansion reservoir (1) The fluid level must be between the embossed "MIN" and "MAX" marks on the expansion reservoir (1). A too low fluid level can be caused by wear of the brake pads and discs; establish cause and eliminate, if necessary correct the fluid level - subject to separate repair order. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.10-p-4210ff, Brake system - inspect fluid level MODELS 454.0

AP42.10-P-4253FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1734 · Applies to: 453 · AR: AP42.10-P-4253FF, AR42.10-P-1010FF, AR42.10-P-0165FF

Check brake lining thickness 20.3.06 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle Shown on left side of vehicle when wheel is removed 1 Plug 2 Brake drum P42.10-2524-11 Checking

1 Remove stop plug (1) on brake carrier plate Left and right side 2 Check lining thickness of brake shoes *BE42.10-P-1002-12D The wear limit of the brake linings should be checked through the inspection hole. Observe recommended wear limit so that wear limit is not violated before the next maintenance service. If the lining thickness is getting close to the brake lining wear limit, the exact lining thickness must be established when the brake drum (2) is removed: If necessary: -subject to separate repair order Remove/install brake drum AR42.10-P-1010FF

Remove/install brake shoes at rear axle AR42.10-P-0165FF

3 Seal inspection hole with stop plug (1) Left and right side Test values for drum brake Number Designation Model 454.0 without code 30Y BE42.10-P-1002-12D Brake lining thickness Wear limit for maintenance service mm 2 (with carrier) Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.10-p-4253ff, Check brake lining thickness MODEL 454.0 except CODE (30Y) Disk brakes on rear axle

AP42.10-P-4246U

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1735 · Applies to: 453 · AR: AP42.10-P-4258NK, AR42.10-P-0120MFC, AP42.10-P-4258NL, AP42.10-P-4258GZ, AP42.10-P-4258GQ (+5 more)

Check general overview of condition of brake disks 20.02.2020 Model 117, 118, 156, 164, 166, 167, 169, 171, 172, 176, 177, 190, 197, 203, 204, 205, 207, 209, 211, 212, 213, 216, 217, 218, 219, 221, 222, 223, 230, 231, 238, 242, 245, 246, 247, 251, 253, 257, 290, 292, 293, 453, 461, 463 Vehicles without code B07 (Ceramic brake system) Inspect condition of brake disks Model 117 AP42.10-P-4258NK Check thickness and condition of brake disks Model 118 AR42.10-P-0120MFC Inspect condition of brake disks Model 156 AP42.10-P-4258NL Inspect condition of brake disks Model 164, 251 AP42.10-P-4258GZ Inspect condition of brake disks Model 166 AP42.10-P-4258GQ Check thickness and condition of brake disks Model 167 AR42.10-P-0120ME Inspect condition of brake disks Model 169 AP42.10-P-4258AK Model 245 (except 245.286) Inspect condition of brake disks Model 171, 172 AP42.10-P-4258V Inspect condition of brake disks Model 176 AP42.10-P-4258NM Check thickness and condition of brake disks Model 177 AR42.10-P-0120MFA Inspect condition of brake disks Model 190 AP42.10-P-4258A except code B07 (AMG - ceramic brake system) Inspect condition of brake disks Model 197.3/4 AP42.10-P-4258RQ except code B07 (AMG - ceramic brake system) Inspect condition of brake disks Model 203 AP42.10-P-4258BP Inspect condition of brake disks Model 204 AP42.10-P-4258CW Inspect condition of brake disks Model 205 AP42.10-P-4258EW except code B07 (AMG - ceramic brake system) Model 207 Model 212 except code B07 (AMG - ceramic brake system) Model 218 except code B07 (AMG - ceramic brake system) Inspect condition of brake disks Model 209 AP42.10-P-4258BQ Inspect condition of brake disks Model 211 AP42.10-P-4258R Model 230 Check thickness and condition of brake disks Model 213, 253 AR42.10-P-0120LWG except code B07 (AMG - ceramic brake system) Inspect condition of brake disks Model 216 AP42.10-P-4258SX Model 221.0/1 Inspect condition of brake disks Model 217 AP42.10-P-4258C except code B07 (AMG - ceramic brake system) Inspect condition of brake disks Model 219 AP42.10-P-4258TX Inspect condition of brake disks Model 222 AP42.10-P-4258HA except code B07 (AMG - ceramic brake system) Inspect condition of brake disks Model 231 AP42.10-P-4258RK except code B07 (AMG - ceramic brake system) Check thickness and condition of brake disks Model 238 AR42.10-P-0120LWO Inspect condition of brake disks Model 242 AP42.10-P-4258NP Inspect condition of brake disks Model 246 AP42.10-P-4258NR Check thickness and condition of brake disks Model 247 AR42.10-P-0120MFB Check thickness and condition of brake disks Model 257 AR42.10-P-0120FR Check thickness and condition of brake disks Model 290 AR42.10-P-0120FRX except code B07 (AMG - ceramic brake system) Check thickness and condition of brake disks Model 292 AR42.10-P-0120A Inspect condition of brake disks Model 453 AP42.10-P-4258S Check brakepad thickness and condition of Model 461 AP42.10-P-4251G brake disks Model 463 up to model year 2012 Inspect condition of brake disks Model 463 AP42.10-P-4258G as of model year 2012 up to model year 2019 Vehicles with code B07 (Ceramic brake system) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.10-p-4246u, Check general overview of condition of brake disks Model 117, 118, 156, 164, 166, 167, 169, 171, 172, 176, 177, 190, 197, 203, 204, 205, 207, 209, 211, 212, 213, 216, 217, 218, 219, 221, 222, 223, 230, 231, 238, 242, 245, 246, 247, 251, 253, ...

Inspect condition of brake disks

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1736 · Applies to: 453 · AR: AP42.10-P-4258AC, AP42.10-P-4258QQ, AR42.10-P-0120LWG, AP42.10-P-4258CC, AP42.10-P-4258HC (+2 more)

Model 190 AP42.10-P-4258AC with code B07 (AMG - ceramic brake system) Inspect condition of brake disks Model 197, 212, 218, 231 AP42.10-P-4258QQ with code B07 (AMG - ceramic brake system) Check thickness and condition of brake disks Model 213, 253 AR42.10-P-0120LWG with code B07 (AMG - ceramic brake system) Inspect condition of brake disks Model 217 AP42.10-P-4258CC with code B07 (AMG - ceramic brake system) Inspect condition of brake disks Model 222 AP42.10-P-4258HC with code B07 (AMG - ceramic brake system) Check thickness and condition of brake disks Model 290 AR42.10-P-0120FRX with code B07 (AMG - ceramic brake system) Vehicles with code B07 (Ceramic brake system) and steel brake disks on rear axle Inspect condition of brake disks Model 205 AP42.10-P-4258AC with code B07 (AMG - ceramic brake system) Front axle Inspect condition of brake disks Model 205 AP42.10-P-4258EW except code B07 (AMG - ceramic brake system) Rear axle Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.10-p-4246u, Check general overview of condition of brake disks Model 117, 118, 156, 164, 166, 167, 169, 171, 172, 176, 177, 190, 197, 203, 204, 205, 207, 209, 211, 212, 213, 216, 217, 218, 219, 221, 222, 223, 230, 231, 238, 242, 245, 246, 247, 251, 253, ...

AP42.10-P-4251FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1737 · Applies to: 453 · AR: AP42.10-P-4251FF, AR42.10-P-0170FF, AR42.10-P-0170FG, AR42.10-P-0230FF, AR42.10-P-0240FF

Check lining thickness of brake pads and condition of brake disks 7.10.03 MODEL 454.0 Shown on front axle 1 Brake disk 2 Brake pads P42.10-2529-11 Check

1 Check lining thickness of brake pads (2) on Check brake pads when installed (2). the front and rear axle Observe recommended service limit so that service limit is not dropped below up to the next maintenance service. If necessary: Replace brake pads (2) - subject to separate repair order. Replacing and installing brake pads Front axle AR42.10-P-0170FF

Rear axle AR42.10-P-0170FG

2 Check brake disk (1) on front and rear axle for If necessary: score marks and cracks Replace brake disk (1) - subject to separate repair order. Remove/install front axle brake disk AR42.10-P-0230FF

Removing and installing rear axle brake disc AR42.10-P-0240FF

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.10-p-4251ff, Check lining thickness of brake pads and condition of brake disks MODEL 454.0

AP42.10-P-4251FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1738 · Applies to: 453 · AR: AP42.10-P-4251FG, AR42.10-P-0170FF, AR42.10-P-0230FF

Check lining thickness of brake pads and condition of brake disks 3.3.05 MODEL 454.0 1 Brake disk 2 Brake pads P42.10-2529-11 Check

1 Check lining thickness of brake pads (2) on Check brake pads when installed (2). front axle Observe recommended service limit so that service limit is not dropped below up to the next maintenance service. If necessary: Replace brake pads (2) - subject to separate repair order. Replacing and installing brake pads AR42.10-P-0170FF

2 Check brake disk (1) on the front axle for If necessary: scores and cracks Replace brake disk (1) - subject to separate repair order. Remove/install front axle brake disk AR42.10-P-0230FF

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.10-p-4251fg, Check lining thickness of brake pads and condition of brake disks MODEL 454.0

AR42.10-P-1030FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1739 · Applies to: 453 · AR: AR42.10-P-1030FF, AR42.10-P-0165FF

Disassemble/assemble brake shoes 20.3.06 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle P42.10-2520-08 1 Spring 5 Brake shoe 8 Star wheel 2 Brake shoe 6 Adjusting lever 9 Thrust sleeve 3 Spring 7 Threaded thrust rod 10 Thermo clip 4 Spring 1 Spring 2 Brake shoe 3 Spring 4 Spring 5 Brake shoe 6 Adjusting lever 11 Automatic adjuster P42.10-2519-11 Disassemble/assemble

1 Remove brake shoes (2, 5) from rear axle AR42.10-P-0165FF 2 Detach and remove spring (3) from brake shoes (2, 5) 3 Detach spring (4) from adjusting lever (6) and from brake shoe (5) and remove 4 Turn adjusting lever (6) slightly Assembly: Adjusting lever (6) must be

counterclockwise, detach from lower guide on positioned between threaded thrust rod (7) brake shoe (5) and remove and brake shoe (5). Adjusting lever (6) must engage in star wheel (8). 5 Detach spring (1) and remove Assembly: To facilitate attachment of the

spring (1), attach the automatic adjuster (11) to the brake shoes (2, 5) using the spring (1). 6 Disassemble automatic adjuster (11) Assembly: Locking pin of thermo clip (10)

must engage in recess on thrust sleeve (9). Before assembly, screw star wheel (8) completely onto threaded thrust rod (7). 7 Assemble in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-1030ff, Disassemble/assemble brake shoes MODEL 454.0 except CODE (30Y) Disk brakes on rear axle

AP42.10-P-4249U

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1740 · Applies to: 453 · AR: AP42.10-P-4256EW

Evaluate condition of brake disks, general view 20.02.2020 Model 117, 118, 156, 164, 166, 167, 169, 171, 172, 176, 177, 190, 197.3/4, 203, 204, 205, 207, 209, 211, 212, 213, 216, 217, 218, 219, 221, 222, 223, 230, 231, 238, 242, 245, 246, 247, 251, 253, 257, 290, 292, 293, 453, 461, 463 Assess condition of brake disks Model 117, 118, 156, 164, 166, 167, 169, 171, AP42.10-P-4256EW 172, 176, 177, 190, 197.3/4, 203, 204, 205, 207, 209, 211, 212, 213, 216, 217, 218, 219, 221, 222, 230, 231, 238, 242, 245, 246, 247, 251, 253, 257, 290, 292, 293, 453, 461, 463 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.10-p-4249u, Evaluate condition of brake disks, general view Model 117, 118, 156, 164, 166, 167, 169, 171, 172, 176, 177, 190, 197.3/4, 203, 204, 205, 207, 209, 211, 212, 213, 216, 217, 218, 219, 221, 222, 223, 230, 231, 238, 242, 245, 246, 247, 251, ...

AP42.10-P-4248U

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1741 · Applies to: 453 · AR: AP42.10-P-4252AH, AP42.10-P-4252CLA, AP42.10-P-4252GLA, AP42.10-P-4252GA, AP42.10-P-4252GB (+5 more)

Evaluate condition of brake linings, general view 20.02.2020 Model 117, 118, 156, 164, 166, 167, 169, 171, 172, 176, 177, 190, 197.3/4, 203, 204, 205, 207, 209, 211, 212, 213, 216, 217, 218, 219, 221, 222, 223, 230, 231, 238, 242, 245, 246, 247, 251, 253, 257, 290, 292, 293, 453, 461, 463 Assess condition of brake linings Model 117 AP42.10-P-4252AH Assess condition of brake linings Model 118 AP42.10-P-4252CLA Assess condition of brake linings Model 156 AP42.10-P-4252GLA Assess condition of brake linings Model 164 AP42.10-P-4252GA Assess condition of brake linings Model 166 AP42.10-P-4252GB Assess condition of brake linings Model 167 AP42.10-P-4252J Assess condition of brake linings Model 169 AP42.10-P-4252AK Assess condition of brake linings Model 171 AP42.10-P-4252SLA Assess condition of brake linings Model 172 AP42.10-P-4252SLB Assess condition of brake linings Model 176 AP42.10-P-4252KN Assess condition of brake linings Model 177 AP42.10-P-4252MFA Assess condition of brake linings Model 190 AP42.10-P-4252A Assess condition of brake linings Model 197.3/4 AP42.10-P-4252RQ Assess condition of brake linings Model 203 AP42.10-P-4252P Assess condition of brake linings Model 204 AP42.10-P-4252CW Assess condition of brake linings Model 205 AP42.10-P-4252CAA Assess condition of brake linings Model 207 AP42.10-P-4252CA Assess condition of brake linings Model 209 AP42.10-P-4252Q Assess condition of brake linings Model 211 AP42.10-P-4252T Assess condition of brake linings Model 212 AP42.10-P-4252EW Assess condition of brake linings Model 213 AP42.10-P-4252E Assess condition of brake linings Model 216 AP42.10-P-4252SC Assess condition of brake linings Model 217 AP42.10-P-4252C Assess condition of brake linings Model 218 AP42.10-P-4252EL Assess condition of brake linings Model 219 AP42.10-P-4252TX Assess condition of brake linings Model 221 AP42.10-P-4252SX Assess condition of brake linings Model 222 AP42.10-P-4252HA Assess condition of brake linings Model 230 AP42.10-P-4252SLC Assess condition of brake linings Model 231 AP42.10-P-4252RK Assess condition of brake linings Model 238 AP42.10-P-4252F Assess condition of brake linings Model 242 AP42.10-P-4252NKG Assess condition of brake linings Model 245 AP42.10-P-4252BK Assess condition of brake linings Model 246 AP42.10-P-4252NK Assess condition of brake linings Model 247.0 AP42.10-P-4252MFB Assess condition of brake linings Model 251 AP42.10-P-4252GC Assess condition of brake linings Model 253 AP42.10-P-4252D Assess condition of brake linings Model 257 AP42.10-P-4252CLS Assess condition of brake linings Model 290 AP42.10-P-4252I Assess condition of brake linings Model 292 AP42.10-P-4252B Assess condition of brake linings Model 293 AP42.10-P-4252EQ Assess condition of brake linings Model 453On front axle AP42.10-P-4252S Model 453at rear axle AP42.10-P-4252SS Assess condition of brake linings Model 461, 463 AP42.10-P-4252G Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.10-p-4248u, Evaluate condition of brake linings, general view Model 117, 118, 156, 164, 166, 167, 169, 171, 172, 176, 177, 190, 197.3/4, 203, 204, 205, 207, 209, 211, 212, 213, 216, 217, 218, 219, 221, 222, 223, 230, 231, 238, 242, 245, 246, 247, 251, ...

AR42.10-P-0169FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1744 · Applies to: 453 · AR: AR42.10-P-0169FF, AR42.10-P-0165FF

Install, remove automatic brake adjuster 20.3.06 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle P42.10-2520-08 1 Spring 5 Brake shoe 8 Star wheel 2 Brake shoe 6 Adjusting lever 9 Thrust sleeve 3 Spring 7 Threaded thrust rod 10 Thermo clip 4 Spring 1 Spring 2 Brake shoe 3 Spring 4 Spring 5 Brake shoe 6 Adjusting lever 11 Automatic adjuster P42.10-2519-11 Remove/install

1 Remove brake shoes (2, 5) from rear axle AR42.10-P-0165FF 2 Detach and remove spring (3) from brake shoes (2, 5) 3 Detach spring (4) from adjusting lever (6) and from brake shoe (5) and remove 4 Turn adjusting lever (6) slightly Installation: Adjusting lever (6) must be

counterclockwise, detach from lower guide on positioned between threaded thrust rod (7) brake shoe (5) and remove and brake shoe (5). Adjusting lever (6) must engage in star wheel (8) 5 Detach spring (1) and remove Installation: To facilitate attachment of

the spring (1), attach the automatic adjuster (11) to the brake shoes (2, 5) using the spring (1). 6 Remove automatic adjuster (11) 7 Disassemble automatic adjuster (11) Installation: Locking pin of thermo clip

(10) must engage in recess on thrust sleeve (9). Before assembly, screw star wheel (8) completely onto threaded thrust rod (7) 8 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0169ff, Install, remove automatic brake adjuster MODEL 454.0 except CODE (30Y) Disk brakes on rear axle

AP42.10-P-4247US

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1745 · Applies to: 453 · AR: AP42.10-P-4247US, AP42.10-P-4210MCC

Overview - Check brake system fluid level 29.08.2014 Model 451, 453 Brake system - inspect fluid level Model 451.3/4 AP42.10-P-4210MCC Brake system - inspect fluid level Model 453 AP42.10-P-4210S Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap42.10-p-4247us, Overview - Check brake system fluid level Model 451, 453

AR42.10-P-0500SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1746 · Applies to: 453 · AR: AR42.10-P-0500SR, AR42.10-P-0070SR

Remove/install brake carrier 21.07.2014 MODEL 453 P42.10-3056-07 Shown on MODEL 453.3 1 Brake caliper 2 Caliper support 3 Bolts Remove/install

Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Remove brake caliper (1) and hang up to one AR42.10-P-0070SR side with attached brake hose

Brake hose must not be under tension. Otherwise, the brake hose can be damaged. 2 Unscrew screws/bolts (3) and remove brake *BA42.10-P-1002-10SR Screw/bolt, brake caliper support to caliper support (2)
steering knuckle 3 Install in the reverse order Front axle brake caliper Number Designation MODEL 453 BA42.10-P-1002-10SR Screw/bolt, brake caliper support to steering knuckle Nm 105 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0500sr, Remove/install brake carrier MODEL 453

AR42.10-P-0164FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1747 · Applies to: 453 · AR: AR42.10-P-0164FF, AR42.10-P-0170FG

Remove/install brake carrier plate 20.3.06 MODEL 454.0 with CODE (30Y) Disk brakes on rear axle 1 Brake caliper 2 Bolt 3 Brake caliper support 4 Bolt 5 Bolts 6 Wheel hub with wheel bearing 7 Brake disk 8 Brake anchor plate L6/3 Left rear rpm sensor L6/4 Right rear rpm sensor P42.10-2499-06 Remove/install

1 Remove brake pads on rear axle AR42.10-P-0170FG Attach brake caliper (1) with cable tie in suitable location. 2 Unscrew bolts (2) and remove brake caliper *BA42.10-P-1003-12A

support (3) 3 Unscrew bolt (4) from left rear rpm sensor Use new bolt (4) when assembling. (L6/3) or right rear rpm sensor (L6/4) *BA42.30-P-1001-02E

4 Pull out the left rear left rear rpm sensor (L6/3) Installation:

Replace sealing ring of left or right rear rpm sensor (L6/4) rear rpm sensor (L6/3) or right rear rpm sensor (L6/4). 5 Remove bolts (5) Replace bolts (5). Installation:

Assistant required to position the first two bolts (5). *BA35.20-P-1001-06B

6 Remove wheel hub with wheel bearing (6) Installation:

The arrow pressed onto the and brake disk (7) wheel hub with wheel bearing (6) has to point into the direction of travel. 7 Remove brake carrier plate (8) 8 Install in the reverse order Hub

Number Designation Model 454.0 BA35.20-P-1001-06B Bolt, hub to rear axle Nm 70 Rear axle floating brake caliper

Number Designation Model 454.0 with code 30Y Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0164ff, Remove/install brake carrier plate MODEL 454.0 with CODE (30Y) Disk brakes on rear axle

AR42.10-P-0164FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1749 · Applies to: 453 · AR: AR42.10-P-0164FG, AR42.10-P-0165FF, AR42.10-P-0167FF

Remove/install brake carrier plate 20.3.06 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle 1 Brake anchor plate 2 Handbrake cable 3 Catch hook 4 Bolts 5 Wheel brake cylinder P42.10-2516-06 Remove/install

Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Remove brake shoes on rear axle AR42.10-P-0165FF 2 Remove wheel brake cylinder (5) AR42.10-P-0167FF 3 Push back catch (3) on hand brake cable (2) Hand brake cable (2) is secured to brake and detach hand brake cable (2) from brake carrier plate (1) with three catches (3). carrier plate (1) 4 Remove bolts (4) and detach brake carrier Bolts (4) are used to ensure more secure plate (1) attachment of brake carrier plate (1). 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0164fg, Remove/install brake carrier plate MODEL 454.0 except CODE (30Y) Disk brakes on rear axle

AR42.10-P-0164SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1750 · Applies to: 453 · AR: AR42.10-P-0164SR, AR42.10-P-0167SR, AR42.40-P-9807SR, AR35.20-P-0302SR

Remove/install brake carrier plate 04.08.2014 MODEL 453 Shown on left side of vehicle on MODEL 453.3 1 Brake cover plate 2 Rubber grommet 3 Axle tube 4 Brake cable P42.10-3045-06 Notes on repairs to brake system AH42.00-P-0003-01A

Remove/install

1 Remove left or right wheel brake cylinder AR42.10-P-0167SR 2 Remove rubber grommet (2) from axle tube (3) bracket 3 Push tabs (arrows) together and route brake cable (4) out of brake cover plate (1) 4 Remove left rear axle rpm sensor or right rear AR42.40-P-9807SR axle rpm sensor from brake cover plate (1) and place to one side Do not detach electrical connection from

left rear axle rpm sensor or electrical connection from right rear axle rpm sensor. 5 Remove wheel bearing with wheel hub AR35.20-P-0302SR 6 Remove brake cover plate (1) 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0164sr, Remove/install brake carrier plate MODEL 453

AR42.10-P-1010FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1751 · Applies to: 453 · AR: AR42.10-P-1010FF, AR40.10-P-1100FF

Remove/install brake drum 20.3.06 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle P42.10-2515-08 1 Brake drum 2 Bolt 3 Wheel hub Remove/install

Notes on repairs to brake system AH42.00-P-0003-01A

1 Remove left or right rear wheel AR40.10-P-1100FF 2 Unscrew bolt (2) of brake drum (1) 3 Remove brake drum (1) from hub (3) BE42.10-P-1001-12D Check brake drum (1) for wear. BR00.45-Z-1060-06A Installation: Clean braking surface and

wheel hub of brake drum (1) until metallic bright and apply a thin coating of grease to centering surface. 4 Install in the reverse order 5 Adjust drum brake AR42.10-P-1010-11FF Test values for drum brake Number Designation Model 454.0 without code 30Y BE42.10-P-1001-12D Brake drum diameter New mm 203.0 Wear limit for maintenance service mm 204.4 Repair materials Number Designation Order number BR00.45-Z-1060-06A Brake paste Q0007414V000000000 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-1010ff, Remove/install brake drum MODEL 454.0 except CODE (30Y) Disk brakes on rear axle

AR42.10-P-1010SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1752 · Applies to: 453 · AR: AR42.10-P-1010SR

Remove/install brake drum 28.01.2016 Model 453 Modification notes 11.01.2016 Document revised completely. 28.01.2016 Presetting for outside diameter of brake shoes Model 453.0 BE42.10-P-1003-12E 1 Brake drum 2 Bolts 3 Wheel hub A Centering surface P42.10-3003-06 4 Brake shoes 5 Adjustment plate 6 Bimetal fuse 7 Adjusting nut P42.10-3133-05 Risk of accident Danger ! when commissioning the Before starting the engine, actuate brake AS42.50-Z-0002-01A

vehicle due to a lack of braking effect when pedal several times until pressure is built up the service brake is operated for the first time and maintained in the brake system. after repair work. Risk of injury. Skin or eye injuries may result Wear protective gloves, protective clothing AS00.00-Z-0002-01A Danger !

when handling hot or glowing objects. and safety glasses, if necessary. Risk of poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Notes on repairs to brake system AH42.00-P-0003-01A

Page 1 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, ar42.10-p-1010sr, Remove/install brake drum Model 453

Brake fluid notes

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1753 · Applies to: 453 · AR: AR42.20-P-0540SR, AR40.10-P-1100SR, AR42.10-P-0165SR, AR42.10-P-0167SR

AH42.50-P-0001-01A

Remove

1 Release adjusting nut of brake cable on AR42.20-P-0540SR parking brake lever up to end of thread and completely lower the parking brake lever The thread must fit flush with the adjusting

nut. 2 Remove left or right rear wheel AR40.10-P-1100SR 3 Unscrew bolts (2) 4 Remove brake drum (1) from wheel hub (3)

The brake drum (1) must have unobstructed movement. Otherwise, the brake may be damaged. If the brake drum (1) cannot be removed. Rest brake shoe (4) by turning the adjusting nut (7) through a wheel bolt threaded hole

The bimetal fuse (6) may not be used here as a support bushing. Otherwise, the bimetal fuse (6) may be damaged. Check

5 Check brake drum (1) for wear and damage Inside diameter of brake drum *BE42.10-P-1001-12E In the event of complaints Replace brake drums (1) and brake shoes (4) on each axle AR42.10-P-0165SR 6 Check brake shoes (4) for wear and damage

The brake lining of the brake shoes (4) must be absolutely free of grease. Otherwise the braking effect will be impaired. Brake lining thickness *BE42.10-P-1002-12E In the event of complaints Replace brake shoes (4) on each axle AR42.10-P-0165SR 7 Check leaktightness of wheel brake cylinder In the event of complaints Replace wheel brake cylinder AR42.10-P-0167SR

At the merest hint of a brake fluid leakage, the wheel brake cylinder must be replaced. Otherwise, the braking effect may be impaired. Clean

8 Clean brake surface and contact surface of wheel hub (3) on brake drum (1) until they are metallic bright 9 Clean contact surface of brake drum on wheel hub (3) until it is metallic bright Install

10 Apply light coating of brake paste to Brake paste *BR00.45-Z-1060-06A centering surface (A) Measure

11 Measure outside diameter of brake shoes (4), as shown 12 Raise adjusting plate (5) using a screwdriver Presetting for outside diameter of brake shoes BE42.10-P-1003-12E and adjust outside diameter of brake shoes (4) by turning adjusting nut (7) using a second screwdriver If adjusting nut (7) is sluggish Replace brake adjuster AR42.10-P-0165SR 13 Mount brake drum (1) onto wheel hub (3) 14 Tighten bolts (2) BA42.10-P-1002-16D Bolt, brake drum to wheel hub 15 Mount left or right rear wheel AR40.10-P-1100SR Only lower vehicle after mounting left or

right rear wheel far enough to enable it still to be turned. Page 2 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, ar42.10-p-1010sr, Remove/install brake drum Model 453

Slowly operate brake pedal repeatedly until

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1754 · Applies to: 453 · AR: AR42.20-P-0540SR, AP42.00-P-4290MCC

16 Slowly operate brake pedal repeatedly until

an adjustment clicking is no longer heard The parking brake lever may not be operated here. Otherwise, the parking brake lever of the brake shoes (4) may be pulled onto the wheel hub bolts where they can no longer be released. 17 Adjust parking brake AR42.20-P-0540SR Check

18 Carry out brake test on the test stand AP42.00-P-4290MCC

Test and adjustment values for drum brake Number Designation Model 453.3/4 Model 453.0 BE42.10-P-1001-12E Inside diameter of brake drum New mm 203,2 228,5 Wear limit for mm 204,4 229,5 maintenance service Test and adjustment values for drum brake Number Designation Model 453.3/4 Model 453.0 BE42.10-P-1002-12E Brake lining thickness New mm 4,2 4,2 Wear limit for mm 2,4 2,4 maintenance service Pad backing plate mm 2,0 2,0 Test and adjustment values for drum brake Number Designation Model 453.3/4 Model 453.0 BE42.10-P-1003-12E Presetting for outside diameter of brake shoes mm 202,7 (-0,5) 227,6 (-0,5) Drum brake Number Designation Model 453 BA42.10-P-1002-16D Bolt, brake drum to wheel hub Nm 21 Repair materials Number Designation Order number BR00.45-Z-1060-06A Brake paste Q0007414V000000000 Page 3 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, ar42.10-p-1010sr, Remove/install brake drum Model 453

AR42.10-P-0301FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1755 · Applies to: 453 · AR: AR42.10-P-0301FF, AR83.25-P-1402FF, AR25.20-P-0070FF, AR42.10-P-0010FF, AR42.10-P-0010FG

Remove/install brake fluid reservoir 10.11.11 MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle 1 Brake fluid reservoir 2 Electrical connector 3 Screw 4 Master brake cylinder S11 Brake fluid indicator switch P42.10-2325-04 Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Remove water collector AR83.25-P-1402FF 2 Extract brake fluid from brake fluid reservoir Brake fluid change unit (1) gotis://B_42/43.2_01 3 Detach electrical connector (2) to the brake fluid indicator switch (S11) 4.1 Detach concealed hose (arrow) of clutch On transmission 717.470/471/473/478 master cylinder on brake fluid expansion reservoir (1) using suitable pliers Pay attention to seal in concealed hose (arrow). Installation:

Check seal in concealed hose (arrow) and replace if necessary. 5 Unscrew bolt (3) 6 Pull reservoir for brake fluid (1) from the Installation:

Replace seals in master master brake cylinder (4) brake cylinder (4). 7.1 Pull brake fluid indicator switch (S11) from the When replacing brake fluid reservoir (1). brake fluid reservoir (1) 8 Install in the reverse order 9.1 Bleed clutch operating system On transmission 717.470/471/473/478 AR25.20-P-0070FF 10 Bleed brake system On vehicles with code (30Y) Disk brakes on AR42.10-P-0010FF rear axle On vehicles without code (30Y) Disk brakes AR42.10-P-0010FG on rear axle Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0301ff, Remove/install brake fluid reservoir MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle

AR42.10-P-0301FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1756 · Applies to: 453 · AR: AR42.10-P-0301FG, AR83.25-P-1402FF, AR25.20-P-0070FF, AR42.10-P-0010FF, AR42.10-P-0010FG

Remove/install brake fluid reservoir 10.11.11 MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle P42.10-2443-08 Shown on vehicle with transmission 717.473 1 Brake fluid reservoir 4 Screw 7 Seals 2 Hose (on transmission 5 Master brake cylinder 717.470/471/473/478) 6 Clip S11 Brake fluid indicator switch 3 Electrical connector Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Remove water collector AR83.25-P-1402FF 2 Extract brake fluid from brake fluid reservoir Brake fluid change unit (1) gotis://B_42/43.2_01 3 Detach electrical connector (3) to the brake fluid indicator switch (S11) 4.1 Detach hose (2) of clutch master cylinder on Only on transmission 717.470/471/473/478 brake fluid expansion reservoir (1) using suitable pliers Pay attention to seal in hose (2). Installation:

Check seal in hose (2) and replace if necessary. 5 Unscrew screw/bolt (4) 6 Pull brake fluid reservoir (1) out of the master Installation:

Replace seals (7) in master brake cylinder (5) and unclip clip (6) in the brake cylinder (5). lower area 7.1 Pull brake fluid indicator switch (S11) from the Only when replacing brake fluid reservoir (1). brake fluid reservoir (1) 8 Install in the reverse order 9.1 Bleed clutch operating system Only on transmission 717.470/471/473/478 AR25.20-P-0070FF 10 Bleed brake system On vehicles with code (30Y) Disk brakes on AR42.10-P-0010FF rear axle On vehicles without code (30Y) Disk brakes AR42.10-P-0010FG on rear axle Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0301fg, Remove/install brake fluid reservoir MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle

AR42.10-P-0023SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1757 · Applies to: 453 · AR: AR42.10-P-0023SR

Remove/install brake hose at rear axle 04.08.2014 MODEL 453 Shown on brake hose (1) of right rear service brake 1 Brake hose 2 Brake line 3 Retaining clamp 4 Brake line 5 Retaining clamp P42.10-3044-06 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 poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

Remove/install

1 Install brake pedal jack with adapter between

brake pedal and driver seat, and depress Cover driver seat. brake pedal by approx. 2 cm Otherwise the driver seat could be soiled or damaged. To prevent the brake fluid reservoir from

running empty. 000589183100 Brake pedal jack 211589003100 Adapter for brake pedal winch 2 Raise vehicle with vehicle lift 3 Unscrew retaining screw of brake line (2) BA42.10-P-1002-04SR Retaining screw, brake line to brake hose from brake hose (1) 4 Seal connections of brake line (2) and brake 129589009100 Record plug hose (1) immediately 5 Installation: Remove brake hose (1) from bracket and

remove retaining clamp (3) Install brake hose (1) without any chafing and free of torsion. Otherwise the brake hose (1) will be damaged. Installation: Make sure that retaining clip

(3) is seated properly. 6 Detach underfloor paneling in area of To create the necessary working area.

connection between brake line (4) and brake hose (1) 7 Unscrew retaining screw of brake line (4) Collect brake fluid in a suitable container.

from brake hose (1) BA42.10-P-1002-04SR Retaining screw, brake line to brake hose 8 Seal connections of brake line (4) and brake 129589009100 Record plug hose (1) immediately Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0023sr, Remove/install brake hose at rear axle MODEL 453

Remove brake hose (1) from bracket and

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1758 · Applies to: 453 · AR: AR42.10-P-0010SR

9 Remove brake hose (1) from bracket and Installation: Make sure that the retaining

remove retaining clamp (5) clamp (5) is seated properly. 10 Install in the reverse order 11 Bleed brake system AR42.10-P-0010SR Brake lines, brake hoses Number Designation MODEL 453 BA42.10-P-1002-04SR Retaining screw, brake line to brake hose Nm 13 211 589 00 31 00 129 589 00 91 00 000 589 18 31 00 Adapter for brake pedal winch Record plug Brake pedal jack Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0023sr, Remove/install brake hose at rear axle MODEL 453

AR42.10-P-0026SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1759 · Applies to: 453 · AR: AR42.10-P-0026SR, AR40.10-P-1100SR, AR42.10-P-0010SR

Remove/install brake hose to front axle 04.08.2014 MODEL 453 Shown on left side of vehicle 1 Brake hose 2 Brake line 3 Retaining clamp 4 Rubber grommet 5 Floating caliper P42.10-3043-05 Risk of poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

Remove/install

1 Insert brake pedal jack with adapter for brake

pedal jack between brake pedal and driver's Cover driver seat. seat, and press brake pedal approx. 2 cm Otherwise the driver's seat may be soiled or damaged. To prevent the brake fluid reservoir from

emptying. 211589003100 Adapter for brake pedal winch 000589183100 Brake pedal jack 2 Remove left or right wheel-and-tire assembly AR40.10-P-1100SR 3 Unscrew retaining screw of brake line (2) Collect brake fluid in a suitable container.

from brake hose (1) BA42.10-P-1002-04SR Retaining screw, brake line to brake hose 4 Immediately seal off brake line (2) and brake 129589009100 Record plug hose (1) connections 5 Installation: Remove brake hose (1) from bracket and

remove retaining clamps (3) Install brake hose (1) without any chafing and free of tension. Otherwise the brake hose (1) will be damaged. Installation: Make sure that retaining clip

(3) is seated properly. 6 Remove rubber grommet (4) from bracket 7 Unscrew brake hose (1) from floating brake Collect brake fluid in a suitable container.

caliper (5) and remove BA42.10-P-1001-04SR Brake hose to front floating caliper 8 Immediately seal off brake hose (1) and 129589009100 Record plug floating brake caliper (5) connections 9 Install in the reverse order 10 Bleed brake system AR42.10-P-0010SR Brake lines, brake hoses Number Designation MODEL 453 BA42.10-P-1001-04SR Brake hose to front floating caliper Nm 17 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0026sr, Remove/install brake hose to front axle MODEL 453

AR42.10-P-0042SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1761 · Applies to: 453 · AR: AR42.10-P-0042SR

Remove/install brake light switch 04.08.2014 MODEL 453 1 Brake pedal bearing bracket S9/1 Stop lamp switch P42.10-3030-11 Remove/install

1 Move driver's seat to rearmost position 2 Turn brake light switch (S9/1) through a quarter turn in counterclockwise direction and remove from brake pedal bearing bracket (1) 3 Detach electrical connector from brake light switch (S91) 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0042sr, Remove/install brake light switch MODEL 453

AR42.10-P-0034SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1762 · Applies to: 453 · AR: AR42.10-P-0034SR, AR20.30-P-4950SR, AR42.10-P-0301SR

Remove/install brake line from master brake cylinder to the ESP(R) hydraulic unit 10.07.2018 Model 453 P42.10-3137-08 Shown on model 453.3## 1# 1 Brake line 3 Hydraulic unit 5 Connecting clip 2 Brake line 4 Master brake cylinder Risk of poisoning Caution from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Topical note Brake fluid notes AH42.50-P-0001-01A Topical note Notes on repairs to brake system AH42.00-P-0003-01A Remove/install

1 Remove coolant expansion reservoir AR20.30-P-4950SR 2 Remove brake fluid reservoir AR42.10-P-0301SR Check

3 Check connections of brake line (1 or 2) for WIS Service Media

color coding wsm://01_201502_12 If a connection that is marked in a color needs to be disconnected. Replace corresponding brake line (1, 2). The connections of a new brake line (1, 2)

must not be marked in color. 4.1 Check the combination of connections of Model 453.### 1# brake lines (1, 2) from master brake cylinder (4) to hydraulic unit (3) The brake line (1) must run between the

front connection of master brake cylinder (4) and left connection of hydraulic unit (3) (arrows A). The brake line (2) must run between the rear connection of master brake cylinder (4) and right connection of hydraulic unit (3) (arrows B). If this is not the case Replace both brake lines (1, 2) with corresponding brake lines. Suitable brake lines can be ordered via

EPC. 4.2 Mark installation position of brake line (1 or 2) Model 453.### 2# at master brake cylinder (4) and hydraulic unit (3) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0034sr, Remove/install brake line from master brake cylinder to the ESP(R) hydraulic unit Model 453

Do not use any color.

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1763 · Applies to: 453 · AR: AR42.10-P-0010SR, AP42.00-P-4290MCC

5 Release connecting clip (5) from brake line (1 or 2) 6 Remove brake line (1 or 2) and collect escaping brake fluid Note on calculation of tightening torque when AH00.00-P-0015-01CW using insertion or socket tools with various effective lengths Installation:

Do not bend brake lines (1, 2) and ensure chafe-free routing. Otherwise brake lines (1, 2) may be damaged. Model 453.### 1# Installation: Check the combination of connections of brake lines (1, 2) from master brake cylinder (4) to hydraulic unit (3) (arrows A, B). Model 453.### 2# Installation: Observe the marks of installation positions. BA42.10-P-1004-04SR Retaining screw, brake line to hydraulic unit BA42.10-P-1003-04SR Retaining screw, brake line to master brake cylinder 7 Seal all connections with stop plugs *129589009100 Record plug 8 Install in the reverse order 9 Bleed brake system AR42.10-P-0010SR Check

10 Check brake system in area of brake lines (1, 2) for leaktightness 11 Carry out brake test on the test stand AP42.00-P-4290MCC

Brake lines, brake hoses Number Designation Model 453 BA42.10-P-1003-04SR Retaining screw, brake line to master brake cylinder Nm 14 Brake lines, brake hoses Number Designation Model 453 BA42.10-P-1004-04SR Retaining screw, brake line to hydraulic unit Nm 14 129 589 00 91 00 Record plug Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0034sr, Remove/install brake line from master brake cylinder to the ESP(R) hydraulic unit Model 453

AR42.10-P-0017FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1764 · Applies to: 453 · AR: AR42.10-P-0017FF, AR09.10-P-1150FF, AR09.10-P-1150FG, AR83.25-P-1402FF, AR42.10-P-0301FF

Remove/install brake lines 20.3.06 MODEL 454.0 Front axle P42.50-2037-09 Shown on vehicle with code (30Y) Rear axle disk brake 1 Hydraulic unit 5 Left brake hose FL Front left connection 2 Brake fluid reservoir 6 Right brake hose FR Front right connection 3 Left brake line 7 Guide grommet RL Rear left connection 4 Right brake line RR Rear right connection Shown on engine 639.9 8 Bolts (on engine 639.9) N14/2 Glow output stage (on engine 639.9) P15.20-2129-04 Modification notes 15.6.05 Check brake line for re-use added Remove/install

Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Remove air filter housing Engines 134.9, 135.9 AR09.10-P-1150FF Engine 122.9, 639.9 AR09.10-P-1150FG 2.1 Remove water collector When removing the right brake line (4) on AR83.25-P-1402FF vehicle with engine 122.9 or 639.9 3.1 Remove brake fluid reservoir (2) When removing the left brake line (3) from the AR42.10-P-0301FF vehicle with code (LHD) Left-hand drive vehicle Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0017ff, Remove/install brake lines MODEL 454.0 Front axle

Extract brake fluid from brake fluid reservoir

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1765 · Applies to: 453 · AR: AR42.10-P-0010FF, AR42.10-P-0010FG

3.2 Extract brake fluid from brake fluid reservoir When removing the right brake line (4) from (2) the vehicle with code (RHD) Right-hand drive vehicle Brake fluid replacement unit *WE58.40-Z-1001-07A 4 Check the bolted connection of the left brake AR42.10-P-0013-05SM line (3) or right brake line (4) for color coding Installation:

Identify or replace the left brake line (3) or right brake line (4) accordingly. Refer to: Mark brake lines AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 5 Detach the front left connection (FL) for left Collect brake fluid which runs out in a brake line (3) or front right front connection suitable container. (FR) for right brake line (4) on the hydraulic Seal openings on the hydraulic unit (1) and on unit (1) the left brake line (3) or right brake line (4) with suitable plugs. *BA42.10-P-1005-04G

6 Detach left brake line (3) from left brake hose Collect brake fluid which runs out in a (5) or right brake line (4) from right brake hose suitable container. (6) Seal opening on left brake line (3), right brake line (4), left brake hose (5), and right brake hose (6) using a suitable plug. *BA42.10-P-1001-04G

7.1 Unscrew bolts (8) and place glow output stage On vehicles with engine 639.9 and code (N14/2) aside with the lines connected (LHD) left-hand drive vehicle 8 Loosen guide grommet (7) on the left and Installation:

In order to avoid damage to right of the body the left brake line (3) or the right brake line (4) due to chafing on the body, damaged guide grommets (7) must always be replaced. 9 Unclip left brake line (3) or.right brake line (4) Installation:

In order to avoid damage to from the brackets the left brake line (3) or the right brake line (4) due to chafing on the body, damaged brackets must always be replaced. 10 Take out left brake line (3) or right brake line Installation:

In order to avoid damage to (4) the left brake line (3) or the right brake line (4), do not bend or buckle the left brake line (3) or right brake line (4). Installation:

Replace the left brake line (3) or right brake line (4) if initial color coding testing makes color coding. 11 Install in the reverse order 12 Bleed brake system On vehicles with code (30Y) Rear axle disk AR42.10-P-0010FF brake On vehicles without code (30Y) Rear axle disk AR42.10-P-0010FG brake 13.1 Carry out transposition test Only when the left brake line (3) and the right brake line (4) have been replaced. Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Brake lines, brake hoses

Number Designation Model Model 454.0 with 454.0 code 30Y without code 30Y BA42.10-P-1001-04G Brake pipe to brake hose Nm 15 15 BA42.10-P-1005-04G Brake line to hydraulic unit Nm 15 15 Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0017ff, Remove/install brake lines MODEL 454.0 Front axle

AR42.10-P-0017FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1767 · Applies to: 453 · AR: AR42.10-P-0017FG

Remove/install brake lines 20.3.06 MODEL 454.0 Rear axle P42.50-2038-09 Shown on vehicle with code (30Y) Rear axle disk brake 1 Hydraulic unit 4 Brake line, right rear RL Rear left connection 2 Brake fluid reservoir 5 Brake hose, rear left RR Rear right connection 3 Brake line, rear left 6 Brake hose, right rear FL Front left connection FR Front right connection P42.50-2039-09 Shown on vehicle with code (30Y) Rear axle disk brake 7 Bracket 10 Bracket 13 Retaining rubber 8 Hose 11 Left hand brake cable 14 Cover 9 Fuel tank 12 Rear muffler Modification notes 15.6.05 Check brake line for re-use added Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0017fg, Remove/install brake lines MODEL 454.0 Rear axle

Installation:

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1769 · Applies to: 453 · AR: AR42.10-P-0010FF, AR42.10-P-0010FG

Replace the left rear brake line (3) or right rear brake line (4) if initial color coding testing makes this color coding. 16 Install in the reverse order 17 Bleed brake system On vehicles with code (30Y) Rear axle disk AR42.10-P-0010FF brake On vehicles without code (30Y) Rear axle disk AR42.10-P-0010FG brake 18.1 Carry out transposition test Only when the left rear brake line (3) and the right rear brake line (4) have been replaced. Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A 19.1 Pour in fuel again which had been drained Only when the fuel tank (9) has been emptied. Brake lines, brake hoses

Number Designation Model Model 454.0 with 454.0 code 30Y without code 30Y BA42.10-P-1001-04G Brake pipe to brake hose Nm 15 15 BA42.10-P-1005-04G Brake line to hydraulic unit Nm 15 15 Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Workshop equipment WE58.40-Z-1001-07A Brake fluid replacement unit Repair materials Number Designation Order number BR00.45-Z-1028-07A "Red" safety paint Lackfabrik Bäder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 BR00.45-Z-1027-07A "Yellow" locking paint Lackfabrik Bäder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0017fg, Remove/install brake lines MODEL 454.0 Rear axle

AR42.10-P-0017FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1770 · Applies to: 453 · AR: AR42.10-P-0017FH, AR83.25-P-1402FF

Remove/install brake lines 10.11.11 MODEL 454.0## 2# with ENGINE 639.9 with CODE (RHD) Right-hand drive vehicle from master brake cylinder to hydraulic unit P42.10-2445-09 Shown on vehicle with transmission 717.473 1 Adapter (on transmission 717.473) 4 Brake lines 7 Bracket 2 Master cylinder (on transmission 5 Bracket 8 Nut 717.473) 6 Hydraulic unit 9 Master brake cylinder 3 Locking clamp (on transmission 717.473) Modification notes 15.6.05 Check brake line for reuse added Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Remove water collector AR83.25-P-1402FF 2 Extract brake fluid from brake fluid reservoir Brake fluid change unit gotis://B_42/43.2_01 3 Check bolted connection of brake lines (4) for AR42.10-P-0013-05SM color coding Installation:

Identify or replace brake lines (4) accordingly. See: Mark brake lines AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 4 Unscrew nuts (8) and loosen clip of wiring harness (arrow) in upper area of the bracket (7) 5 Remove bracket (7) forwards until the brake Do not remove bracket (7). lines (4) are accessible 6.1 Loosen locking clamp (3) using a suitable tool Only if transmission 717.473 is fitted and loosen adapter (1) with line from the master cylinder (2) and place to one side Do not bend the line as strain cracks may occur which make the line unusable. Do not detach the locking clamp (3). Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0017fh, Remove/install brake lines MODEL 454.0## 2# with ENGINE 639.9 with CODE (RHD) Right-hand drive vehicle from master brake cylinder to hydraulic unit

Unscrew brake lines (4) from master brake

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1771 · Applies to: 453 · AR: AR25.20-P-0070FF, AR42.10-P-0010FF, AR42.10-P-0010FG

7 Unscrew brake lines (4) from master brake Collect brake fluid which runs out in a cylinder (9) suitable container. Seal the openings on the brake lines (4) and on the master brake cylinder (9) using suitable plugs. *BA42.10-P-1006-04G

8 Unscrew brake lines (4) on the hydraulic unit Collect brake fluid which runs out in a (6) suitable container. Seal openings on the brake lines (4) and hydraulic unit (6) with suitable plugs. *BA42.10-P-1005-04G

9 Unclip brake lines (4) from the brackets (5) Observe installation position. and remove cautiously Installation:

In order to prevent damage to the brake lines (4) due to chafing on the body, damaged brackets (5) must always be replaced. Installation:

Replace the brake lines (4), if necessary after initial testing of the color coding. 10 Install in the reverse order 11.1 Bleed clutch operating system Only if transmission 717.473 is fitted AR25.20-P-0070FF 12 Bleed brake system On vehicles with code (30Y) Disk brakes on AR42.10-P-0010FF rear axle On vehicles without code (30Y) Disk brakes AR42.10-P-0010FG on rear axle 13.1 Carry out transposition test Only if both brake lines (4) have been replaced. Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Brake lines, brake hoses

Number Designation Model 454.0 with code 30Y BA42.10-P-1005-04G Brake line to hydraulic unit Nm 15 BA42.10-P-1006-04G Hydraulic unit brake line to master brake Nm 15 cylinder Repair materials Number Designation Order number BR00.45-Z-1027-07A "Yellow" locking paint Lackfabrik Bäder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 BR00.45-Z-1028-07A "Red" safety paint Lackfabrik Bäder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0017fh, Remove/install brake lines MODEL 454.0## 2# with ENGINE 639.9 with CODE (RHD) Right-hand drive vehicle from master brake cylinder to hydraulic unit

AR42.10-P-0017FI

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1772 · Applies to: 453 · AR: AR42.10-P-0017FI, AR88.00-P-2792FF, AR09.10-P-1150FF

Remove/install brake lines 10.11.11 MODEL 454.0## 2# with ENGINE 134.9, 135.9 with CODE (RHD) Right-hand drive vehicle from master brake cylinder to hydraulic unit P42.10-2459-07 1 Brake fluid reservoir 5 Nut 8 Master brake cylinder 2 Activated charcoal canister 6 Brake booster vacuum line 9 Hydraulic unit 3 Bracket 7 Brake lines 10 Cover 4 Electrical line Modification notes 15.6.05 Check brake line for reuse added Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 2 Take off cover (10) 3 Extract brake fluid from brake fluid reservoir Brake fluid change unit (1) gotis://B_42/43.2_01 4 Remove air filter housing AR09.10-P-1150FF 5 Pull activated charcoal canister (2) upwards Installation:

Observe the correct seat of out of the bracket (3) the vent line in the clip (arrow). 6 Unclip electrical line (4) from bracket (3) and The bracket (3) is attached to the firewall remove clip (3) with two nuts. 7 Check bolted connection of brake lines (7) for AR42.10-P-0013-05SM color coding Installation:

Identify or replace brake lines (7) accordingly. See: Mark brake lines AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 8 Unscrew nuts (5) of vacuum line of brake booster (6) on the splash wall 9 Unscrew brake lines (7) from master brake Collect brake fluid which runs out in a cylinder (8) suitable container. Seal the openings on the brake lines (7) and on the master brake cylinder (8) using suitable plugs. *BA42.10-P-1006-04G

10 Unscrew brake lines (7) on the hydraulic unit Collect brake fluid which runs out in a (9) suitable container. Seal openings on the brake lines (7) and hydraulic unit (9) with suitable plugs. *BA42.10-P-1005-04G

11 Unclip brake lines (7) from the brackets on the Observe installation position of the brake firewall and take out carefully lines (7). Installation:

In order to prevent damage to the brake lines (7) due to chafing on the body, damaged brackets must be replaced. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0017fi, Remove/install brake lines MODEL 454.0## 2# with ENGINE 134.9, 135.9 with CODE (RHD) Right-hand drive vehicle from master brake cylinder to hydraulic unit

Installation:

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1773 · Applies to: 453 · AR: AR42.10-P-0010FF, AR42.10-P-0010FG

Replace the brake lines (7), if necessary after initial testing of the color coding. 12 Install in the reverse order 13 Bleed brake system On vehicles with code (30Y) Disk brakes on AR42.10-P-0010FF rear axle On vehicles without code (30Y) Disk brakes AR42.10-P-0010FG on rear axle 14.1 Carry out transposition test Only if both brake lines (7) have been replaced. Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Brake lines, brake hoses

Number Designation Model Model 454.0 with 454.0 code 30Y without code 30Y BA42.10-P-1005-04G Brake line to hydraulic unit Nm 15 15 BA42.10-P-1006-04G Hydraulic unit brake line to master brake Nm 15 15 cylinder Repair materials Number Designation Order number BR00.45-Z-1027-07A "Yellow" locking paint Lackfabrik Bäder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 BR00.45-Z-1028-07A "Red" safety paint Lackfabrik Bäder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0017fi, Remove/install brake lines MODEL 454.0## 2# with ENGINE 134.9, 135.9 with CODE (RHD) Right-hand drive vehicle from master brake cylinder to hydraulic unit

AR42.10-P-0017FJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1774 · Applies to: 453 · AR: AR42.10-P-0017FJ, AR42.10-P-0010FG

Remove/install brake lines 20.3.06 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle brake line on wheel brake cylinder P42.10-2522-08 1 Wheel brake cylinder 2 Brake line to wheel brake cylinder 3 Brake hose Modification notes 15.6.05 Check brake line for re-use added Remove/install

Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Extract brake fluid from brake fluid reservoir Brake fluid replacement unit *WE58.40-Z-1001-07A 2 Check bolted connection of brake line on AR42.10-P-0013-05SM wheel brake cylinder (2) for color coding Installation:

Identify or replace brake line on wheel brake cylinder (2) accordingly. Refer to: Mark brake lines AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 3 Detach brake line from left rear or right rear Collect brake fluid which runs out in a wheel brake cylinder (2) suitable container. Seal opening of brake line on left rear or right rear wheel brake cylinder (2) and on wheel brake cylinder (1) with suitable plugs. *BA42.10-P-1007-04G

4 Unscrew brake line to left rear and right rear Collect brake fluid which runs out in a wheel brake cylinder (2) from left rear and suitable container. right rear brake hose (3) Seal opening on the brake line on left rear or right rear wheel brake cylinder (2) and on brake hose (3) with suitable plugs. *BA42.10-P-1001-04G

5 Disconnect brake line from left rear and right Installation: In order to avoid damage to

rear wheel brake cylinder (2) the brake line on the left rear or right rear wheel brake cylinder (2), do not bend or kink brake line on left rear or right rear wheel brake cylinder (2). Installation:

Replace the brake line on the left rear or right rear wheel brake cylinder (2) if initial color coding testing makes this color coding. 6 Install in the reverse order 7 Bleed brake system AR42.10-P-0010FG Brake lines, brake hoses

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0017fj, Remove/install brake lines MODEL 454.0 except CODE (30Y) Disk brakes on rear axle brake line on wheel brake cylinder

AR42.10-P-0017FK

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1776 · Applies to: 453 · AR: AR42.10-P-0017FK, AR09.10-P-1150FF, AR09.10-P-1150FG, AR42.10-P-0010FF, AR42.10-P-0010FG

Remove/install brake lines 10.11.11 MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle from master brake cylinder to hydraulic unit 1 Brake lines 2 Brake fluid reservoir 3 Master brake cylinder 4 Hydraulic unit P42.10-2549-05 Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Extract brake fluid from brake fluid reservoir Brake fluid change unit (2) gotis://B_42/43.2_01 2 Remove air filter housing Engine 134.9, 135.9 AR09.10-P-1150FF Engine 122.9, 639.9 AR09.10-P-1150FG 3 Check bolted connection of brake lines (1) for AR42.10-P-0013-05SM color coding Installation:

Identify or replace brake lines (1) accordingly. See: Mark brake lines AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 4 Unscrew brake lines (1) from master brake Collect brake fluid which runs out in a cylinder (3) suitable container. Seal the openings on the brake lines (1) and on the master brake cylinder (3) using suitable plugs. *BA42.10-P-1006-04G

5 Unscrew brake lines (1) on the hydraulic unit Collect brake fluid which runs out in a (4) suitable container. Seal openings on the brake lines (1) and hydraulic unit (4) with suitable plugs. *BA42.10-P-1005-04G

6 Remove brake lines (1) Installation: In order to prevent damage

to the brake lines (1), do not bend or buckle brake lines (1). Installation:

Replace the brake lines (1), if necessary after initial testing of the color coding. 7 Install in the reverse order 8 Bleed brake system On vehicles with code (30Y) Disk brakes on AR42.10-P-0010FF rear axle On vehicles without code (30Y) Disk brakes AR42.10-P-0010FG on rear axle 9.1 Carry out transposition test Only if both brake lines (1) have been replaced. Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0017fk, Remove/install brake lines MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle from master brake cylinder to hydraulic unit

AR42.10-P-0001SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1778 · Applies to: 453 · AR: AR42.10-P-0001SR

Remove/install brake lines on underfloor 4.5.15 Model 453 Shown on MODEL 453.3 with CODE I01 (Automatic air conditioning) 1 Brake line, rear left 2 Brake line, right rear 3 Separating points 4 Brake hose, rear left 5 Brake hose, right rear 6 Bracket P42.10-3039-06 Risk of poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. 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. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

Remove/install

1 Insert brake pedal jack with adapter for brake

pedal jack between brake pedal and driver's Cover driver seat. seat, and press brake pedal approx. 2 cm Otherwise the driver's seat may be soiled or damaged. 000589183100 Brake pedal jack 211589003100 Adapter for brake pedal winch 2 Raise vehicle with vehicle lift 3 Remove underfloor panels 4 Unscrew left rear brake line (1) or right rear BA42.10-P-1005-04SR Retaining screw, brake line to threaded brake line (2) at separating point (3) and seal socket off connections 129589009100 Record plug 5 Unscrew left rear brake line (1) from left rear BA42.10-P-1002-04SR Retaining screw, brake line to brake hose brake hose (4) or right rear brake line (2) from right rear brake hose (5) and seal off connections 129589009100 Record plug 6 Detach bracket (6) from body

Model 453 with code I01 (Air conditioning Plus) Model 453 with code I77 (Air conditioning, manual) Do not kink or bend the refrigerant lines. Otherwise leaks can occur in the refrigerant circuit. 7 Unclip left rear brake line (1) or right rear Make sure that the left rear brake line (1)

brake line (2) or right rear brake line (2) is correctly seated. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0001sr, Remove/install brake lines on underfloor Model 453

Remove left rear brake line (1) or right rear

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1779 · Applies to: 453 · AR: AR42.10-P-0010SR

8 Remove left rear brake line (1) or right rear

brake line (2) Do not kink or bend the left rear brake line (1) or right rear brake line (2). Otherwise leaks can occur in the brake circuit. 9 Install in the reverse order 10 Bleed brake system AR42.10-P-0010SR Brake lines, brake hoses Number Designation Model 453 BA42.10-P-1002-04SR Retaining screw, brake line to brake hose Nm 13 Brake lines, brake hoses Number Designation Model 453 BA42.10-P-1005-04SR Retaining screw, brake line to threaded socket Stage 1 Nm 8 ° Stage 2 40 211 589 00 31 00 129 589 00 91 00 000 589 18 31 00 Adapter for brake pedal winch Record plug Brake pedal jack Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0001sr, Remove/install brake lines on underfloor Model 453

AR42.10-P-0165FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1780 · Applies to: 453 · AR: AR42.10-P-0165FF, AR42.10-P-1010FF, AR35.20-P-0302FF, AR42.10-P-0167FF, AR42.10-P-1030FF

Remove/install brake shoes at rear axle 21.4.08 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle 1 Wheel brake cylinder 2 Retaining pin 3 Clamping spring 4 Brake shoe 5 Handbrake cable 6 Support bushing P42.10-2521-11 Modification notes 31.3.08 Check brake shoes and brake drums as well as appropriate Step 11 BE, added Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A

brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Remove brake drum AR42.10-P-1010FF 2 Remove wheel bearing AR35.20-P-0302FF The wheel bearing bolts remain in the rear axle so that the brake anchor plate cannot fall off. 3 Unhook brake shoes (4) from support bushing (6) using suitable tool 4 Remove clamping springs (3) from brake *168589003700

shoes (4) using pliers and detach retaining pins (2) 5 Lift out brake shoes (4) together with springs Do not damage the dust boots of the and slack adjuster, while simultaneously wheel brake cylinder (1), otherwise a new pushing together pistons of wheel brake wheel brake cylinder will have to be installed. cylinder (1) 6 Unhook hand brake cable (5) from rear brake shoe (4) 7 Remove brake shoes (4) Installation: The brake lining of the brake

shoes (4) must be free of grease, otherwise the braking effect will be uneven. 8 Clean brake anchor plate Installation: Apply a thin coating of brake paste to the contact surfaces of the brake shoes (4) on the brake anchor plate. Brake paste *BR00.45-Z-1060-06A 9 Check the ease of movement of the wheel Install a new wheel brake cylinder (1) at brake cylinder (1) and leaktightness of the the first sign of brake fluid leakage or boots sluggishness. Refer to: Remove/install wheel brake cylinder AR42.10-P-0167FF 10 Disassemble brake shoes (4) Only if individual components are to be AR42.10-P-1030FF replaced. Checking

11 Check wear and condition of brake shoes (4) Brake drum diameter BE42.10-P-1001-12D and brake drums using vernier caliper; replace if necessary Brake lining thickness BE42.10-P-1002-12D *450589011900

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0165ff, Remove/install brake shoes at rear axle MODEL 454.0 except CODE (30Y) Disk brakes on rear axle

AR42.10-P-0165SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1782 · Applies to: 453 · AR: AR42.10-P-0165SR

Remove/install brake shoes at rear axle 16.02.2017 Model 453 Modification notes 12.01.2016 Document revised completely. P42.10-3125-09 1 Brake shoe 5 Spring 10 Spring 2 Clamping spring 6 Brake cover plate 11 Contact surfaces 3 Retaining pin 7 Wheel brake cylinder 12 Support bushing 4 Brake cable 9 Parking brake lever Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0165sr, Remove/install brake shoes at rear axle Model 453

P42.10-3126-09

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1783 · Applies to: 453 · AR: AR42.10-P-1010SR, AR42.10-P-0167SR

13 Slack adjuster 13.2 Bimetal locking clip 13.4 Adjusting nut 13.1 Brake shoe mounting 13.3 Adjustment plate Risk of accident Danger when commissioning the Before starting the engine, actuate brake AS42.50-Z-0002-01A

vehicle due to a lack of braking effect when pedal several times until pressure is built up the service brake is operated for the first time and maintained in the brake system. after repair work. Risk of poisoning Caution from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Topical note Notes on repairs to brake system AH42.00-P-0003-01A Topical note Brake fluid notes AH42.50-P-0001-01A Remove

1 Remove brake drum AR42.10-P-1010SR 2 Remove clamping springs (2) and remove retaining pins (3) 3 Pull brake shoes (1) one after the other out of

the support bushing (12), tilt slightly upwards The spring (5) may not be stretched. and position on support bushing (12) Otherwise, the brake may suffer damage or malfunction. 4 Detach spring (5) and remove Note the installation position.

5 Unhook brake cable (4) from parking brake lever (9) 6 Tilt brake shoes (1) upwards over the wheel

hub, push piston of wheel brake cylinder (7) Carefully guide brake shoes (1) over dust together and remove brake shoes (1) with boots of wheel brake cylinder (7). spring (10) and slack adjuster (13) If a dust boot is damaged, the wheel brake cylinder (7) must be replaced. 7 Detach spring (10) and slack adjuster (13) Note installation position of spring (10) and

from brake shoe (1) slack adjuster (13). Clean

8 Clean brake cover plate (6) Check

9 Check wear and condition of brake shoes (1)

The parking brake lever (9) must operate smoothly. Otherwise, the parking brake will be difficult to operate or it may not release.

The brake lining of the brake shoes (1) must be absolutely free of grease. Otherwise the braking effect will be impaired. Brake lining thickness *BE42.10-P-1002-12E In the event of complaints Replace brake shoes (1) on each axle. 10 Check ease of movement of pistons and leak In the event of complaints tightness of wheel brake cylinder (7) Replace wheel brake cylinder (7). AR42.10-P-0167SR

In the event of even the slightest signs of brake fluid leaks or sluggishness of the pistons of the wheel brake cylinder (7) this must be replaced. Otherwise, the braking effect may be impaired. 11 Check slack adjuster (13) for damage In the event of complaints Replace slack adjuster (13). Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0165sr, Remove/install brake shoes at rear axle Model 453

Check bimetal locking clip (13.2)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1784 · Applies to: 453 · AR: AR42.10-P-1010SR

12 Check bimetal locking clip (13.2) The bimetal locking clip (13.2) must be

located in unloaded state under the hook of the slack adjuster (13) (arrow B). When under load, the bimetal locking clip (13.2) must be capable of being pushed into the hook (arrow C). If the slack adjuster (13) is relieved, while the bimetal locking clip (13.2) is in the hook, the bimetal locking clip (13.2) must hold the slack adjuster (13) in place. In the event of complaints Replace slack adjuster (13). 13 Check adjuster mechanism of slack adjuster The adjusting nut (13.4) must turn easily

(13) by pushing together and then releasing and reliably when the brake shoe mounting again (13.1) is held in place by the adjusting plate (13.3). In the event of complaints Replace slack adjuster (13). Install

14 Set slack adjuster (13) back slightly, by

screwing-in the brake shoe mounting (13.1) Do not screw brake shoe mounting (13.1) all the way in or tighten it. Otherwise, reliable adjustment is no longer assured. 15 Coat contact surfaces (11) and contact MB Never Seeze brake paste (gray) *BR00.45-Z-1083-06A surfaces on slack adjuster (13) with thin coating of brake paste 16 Mount spring (10) and slack adjuster (13) to Note installation position of spring (10) and

brake shoes (1) slack adjuster (13). The longer part (arrow A) of the brake shoe mounting (13.1) must be located on the outside of the brake shoe (1) with the parking brake lever (9). 17 Push piston of wheel brake cylinder (7)

together, mount brake shoes (1) with spring Carefully guide brake shoes (1) over dust (10) and slack adjuster (13) onto piston of boots of wheel brake cylinder (7). wheel brake cylinder (7), tilt downwards over If a dust boot is damaged, the wheel brake wheel hub, and position on support bushing cylinder (7) must be replaced. (12) 18 Hook brake cable (4) into parking brake lever (9) 19 Attach spring (5) Note the installation position.

20 Position brake shoes (1) one after the other

into the support bushing (12) The spring (5) may not be stretched. Otherwise, the brake may suffer damage or malfunction. 21 Insert retaining pins (3) and install clamping springs (2) 22 Install brake drum AR42.10-P-1010SR Test and adjustment values for drum brake Number Designation Model 453.3/4 Model 453.0 BE42.10-P-1002-12E Brake lining thickness New mm 4,2 4,2 Wear limit for mm 2,4 2,4 maintenance service Pad backing plate mm 2,0 2,0 Repair materials Number Designation Order number BR00.45-Z-1083-06A MB Never Seeze brake paste (gray) A 001 989 94 51 12 Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0165sr, Remove/install brake shoes at rear axle Model 453

AR42.10-P-0070FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1785 · Applies to: 453 · AR: AR42.10-P-0070FF, AR42.10-P-0170FF, AR42.10-P-0010FF, AR42.10-P-0010FG

Remove/install front axle brake caliper 20.3.06 MODEL 454.0 1 Brake caliper 2 Brake hose 3 Brake caliper support 4 Bolt 5 Guide bolts P42.10-2284-04 Remove/install

Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Open engine hood and suction off brake fluid Brake fluid replacement unit *WE58.40-Z-1001-07A from the brake fluid reservoir 2 Remove brake pads from the front axle AR42.10-P-0170FF 3 Disconnect brake hose (2) from brake caliper Installation:

Replace seals of brake hose (1), remove seals and seal openings with (2). suitable plugs *BA42.10-P-1003-04G

4.1 Fold down the folded-up brake caliper (1) and Only when replacing the brake caliper (1) unscrew bolt (4) Counterhold the guide bolt (5) when loosening the bolt (4). Installation:

Install new self-locking bolt (4) *BA42.10-P-1001-10A

4.2 Pull the raised brake caliper (1) inwards of the Only when reinstalling the brake caliper (1). brake caliper support (3). 5 Remove brake caliper (1) 6 Install in the reverse order 7 Bleed brake system On vehicles with code (30Y) Rear axle disk AR42.10-P-0010FF brake On vehicles without code (30Y) Rear axle disk AR42.10-P-0010FG brake Brake lines, brake hoses

Number Designation Model Model 454.0 with 454.0 code 30Y without code 30Y BA42.10-P-1003-04G Banjo bolt, brake hose to brake caliper Nm 30 30 Front axle floating caliper

Number Designation Model 454.0 BA42.10-P-1001-10A Bolt, brake caliper to brake caliper support Nm 30 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0070ff, Remove/install front axle brake caliper MODEL 454.0

AR42.10-P-0070SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1787 · Applies to: 453 · AR: AR42.10-P-0070SR, AR40.10-P-1100SR

Remove/install front axle brake caliper 06.03.2020 Model 453 1 Brake caliper 2 Bolts 3 Brake hose 4 Dust caps P42.10-2998-11 1 Brake caliper 5 Retaining clamp P42.10-3025-11 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 poisoning Caution from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Topical note Notes on repairs to brake system AH42.00-P-0003-01A Topical note Brake fluid notes AH42.50-P-0001-01A Remove/install

1 Using the adapter, install the brake pedal

retaining tool between the pedal and the driver Cover brake pedal and driver seat. seat Otherwise the brake pedal and the driver seat may be soiled or damaged. 211589003100 Adapter for brake pedal winch 000589183100 Brake pedal jack 2 Remove left or right front wheel AR40.10-P-1100SR 3 Loosen threaded connection of brake line with Installation:

brake hose (3) and unhook brake hose (3)
The brake hose (3) must be unobstructed at every steering angle and at every jounce position of the wheel and must not be installed twisted. Otherwise, the brake hose (3) may be damaged. *BA42.10-P-1002-04SR Retaining screw, brake line to brake hose Page 1 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, ar42.10-p-0070sr, Remove/install front axle brake caliper Model 453

Collect brake fluid in a suitable container and

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1788 · Applies to: 453 · AR: AR42.10-P-0010SR

4 Collect brake fluid in a suitable container and 129589009100 Record plug seal connections with stop plugs 5 Remove retaining clamp (5) 6 Remove dust caps (4) 7 Remove screws (2) BA42.10-P-1003-10SR Screw/bolt, brake caliper to brake caliper support 8 Unscrew brake hose (3) from brake caliper (1) When replacing the brake caliper (1). BA42.10-P-1001-04SR Brake hose to front floating caliper 9 Collect brake fluid in a suitable container and 129589009100 Record plug seal connections with stop plugs 10 Remove brake caliper (1)
Although replacement of the brake calipers

(1) as a pair is not specified by Daimler, it is recommended. 11 Remove brake linings When replacing the brake caliper (1). Observe installation position of brake lining

with wear indicator. Check

12 Check brake caliper (1) and dust boots of Replace brake caliper (1) if dust boots are

brake piston for leaktightness and damage damaged. 13 Press back brake piston using resetting device If the brake pistons are sluggish, replace

brake caliper (1). Clean

14 Clean contact surfaces of brake linings on

brake caliper (1) While doing so, do not damage the dust boots of the brake piston, and do not use any sharp- edged or pointed objects. Otherwise, the brake caliper (1) must be replaced. Assembly cleaner *BR00.45-Z-1028-04A 15 Install in the reverse order 16 Bleed brake system AR42.10-P-0010SR Check

Risk of accident Danger when commissioning the Before starting the engine, actuate brake AS42.50-Z-0002-01A

vehicle due to a lack of braking effect when pedal several times until pressure is built up the service brake is operated for the first time and maintained in the brake system. after repair work. 17 Press the brake pedal several times until the brake linings contact the brake disks 18 Check fluid level in brake fluid reservoir, and correct if necessary Brake fluids (DOT 4 plus) BB00.40-P-0331-00A

General brake fluid BB00.40-P-0330-01A

19 Check brake system for leaks 20 Carry out brake test on the test stand Brake lines, brake hoses Number Designation Model 453 BA42.10-P-1001-04SR Brake hose to front floating caliper Nm 17 Brake lines, brake hoses Number Designation Model 453 BA42.10-P-1002-04SR Retaining screw, brake line to brake hose Nm 13 Front axle brake caliper Number Designation Model 453 BA42.10-P-1003-10SR Screw/bolt, brake caliper to brake caliper support Nm 30 Page 2 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, ar42.10-p-0070sr, Remove/install front axle brake caliper Model 453

AR42.10-P-0230FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1790 · Applies to: 453 · AR: AR42.10-P-0230FF, AR42.10-P-0170FF

Remove/install front axle brake disk 21.4.08 MODEL 454.0 P42.10-2324-07 1 Brake disk 3 Caliper support 5 Wheel hub 2 Bolts 4 Brake caliper Modification notes 31.3.08 Check brake disk as well as appropriate BE, added Step 5 Remove/install

1 Remove front axle brake pads AR42.10-P-0170FF 2 Detach brake caliper (4) inwards from the brake caliper support (3) and attach to suspension strut with cable tie 3 Unscrew bolts (2) on brake caliper support (3) *BA42.10-P-1003-10A

and remove brake caliper support (3) 4 Remove brake disk (1) *BR00.45-Z-1060-06A Installation: Brake disks (1) must only be replaced in pairs. Clean wheel hub (5) and grease lightly on the centering surface with brake paste. Checking

5 Check wear and condition of brake disk (1) Brake disk thickness BE42.10-P-1001-08E using vernier caliper; replace if necessary 450589011900

6 Install in the reverse order Test values for front brake disks Number Designation Model 454.0 BE42.10-P-1001-08E Brake disk thickness New mm 24 Wear limit mm 21.5 Front axle floating caliper

Number Designation Model 454.0 BA42.10-P-1003-10A Bolt, brake caliper support to Nm 105 steering knuckle Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0230ff, Remove/install front axle brake disk MODEL 454.0

AR42.10-P-0230SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1792 · Applies to: 453 · AR: AR42.10-P-0230SR, AR42.10-P-0500SR

Remove/install front axle brake disk 16.02.2017 Model 453 1 Brake disk 2 Bolts 3 Wheel hub A Centering surface P42.10-2997-11 Remove/install

Risk of injury. Skin or eye injuries may result Wear protective gloves, protective clothing AS00.00-Z-0002-01A Danger !

when handling hot or glowing objects. and safety glasses, if necessary. 1 Remove left or right engine support
AR42.10-P-0500SR 2 Remove screws/bolts (2) and remove brake Installation: Always replace brake disks

disk (1)
(1) in pairs. BA42.10-P-1002-06SR Locking bolt of front axle brake disk 3 Clean wheel hub (3) and grease lightly at the MB Never Seeze brake paste (gray) BR00.45-Z-1083-06A centering surface (A) using brake paste 4 Install in the reverse order Risk of accident Danger ! when commissioning the Before starting the engine, actuate brake AS42.50-Z-0002-01A

vehicle due to a lack of braking effect when pedal several times until pressure is built up the service brake is operated for the first time and maintained in the brake system. after repair work. 5 Operate the brake pedal several times until A firm resistance must be noticeable at brake linings make contact with the brake the brake pedal. disks (1)
Brake disks, brake cover plate Number Designation Model 453 BA42.10-P-1002-06SR Locking bolt of front axle brake disk Nm 21 Repair materials Number Designation Order number BR00.45-Z-1083-06A MB Never Seeze brake paste (gray) A 001 989 94 51 12 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0230sr, Remove/install front axle brake disk Model 453

AR42.10-P-0032SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1793 · Applies to: 453 · AR: AR42.10-P-0032SR, AR20.30-P-4950SR, AR40.10-P-1100SR, AR42.10-P-0010SR

Remove/install left front brake line 04.08.2014 MODEL 453 P42.10-3037-07 Shown on MODEL 453.3 1 Left front brake line 3 Left front brake hose 2 Hydraulic unit Risk of poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

Remove/install

1 Install brake pedal jack with adapter between

brake pedal and driver seat, and depress Cover driver seat. brake pedal by approx. 2 cm Otherwise the driver seat could be soiled or damaged. To prevent the brake fluid reservoir from

running empty. 000589183100 Brake pedal jack 211589003100 Adapter for brake pedal winch 2 Unhook coolant expansion reservoir and MODEL 453 with ENGINE 281 AR20.30-P-4950SR remove from working area with lines connected 3 Disconnect left front brake line (1) from BA42.10-P-1004-04SR Retaining screw, brake line to hydraulic hydraulic unit (2) and seal off connections unit 129589009100 Record plug 4 Remove left front wheel AR40.10-P-1100SR 5 Disconnect left front brake line (1) from left BA42.10-P-1002-04SR Retaining screw, brake line to brake hose front brake hose (3) and seal off connections 129589009100 Record plug 6 Unclip left front brake line (1) Installation: Make sure that the left front

brake line (1) is seated correctly. 7 Remove left front brake line (1)

Do not kink or bend the left front brake line (1). Leaks can occur otherwise. 8 Install in the reverse order 9 Bleed brake system AR42.10-P-0010SR Brake lines, brake hoses Number Designation MODEL 453 BA42.10-P-1002-04SR Retaining screw, brake line to brake hose Nm 13 Brake lines, brake hoses Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0032sr, Remove/install left front brake line MODEL 453

AR42.10-P-0036SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1795 · Applies to: 453 · AR: AR42.10-P-0036SR, AR42.10-P-0010SR

Remove/install left rear brake line 04.08.2014 MODEL 453 P42.10-3035-08 1 Brake line, rear left 3 Wheel brake cylinder 2 Brake hose, rear left 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 poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

Remove/install

1 Install brake pedal jack with adapter between

brake pedal and driver seat, and depress Cover driver seat. brake pedal by approx. 2 cm Otherwise the driver seat could be soiled or damaged. To prevent the brake fluid reservoir from

running empty. 000589183100 Brake pedal jack 211589003100 Adapter for brake pedal winch 2 Raise vehicle with vehicle lift 3 Disconnect left rear brake line (1) from left BA42.10-P-1002-04SR Retaining screw, brake line to brake hose rear brake hose (2) and seal off connections 129589009100 Record plug 4 Unscrew left rear brake line (1) from wheel BA42.10-P-1006-04SR Retaining screw, brake line to rear wheel brake cylinder (3) and seal off connections brake cylinder 129589009100 Record plug 5 Unclip left rear brake line (1) Installation: Make sure that the left rear

brake line (1) is seated correctly. 6 Remove left rear brake line (1)

Do not kink or bend the left rear brake line (1). Leaks can occur otherwise. 7 Install in the reverse order 8 Bleed brake system AR42.10-P-0010SR Brake lines, brake hoses Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar42.10-p-0036sr, Remove/install left rear brake line MODEL 453

AR42.10-P-0300FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1797 · Applies to: 453 · AR: AR42.10-P-0300FF, AR83.25-P-1402FF, AR42.10-P-0017FK, AR25.20-P-0070FF, AR42.10-P-0010FF (+1 more)

Remove/install master brake cylinder 10.11.11 MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle Shown on vehicle with transmission 717.471 1 Brake fluid reservoir 2 Electrical connector 3 Brake lines 4 Master brake cylinder 5 Brake booster P42.10-2409-04 Modification notes 15.6.05 Check brake line for reuse added Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Remove water collector AR83.25-P-1402FF 2 Extract brake fluid from brake fluid reservoir Brake fluid change unit (1) gotis://B_42/43.2_01 3 Unplug electrical connector (2) 4.1 Detach concealed hose (arrow) of clutch On transmission 717.470/471/473/478 master cylinder on brake fluid expansion reservoir (1) using suitable pliers Installation: Replace seal in concealed

hose (arrow). 5 Check bolted connection of brake lines (3) for AR42.10-P-0013-05SM color coding Installation:

Identify or replace brake lines (3) accordingly. See: Mark brake lines AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 6 Detach brake lines (3) from master brake Collect brake fluid which runs out in a cylinder (4) suitable container. Seal the openings on the brake lines (3) and on the master brake cylinder (4) using suitable plugs. *BA42.10-P-1005-04G

*BA42.10-P-1006-04G

Installation:

Replace the brake lines (3), if necessary after initial testing of the color coding. See: Remove/install brake lines AR42.10-P-0017FK 7 Detach master brake cylinder (4) from brake Replace nuts. booster (5) *BA42.10-P-1001-05E

8.1 Detach brake fluid expansion reservoir (1) When replacing from master brake cylinder (4) Master brake cylinder (4). 9 Install in the reverse order 10.1 Bleed clutch operating system On transmission 717.470/471/473/478 AR25.20-P-0070FF 11 Bleed brake system On vehicles with code (30Y) Disk brakes on AR42.10-P-0010FF rear axle On vehicles without code (30Y) Disk brakes AR42.10-P-0010FG on rear axle 12 Carry out transposition test Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0300ff, Remove/install master brake cylinder MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle

AR42.10-P-0300FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1799 · Applies to: 453 · AR: AR42.10-P-0300FG, AR42.10-P-0301FG, AR42.10-P-0017FH

Remove/install master brake cylinder 10.3.06 MODEL 454.0## 2# with ENGINE 639.9 with CODE (RHD) Right-hand drive vehicle P42.10-2444-08 1 Brake fluid reservoir 3 Bracket 5 Master brake cylinder 2 Nut 4 Brake line Modification notes 15.6.05 Check brake line for re-use added Remove/install

Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Check bolted connection of brake lines (4) for AR42.10-P-0013-05SM color coding Installation:

Identify or replace brake line (4) accordingly. Refer to: Mark brake lines AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 2 Remove brake fluid reservoir (1) AR42.10-P-0301FG 3 Detach brake lines (4) from master brake Collect brake fluid which runs out in a cylinder (5) suitable container. Seal the openings on the brake lines (4) and on the master brake cylinder (5) using suitable plugs. *BA42.10-P-1006-04G

Installation:

Replace the brake lines (4), if necessary after initial testing of the color coding. Refer to: Remove/install brake lines AR42.10-P-0017FH 4 Unscrew nuts (2) on master brake cylinder (5) Replace self-locking nuts (2). *BA42.10-P-1001-05E

5 Remove bracket (3) of wiring harness 6 Remove master brake cylinder (5) 7 Install in the reverse order 8.1 Carry out transposition test Only if both brake lines (4) have been replaced. Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system 9 Check brake system in the area of the master brake cylinder (4) for leaks Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0300fg, Remove/install master brake cylinder MODEL 454.0## 2# with ENGINE 639.9 with CODE (RHD) Right-hand drive vehicle

AR42.10-P-0300FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1801 · Applies to: 453 · AR: AR42.10-P-0300FH, AR42.10-P-0017FI, AR25.20-P-0070FF, AR42.10-P-0010FF

Remove/install master brake cylinder 10.11.11 MODEL 454.0## 2# with ENGINE 134.9, 135.9 with CODE (RHD) Right-hand drive vehicle Shown on vehicle with transmission 717.474 1 Master brake cylinder 2 Electrical connector 3 Brake fluid reservoir 4 Brake booster 5 Bracket P42.10-2458-04 Modification notes 15.6.05 Check brake line for reuse added Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Extract brake fluid from brake fluid reservoir Brake fluid change unit (3) gotis://B_42/43.2_01 2 Check the bolted connections of the brake AR42.10-P-0013-05SM lines between the master brake cylinder (1) and hydraulic unit for color coding Installation:

Identify or replace brake lines between the master brake cylinder (1) and hydraulic unit accordingly. See: Mark brake lines AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 3 Detach brake lines between the master brake Seal the openings on the brake lines and cylinder (1) and hydraulic unit on the master on the master brake cylinder (1) with suitable brake cylinder (1) plugs. *BA42.10-P-1006-04G

Installation:

Replace the brake lines between the master brake cylinder (1) and hydraulic unit if initial color coding testing makes this color coding. See: Remove/install brake lines AR42.10-P-0017FI 4 Unplug electrical connector (2) 5 Unclip electrical line from reservoir brake fluid (3) 6.1 Detach hose of master cylinder on brake fluid With transmission 717.470/471 reservoir (3) using suitable pliers Installation: Replace seal in master cylinder hose. 7 Detach master brake cylinder (1) from brake Install new self-locking nuts. booster (4) The master brake cylinder (1) is secured to the brake booster (4) with two nuts. Installation:

Replace sealing ring of master brake cylinder (1). Pay attention to correct seat of bracket (5). *BA42.10-P-1001-05E

8.1 Detach brake fluid expansion reservoir (3) Only when replacing the master brake from master brake cylinder (1) cylinder (1). 9 Install in the reverse order 10.1 Bleed clutch operating system With transmission 717.470/471 AR25.20-P-0070FF 11 Bleed brake system On vehicles with code (30Y) Disk brakes on AR42.10-P-0010FF rear axle Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0300fh, Remove/install master brake cylinder MODEL 454.0## 2# with ENGINE 134.9, 135.9 with CODE (RHD) Right-hand drive vehicle

On vehicles without code (30Y) Disk brakes

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1802 · Applies to: 453 · AR: AR42.10-P-0010FG

AR42.10-P-0010FG on rear axle 12 Carry out transposition test Only if both brake lines have been replaced between the master brake cylinder (1) and hydraulic unit. Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Brake lines, brake hoses

Number Designation Model Model 454.0 with 454.0 code 30Y without code 30Y BA42.10-P-1006-04G Hydraulic unit brake line to master brake Nm 15 15 cylinder Master brake cylinder

Number Designation Model 454.0 BA42.10-P-1001-05E Nut, brake master cylinder to brake booster Nm 16 Repair materials Number Designation Order number BR00.45-Z-1027-07A "Yellow" locking paint Lackfabrik Bäder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 BR00.45-Z-1028-07A "Red" safety paint Lackfabrik Bäder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0300fh, Remove/install master brake cylinder MODEL 454.0## 2# with ENGINE 134.9, 135.9 with CODE (RHD) Right-hand drive vehicle

AR42.10-P-0300SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1803 · Applies to: 453 · AR: AR42.10-P-0300SR, AR42.10-P-0301SR

Remove/install master brake cylinder 04.08.2014 MODEL 453 1 Master brake cylinder 2 Brake lines 3 Nut 4 Brake booster P42.10-3029-11 Risk of poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Notes on repairs to brake system AH42.00-P-0003-01A

Brake fluid notes AH42.50-P-0001-01A

Remove/install

1 Reduce vacuum in brake booster (4) by The engine must be switched off.

depressing brake pedal several times 2 Remove brake fluid reservoir AR42.10-P-0301SR 3 Identify brake lines (2) at the corresponding connections 4 Detach brake lines (2) from master brake Installation: Observe marking of the brake

cylinder (1) and seal connections lines (2). BA42.10-P-1003-04SR Retaining screw, brake line to master brake cylinder 129589009100 Record plug 5 Unscrew nuts (3) *BA42.10-P-1001-05M Nut, brake master cylinder to brake booster 6 Pull out master brake cylinder (1) directly

forward out of brake booster (4) Do not tilt master brake cylinder (1). The push rod will otherwise be pressed out of its axial position.

Collect brake fluid which runs out with an absorbent rag. Otherwise the vehicle paint may be damaged. Installation: Replace the seal between the

brake booster (4) and master brake cylinder (1). 7 Install in the reverse order Master brake cylinder Number Designation MODEL 453 BA42.10-P-1001-05M Nut, brake master cylinder to brake booster Nm 21 Brake lines, brake hoses Number Designation MODEL 453 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0300sr, Remove/install master brake cylinder MODEL 453

AR42.10-P-0040FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1805 · Applies to: 453 · AR: AR42.10-P-0040FF, AR68.10-P-1500FF

Remove/install mechanical stop lamp switch 8.1.07 MODEL 454.0 P42.10-2395-08 Illustrated on vehicle with Code (LHD) left-hand drive vehicle 1 Brake pedal 2 Rubber stopper S9/1 Stop lamp switch Modification notes 27.11.06 Quality note: "The brake light switch must on no account come into contact with grease or any antifriction agent" added Removing

The brake light switch (S9/1) must on no

account come into contact with grease or any antifriction agent, as this may otherwise result in malfunctions. 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 Disconnect electrical connector for brake light switch (S9/1) 4 Push brake pedal (1) down until the button of the brake light switch (S9/1) no longer makes contact with the rubber bump (2) 5 Rotate the brake light switch (S9/1) through 90° to the left and remove upwards Install

6 Extract button on brake light switch (S9/1) Pull out button on brake light switch (S9/1) carefully to avoid damage to the Brake light switch (S9/1). 7 Depress brake pedal (1) and retain 8 Insert brake light switch (S9/1) onto bearing bracket of brake pedal (1) and rotate through 90° to the right 9 Slowly release the brake pedal (1) 10 Connect STAR DIAGNOSIS and check signal from brake light switch (S9/1) 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, ar42.10-p-0040ff, Remove/install mechanical stop lamp switch MODEL 454.0

AR42.10-P-0080FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1806 · Applies to: 453 · AR: AR42.10-P-0080FF, AR68.20-P-2025FF, AR40.10-P-1100FF, AR42.10-P-0170FG, AR42.10-P-0010FF

Remove/install rear axle brake caliper 20.3.06 MODEL 454.0 with CODE (30Y) Disk brakes on rear axle Shown: removal of right-hand brake caliper 1 Beverage holder 2 Handbrake lever 3 Handbrake cable 4 Nut 5 Hand brake lever rocker 6 Brake caliper 7 Brake hose 8 Cover P42.10-2574-06 Remove/install

Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Open engine hood and suction off brake fluid Brake fluid replacement unit WE58.40-Z-1001-07A from the brake fluid reservoir 2 Release handbrake lever (2) 3.1 Lift up cover (8) in the rear area and pull out On vehicles without code (S29) Multifunction beverage holder (1) armrest (DFO/FFO) 3.2 Remove center armrest On vehicles with code (S29) Multifunction AR68.20-P-2025FF armrest (DFO/FFO) 4 Loosen nut (4) and unhook hand brake cable (3) from hand brake lever rocker (5) 5 Remove left or right rear wheel AR40.10-P-1100FF 6 Unhook hand brake cable (3) from brake caliper (6) 7 Disconnect brake hose (7) from brake caliper Collect brake fluid which runs out in a (6) suitable container. BA42.10-P-1004-04G

8 Remove brake pads on the left and right of AR42.10-P-0170FG the rear axle 9 Unscrew brake hose (7) from brake caliper (6) Collect brake fluid which runs out in a suitable container. Seal openings of brake caliper (6) and brake hose (7) using a suitable plug. 10 Install in the reverse order 11 Bleed brake system AR42.10-P-0010FF Brake lines, brake hoses

Number Designation Model 454.0
with code 30Y Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0080ff, Remove/install rear axle brake caliper MODEL 454.0 with CODE (30Y) Disk brakes on rear axle

AR42.10-P-0240FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1808 · Applies to: 453 · AR: AR42.10-P-0240FF, AR42.10-P-0170FG

Remove/install rear axle brake disc 21.4.08 MODEL 454.0 with CODE (30Y) Disk brakes on rear axle P42.10-2336-07 1 Screw 3 Brake disk 4 Wheel hub 2 Caliper support Modification notes 31.3.08 Check brake disk as well as appropriate BE, added Step 5 Remove/install

1 Remove brake pads on rear axle AR42.10-P-0170FG Use cable ties to secure brake caliper at suitable position. 2 Remove bolts (1) from brake caliper support *BA42.10-P-1003-12A

(2) 3 Detach brake caliper support (2) 4 Remove brake disk (3) *BR00.45-Z-1060-06A Installation:

Clean the contact surfaces of the brake disk (3) on the wheel hub (4) and grease the centering surface lightly with brake paste. Checking

5 Check wear and condition of brake disk (3) Brake disk thickness BE42.10-P-1001-09F using vernier caliper; replace if necessary 450589011900

6 Install in the reverse order Test values for rear brake disks Number Designation Model 454.0 with code 30Y BE42.10-P-1001-09F Brake disk thickness New mm 10 Wear limit mm 8 Rear axle floating brake caliper

Number Designation Model 454.0 with code 30Y BA42.10-P-1003-12A Bolt, brake caliper support to wheel carrier Nm 60 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0240ff, Remove/install rear axle brake disc MODEL 454.0 with CODE (30Y) Disk brakes on rear axle

AR42.10-P-0003SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1810 · Applies to: 453 · AR: AR42.10-P-0003SR, AR20.30-P-4950SR, AR33.10-P-0100SR

Remove/install rear left brake line from ESP(R) hydraulic unit to underfloor 10.07.2018 Model 453 P42.10-3040-07 Shown on MODEL 453.3 1 Brake line, rear left 3 Separation point 2 Hydraulic unit Risk of poisoning Caution from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Topical note Notes on repairs to brake system AH42.00-P-0003-01A Topical note Brake fluid notes AH42.50-P-0001-01A Remove/install

1 Unhook coolant expansion reservoir and Model 453 with engine 281 AR20.30-P-4950SR remove from working area with lines connected 2 Disconnect left rear brake line (1) from BA42.10-P-1004-04SR Retaining screw, brake line to hydraulic hydraulic unit (2) and seal off connections unit 129589009100 Record plug 3 Remove front axle AR33.10-P-0100SR 4 Disconnect left rear brake line (1) at BA42.10-P-1005-04SR Retaining screw, brake line to threaded connecting point (3) and seal off connections socket 129589009100 Record plug 5 Unclip left rear brake line (1) Installation: Make sure that the left rear

brake line (1) is seated correctly. 6 Remove left rear brake line (1)

Do not kink or bend the left rear brake line (1). Leaks can occur otherwise. 7 Install in the reverse order Brake lines, brake hoses Number Designation Model 453 BA42.10-P-1004-04SR Retaining screw, brake line to hydraulic unit Nm 14 Brake lines, brake hoses Number Designation Model 453 BA42.10-P-1005-04SR Retaining screw, brake line to threaded socket Stage 1 Nm 8 ° Stage 2 40 Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar42.10-p-0003sr, Remove/install rear left brake line from ESP(R) hydraulic unit to underfloor Model 453

AR42.10-P-0002SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1812 · Applies to: 453 · AR: AR42.10-P-0002SR, AR42.10-P-0003SR

Remove/install rear right brake line from ESP(R) hydraulic unit to underfloor 10.07.2018 Model 453 P42.10-3041-07 Shown on MODEL 453.3 1 Brake line, right rear 3 Separation point 2 Hydraulic unit Risk of poisoning Caution from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Topical note Notes on repairs to brake system AH42.00-P-0003-01A Topical note Brake fluid notes AH42.50-P-0001-01A Remove/install

1 Remove left rear brake line from hydraulic unit AR42.10-P-0003SR (2) to underfloor 2 Disconnect left rear brake line (1) from BA42.10-P-1004-04SR Retaining screw, brake line to hydraulic hydraulic unit (2) and seal off connections unit 129589009100 Record plug 3 Disconnect right rear brake line (1) at BA42.10-P-1005-04SR Retaining screw, brake line to threaded connecting point (3) and seal off connections socket 129589009100 Record plug 4 Unclip right rear brake line (1) Installation: Make sure that the right rear

brake line (1) is seated correctly. 5 Remove right rear brake line (1)

Do not kink or bend the right rear brake line (1). Leaks can occur otherwise. 6 Install in the reverse order Brake lines, brake hoses Number Designation Model 453 BA42.10-P-1004-04SR Retaining screw, brake line to hydraulic unit Nm 14 Brake lines, brake hoses Number Designation Model 453 BA42.10-P-1005-04SR Retaining screw, brake line to threaded socket Stage 1 Nm 8 ° Stage 2 40 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0002sr, Remove/install rear right brake line from ESP(R) hydraulic unit to underfloor Model 453

AR42.10-P-0033SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1814 · Applies to: 453 · AR: AR42.10-P-0033SR, AR20.30-P-4950SR, AR33.10-P-0100SR

Remove/install right front brake line 04.08.2014 MODEL 453 P42.10-3038-08 Shown on MODEL 453.3 1 Brake line 4 Brake line 2 Brake line 5 Hydraulic unit 3 Brake line Risk of poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Notes on repairs to brake system AH42.00-P-0003-01A

Brake fluid notes AH42.50-P-0001-01A

Remove/install

1 Unhook coolant expansion reservoir and MODEL 453 with ENGINE 281 AR20.30-P-4950SR remove from working area with lines connected 2 Remove front axle AR33.10-P-0100SR 3 Mark brake lines (1, 2, 3, 4) with respect to corresponding connections 4 Disconnect brake lines (1, 2, 3, 4) from Installation: Observe markings on brake

hydraulic unit (5) and seal off lines (1, 2, 3, 4). BA42.10-P-1004-04SR Retaining screw, brake line to hydraulic unit 129589009100 Record plug 5 Unclip brake lines (1, 2, 3, 4) Installation: Make sure that the brake

lines (1, 2, 3, 4) are seated correctly. 6 Remove brake line (2)

Do not bend or kink the brake line (2). Leaks can occur otherwise. 7 Install in the reverse order Brake lines, brake hoses Number Designation MODEL 453 BA42.10-P-1004-04SR Retaining screw, brake line to hydraulic unit Nm 14 Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar42.10-p-0033sr, Remove/install right front brake line MODEL 453

AR42.10-P-0037SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1816 · Applies to: 453 · AR: AR42.10-P-0037SR, AR42.10-P-0010SR

Remove/install right rear brake line 04.08.2014 MODEL 453 P42.10-3036-08 1 Brake line, right rear 3 Wheel brake cylinder 2 Brake hose, right rear 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 poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Notes on repairs to brake system AH42.00-P-0003-01A

Brake fluid notes AH42.50-P-0001-01A

Remove/install

1 Install brake pedal jack with adapter between

brake pedal and driver seat, and depress Cover driver seat. brake pedal by approx. 2 cm Otherwise the driver seat could be soiled or damaged. To prevent the brake fluid reservoir from

running empty. 000589183100 Brake pedal jack 211589003100 Adapter for brake pedal winch 2 Raise vehicle with vehicle lift 3 Disconnect right rear brake line (1) from right BA42.10-P-1002-04SR Retaining screw, brake line to brake hose rear brake hose (2) and seal off connections 129589009100 Record plug 4 Disconnect right rear brake line (1) from BA42.10-P-1006-04SR Retaining screw, brake line to rear wheel wheel brake cylinder (3) and seal off brake cylinder connections 129589009100 Record plug 5 Unclip right rear brake line (1) Installation: Make sure that the right rear

brake line (1) is seated correctly. 6 Remove right rear brake line (1)

Do not kink or bend the right rear brake line (1). Leaks can occur otherwise. 7 Install in the reverse order 8 Bleed brake system AR42.10-P-0010SR Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0037sr, Remove/install right rear brake line MODEL 453

AR42.10-P-0233SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1818 · Applies to: 453 · AR: AR42.10-P-0233SR, AR42.10-P-0230SR

Remove/install splash shield on front brake 21.07.2014 MODEL 453 1 Splash shield 2 Bolts 3 Screw 4 Hub P42.10-3014-04 Remove/install

1 Remove left or right brake disk AR42.10-P-0230SR 2 Unscrew bolts (2)
3 Turn hub (4) so that the screw/bolt (3) is accessible through a wheel bolt bore in the hub (4) and remove screw/bolt (3)
4 Remove splash shield (1) 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0233sr, Remove/install splash shield on front brake MODEL 453

AR42.10-P-0167FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1819 · Applies to: 453 · AR: AR42.10-P-0167FF, AR42.10-P-1010FF, AR42.10-P-0017FJ, AR42.10-P-0010FG

Remove/install wheel brake cylinder 20.3.06 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle P42.10-2518-08 1 Wheel brake cylinder 4 Clamping spring 6 Brake line 2 Brake anchor plate 5 Bolt 7 Nut 3 Retaining pin Modification notes 15.6.05 Check brake line for re-use added Remove/install

Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Check threaded connection of brake line (6) AR42.10-P-0013-05SM for color coding Installation:

Mark the brake line (6) accordingly. Refer to: Mark brake lines AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 2 Remove brake drum AR42.10-P-1010FF 3 Remove clamping springs (4) from brake *168589003700

shoes using pliers and detach retaining pins (3) 4 Unscrew nut (7) securing brake line (6) to Collect brake fluid which runs out in a wheel brake cylinder (1) suitable container. Seal opening of wheel brake cylinder (1) and brake line (6) using suitable plugs. *BA42.10-P-1007-04G

5 Remove bolt (5) from wheel brake cylinder (1) *BA42.10-P-1001-16C

6 Carefully lift off wheel brake cylinder (1) Do not allow brake fluid to get on the brake linings as brake fluid damages the brake linings. 7 Clean brake carrier plate (2) 8.1 Remove brake line (6) Only if initial color coding testing makes color AR42.10-P-0017FJ coding. 9 Install in the reverse order 10 Bleed brake system AR42.10-P-0010FG Brake lines, brake hoses

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0167ff, Remove/install wheel brake cylinder MODEL 454.0 except CODE (30Y) Disk brakes on rear axle

AR42.10-P-0167SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1821 · Applies to: 453 · AR: AR42.10-P-0167SR, AR42.10-P-0165SR, AR42.10-P-0010SR

Remove/install wheel brake cylinder 04.08.2014 MODEL 453 1 Wheel brake cylinder 2 Brake line 3 Bolts 4 Brake cover plate P42.10-3046-05 Risk of poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Notes on repairs to brake system AH42.00-P-0003-01A

Brake fluid notes AH42.50-P-0001-01A

Remove/install

1 Remove left or right brake shoe from rear AR42.10-P-0165SR axle 2 Unscrew retaining screw of brake line (2) Removal: Collect brake fluid in a suitable

from wheel brake cylinder (1) container. Installation: Do not bend the brake line

(2), and check the routing, leaktightness and clearance for the rear axle. BA42.10-P-1006-04SR Retaining screw, brake line to rear wheel brake cylinder 3 Immediately seal off the connections for the 129589009100 Record plug brake line (2) and wheel brake cylinder (1) 4 Remove bolts (3) and wheel brake cylinder *BA42.10-P-1001-16D Bolt, wheel brake cylinder to brake cover (1) plate Clean

5 Clean brake cover plate (4) 6 Install in the reverse order 7 Bleed brake system AR42.10-P-0010SR Drum brake Number Designation MODEL 453 BA42.10-P-1001-16D Bolt, wheel brake cylinder to brake cover plate Nm 9 Brake lines, brake hoses Number Designation MODEL 453 BA42.10-P-1006-04SR Retaining screw, brake line to rear wheel brake cylinder 15 Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar42.10-p-0167sr, Remove/install wheel brake cylinder MODEL 453

AR42.10-P-0301SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1823 · Applies to: 453 · AR: AR42.10-P-0301SR, AR42.10-P-0010SR

Removing and installing brake fluid reservoir 28.07.2014 MODEL 453 P42.10-3012-07 1 Master brake cylinder 3 Hydraulic fluid reservoir for brake fluid 2 Retaining clamp Risk of poisoning Danger ! from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Notes on repairs to brake system AH42.00-P-0003-01A

Brake fluid notes AH42.50-P-0001-01A

Remove/install

1 Remove maintenance flap 2 Disconnect electrical connector from hydraulic fluid reservoir for brake fluid (3) Clean

3 Clean area around cap of hydraulic fluid reservoir for brake fluid (3) 4 Unscrew cap of hydraulic fluid reservoir for brake fluid (3) and extract brake fluid from hydraulic fluid reservoir for brake fluid (3) 5 Pinch off brake hose for clutch operating system using suitable hose clamp pliers and pull off brake hose for clutch operating system 6 Remove retaining clip (2) carefully in direction of arrow 7 Lift out hydraulic fluid reservoir for brake fluid Installation: Check the sealing rings in the

(3) in direction of arrow master brake cylinder (1); replace if necessary. 8 Collect escaping brake fluid with an So that the vehicle paint does not get

absorbent rag damaged. 9 Seal connections on master brake cylinder So that no foreign objects can enter the

(1) system. *129589009100 Record plug 10 Install in the reverse order 11 Bleed brake system AR42.10-P-0010SR Check

12 Check brake system in area of hydraulic fluid reservoir for brake fluid (3) for leaktightness 13 Check fluid level in hydraulic fluid reservoir for brake fluid (3); correct if necessary General brake fluid BB00.40-P-0330-01A

Brake fluids (DOT 4 plus) BB00.40-P-0331-00A

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0301sr, Removing and installing brake fluid reservoir MODEL 453

AR42.10-P-0013FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1825 · Applies to: 453 · AR: AR42.10-P-0013FF

Replace brake hoses 18.2.09 MODEL 454.0 Front axle P42.10-2314-08 1 Brake line 4 Brake hose 6 Sealing rings 2 Retaining spring 5 Banjo bolt 7 Brake caliper 3 Screw Modification notes 12.2.09 Infotext for both brake hoses, added Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

In general both brake hose (4) must always

be replaced. 1 Extract brake fluid from brake fluid reservoir 2 Check bolted connection of brake line (1) for AR42.10-P-0013-05SM color coding Installation:

Identify the brake line (1) accordingly. Refer to: Mark brake lines AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 3 Counterhold brake hose (4) using a suitable Collect brake fluid which runs out in a tool and detach brake line (1) from brake hose suitable container. (4) Seal opening on the brake line (1) and brake hose (4) using a suitable plug. *BA42.10-P-1001-04G

Installation: The brake hose (4) must be

able to move freely at every steering angle and every jounce condition of the wheel. The brake hose (4) must not be mounted twisted otherwise the brake hose (4) may be damaged. 4 Detach retaining spring (2) from brake hose (4) 5 Unscrew bolt (3) *BA42.10-P-1002-04G

6 Unscrew banjo bolt (5) Installation: Replace sealing rings (6).

*BA42.10-P-1003-04G

7 Detach brake hose (4) from the brake caliper Collect brake fluid which runs out in a (7) suitable container. Seal opening in brake caliper (7) using a suitable stop plug. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0013ff, Replace brake hoses MODEL 454.0 Front axle

Remove brake line (1)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1826 · Applies to: 453 · AR: AR42.10-P-0017FF, AR42.10-P-0010FF, AR42.10-P-0010FG

8 Remove brake line (1) Only if initial color coding testing makes color AR42.10-P-0017FF coding. 9 Install in the reverse order 10 Bleed brake system On vehicles with code (30Y) Disk brakes on AR42.10-P-0010FF rear axle On vehicles without code (30Y) Disk brakes AR42.10-P-0010FG on rear axle 11 Carry out transposition test Only when both front brake lines (1) have been removed. Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory Brake lines, brake hoses

Number Designation Model Model 454.0 with 454.0 code 30Y without code 30Y BA42.10-P-1001-04G Brake pipe to brake hose Nm 15 15 BA42.10-P-1002-04G Bolt, brake hose bracket to suspension strut Nm 10 10 BA42.10-P-1003-04G Banjo bolt, brake hose to brake caliper Nm 30 30 Repair materials Number Designation Order number BR00.45-Z-1027-07A "Yellow" locking paint Lackfabrik Bäder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 BR00.45-Z-1028-07A "Red" safety paint Lackfabrik Bäder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0013ff, Replace brake hoses MODEL 454.0 Front axle

AR42.10-P-0013FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1827 · Applies to: 453 · AR: AR42.10-P-0013FG, AR42.10-P-0017FG, AR42.10-P-0010FF

Replace brake hoses 30.3.09 MODEL 454.0 with CODE (30Y) Disk brakes on rear axle Rear axle P42.10-2315-08 Shown on wheel which has been removed 8 Brake line 10 Brake hose 12 Brake caliper 9 Retaining spring 11 Retaining spring Modification notes 10.3.09 Infotext: Replace both brake hoses, added Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

In general both brake hoses (10) must always

be replaced 1 Extract brake fluid from brake fluid reservoir 2 Check bolted connection of brake line (8) for AR42.10-P-0013-05SM color coding Installation:

Identify brake line (8) accordingly. Refer to: Mark brake lines (2, 4) AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 3 Counterhold brake hose (10) with a suitable Collect brake fluid which runs out in a tool and detach brake line (8) from brake hose suitable container. (10) Seal opening on the brake line (8) with a suitable plug. *BA42.10-P-1001-04G

Installation: The brake hose (10) must

not be installed twisted and must be free to move for each jounce condition of the wheel otherwise the brake hose (10) may be damaged. 4 Detach retaining spring (9) and retaining spring (11) from brake hose (10) 5 Remove brake hose (10) from brake caliper Collect brake fluid which runs out in a (12), take out and seal using a suitable plug suitable container. Seal opening on brake caliper (12) using a suitable plug *BA42.10-P-1004-04G

6 Remove brake line (8) Only if initial color coding testing makes color AR42.10-P-0017FG coding. 7 Install in the reverse order 8 Bleed brake system AR42.10-P-0010FF Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0013fg, Replace brake hoses MODEL 454.0 with CODE (30Y) Disk brakes on rear axle Rear axle

AR42.10-P-0013FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1829 · Applies to: 453 · AR: AR42.10-P-0013FH, AR42.10-P-0017FG, AR42.10-P-0010FG

Replace brake hoses 30.3.09 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle Rear axle P42.10-2523-08 1 Retaining spring 3 Brake hose 4 Brake line 2 Brake line Modification notes 10.3.09 Infotext: Replace both brake hoses, added Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

In general both brake hoses (3) must always

be replaced 1 Extract brake fluid from brake fluid reservoir 2 Check bolted connection of brake line (2, 4) AR42.10-P-0013-05SM for color coding Installation:

Identify brake lines (2, 4) accordingly. Refer to: Mark brake lines (2, 4) AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 3 Counterhold brake hose (3) with a suitable Collect brake fluid which runs out in a tool and detach brake line (2) from brake hose suitable container. (3) Seal the opening on brake line (2) and on brake hose (3) with suitable plugs *BA42.10-P-1001-04G

Installation: The brake hose (3) must not

be installed twisted and must be free to move for each jounce condition of the wheel otherwise the brake hose (3) may be damaged. 4 Counterhold brake hose (3) with a suitable Collect brake fluid which runs out in a tool and detach brake line (4) from brake hose suitable container. (3) Seal the opening of brake line (4) with a suitable plug *BA42.10-P-1001-04G

5 Detach retaining spring (1) and retaining spring (arrow) from brake hose (3) 6 Remove brake hose (3) 7 Remove brake lines (2, 4) Only if initial color coding testing makes color AR42.10-P-0017FG coding. 8 Install in the reverse order 9 Bleed brake system AR42.10-P-0010FG Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0013fh, Replace brake hoses MODEL 454.0 except CODE (30Y) Disk brakes on rear axle Rear axle

AR42.10-P-0170FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1831 · Applies to: 453 · AR: AR42.10-P-0170FF, AR40.10-P-1100FF

Replacing and installing brake pads 21.4.08 MODEL 454.0 Front axle P42.10-2323-07 1 Brake caliper 5 Caliper support 8 Clamp 2 Screw 6 Springs 9 Guide bolts 3 Guide bolts 7 Brake piston 10 Bellows 4 Brake pads Modification notes 31.3.08 Check brake pads and brake drums as well as appropriate Step 9 BE, added Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A

brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Remove front wheels AR40.10-P-1100FF 2 Remove bolt (2) from brake caliper (1) When loosening the bolt (2) counterhold the guide bolt (3). Installation:

Install new bolt (2). *BA42.10-P-1001-10A 3 Fold brake caliper (1) upwards Installation: When folding down the brake

caliper (1) ensure that the springs (6) of the brake pads (4) are clamped under the brake caliper (1). 4 Take out brake pads (4) When the brake pads (4) are removed, do not depress the brake pedal otherwise the brake piston (7) is pushed out of the housing and the brake caliper (1) may be damaged. Observe installation position of clamp (8). 5 Press back brake piston using pusher tool (7) The fluid level in the brake fluid reservoir rises when the brake piston (7) is pushed back. Ensure that the reservoir does not overflow. It must be possible to move the brake piston (7) easily. 454589004300 6 Clean contact surface of brake pads (4) on BR00.45-Z-1060-06A Installation:

Apply a thin coating of brake brake caliper support (5) and on brake caliper paste to the contact surfaces on the brake (1) caliper support (5), on the brake caliper (1) and on the brake pad (4). 7 Detach brake caliper (1) inward from brake Damaged bellows (10) should be caliper support (5) and check guide pins (3, 9) replaced. Check the ease of movement of the and boots (10) guide bolts (3, 9), if the guide bolts are notchy or sluggish (3, 9) they should be replaced, otherwise the satisfactory function of the brake system is not guaranteed. *BR00.45-Z-1060-06A Installation:

Apply a thin coating of brake paste to the guide bolt (3, 9) and pay attention to correct seating of the bellows (10). 8 Check brake caliper (1) for leaks and dust If the brake caliper (1) is leaking or the boot on brake piston (7) for damage dust boot on the brake piston (7) is damaged the brake caliper (1) must be replaced. Refer to: Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0170ff, Replacing and installing brake pads MODEL 454.0 Front axle

Remove/install front axle brake caliper

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1832 · Applies to: 453 · AR: AR42.10-P-0070FF

AR42.10-P-0070FF Checking

9 Check wear and condition of brake pads (4) Brake pad thickness BE42.10-P-1001-05G and brake disk using vernier caliper; replace if necessary Brake disk thickness BE42.10-P-1001-08E *450589011900

10 Install in the reverse order Risk of accident Danger! when commissioning the Before starting engine, actuate brake pedal AS42.50-Z-0002-01A

vehicle due to a lack of braking effect when several times until the pressure is built up and the service brake is operated for the first time maintained in the brake system. after repair work 11 Operate the brake pedal several times until Firm resistance must be noticeable. the brake pads (4) contact the brake disks 12 Check brake fluid in the brake fluid Fill up or suction off brake fluid to the MAX

reservoir and correct if necessary mark on the brake fluid reservoir in order to guarantee faultless function of the brake system. General brake fluid Sheet 330.1 BB00.40-P-0330-01A

Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40-P-0331-00A

Check values for front brake pad Number Designation Model 454.0 BE42.10-P-1001-05G Brake pad New (with pad backing plate mm 17.3 thickness and shim) 1.5 Wear limit (without pad mm backing plate) for maintenance service 7.4 Wear limit (with pad backing mm plate and shim) for maintenance service 7.4 Response of wear indicator mm (with pad backing plate and shim) Test values for front brake disks Number Designation Model 454.0 BE42.10-P-1001-08E Brake disk thickness New mm 24 Wear limit mm 21.5 Front axle floating caliper

Number Designation Model 454.0 BA42.10-P-1001-10A Bolt, brake caliper to brake caliper support Nm 30 Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0170ff, Replacing and installing brake pads MODEL 454.0 Front axle

AR42.10-P-0170FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1834 · Applies to: 453 · AR: AR42.10-P-0170FG, AR40.10-P-1100FF

Replacing and installing brake pads 21.4.08 MODEL 454.0 with CODE (30Y) Disk brakes on rear axle Rear axle P42.10-2415-07 1 Beverage holder 3 Cover 5 Hand brake lever rocker 2 Hand brake lever 4 Nut 6 Handbrake cable P42.10-2414-09 6 Handbrake cable 10 Caliper support 14 Pusher tool

7 Brake caliper 11 Brake pads 15 Bellows 8 Screw 12 Clamp 16 Dust boot 9 Guide bolts 13 Brake piston Modification notes 31.3.08 Check brake pads and brake drums as well as appropriate Step 12 BE, added Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A

brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Release handbrake lever (2) 2 Lift cover (3) at rear and pull out beverage holder (1) 3 Loosen nut (4) and unhook hand brake cable (6) from the rocker of hand brake lever (5) 4 Remove left or right rear wheel AR40.10-P-1100FF 5 Counterhold guide pin (9) and unscrew bolts Replace bolts (8). (8) from brake caliper (7) Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0170fg, Replacing and installing brake pads MODEL 454.0 with CODE (30Y) Disk brakes on rear axle Rear axle

*BA42.10-P-1001-12A

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1835 · Applies to: 453 · AR: AR42.20-P-0540FF

6 Detach brake caliper (7) from brake caliper When the brake caliper (7) is removed, do support (10) not depress the brake pedal as otherwise the brake piston (13) will be pressed out of the housing and the brake caliper (7) may be damaged. Installation: When inserting the brake

caliper (7) ensure that the springs (arrows) of the brake pads (11) are clamped under the brake caliper (7). 7 Remove brake pads (11) with clip (12) Installation: Observe correct installation position of clip (12). 8 Push back brake piston (13) of brake caliper The fluid level in the brake fluid reservoir (7) using resetting device (14) rises when the brake piston (13) is pushed back. Ensure that the brake fluid reservoir does not overflow. It must be possible to move the brake piston (13) easily. *454589004300 9 Clean contact surface of brake pads (11) on Installation:

Apply a thin coating of brake brake caliper support (10) and on brake paste to the contact surfaces on the brake caliper (7) caliper support (10) and on the brake caliper (7). Brake paste *BR00.45-Z-1060-06A 10 Pull guide pin (9) out of brake caliper support Check the ease of movement of the guide (10) and check bellows (15) for damage pins (9), if the guide pins (9) movement is sluggish, the brake caliper (7) should be replaced otherwise there is the risk of uneven braking effect. Installation:

Replace damaged bellows (15). Apply a thin coating of brake paste to the guide pins (9) and ensure that the bellows (15) are properly seated. Brake paste *BR00.45-Z-1060-06A 11 Check brake caliper (7) for leaks and dust If the brake caliper (7) is leaky or the dust boot (16) on the brake piston (13) for damage boot (16) is damaged, the brake caliper (7) should be replaced otherwise there is a risk of uneven braking effect. Checking

12 Check wear and condition of brake pads (11) Brake disk thickness BE42.10-P-1001-09F and brake disk using vernier caliper; replace if necessary Brake pad thickness BE42.10-P-1001-15F *450589011900

13 Install in the reverse order Risk of accident Danger! when commissioning the Before starting engine, actuate brake pedal AS42.50-Z-0002-01A

vehicle due to a lack of braking effect when several times until the pressure is built up and the service brake is operated for the first time maintained in the brake system. after repair work 14 Operate the brake pedal several times until Firm resistance of the brake pedal should the brake pads (11) contact the brake disks be noticeable. 15 Adjust parking brake AR42.20-P-0540FF 16 Check brake fluid in brake fluid reservoir and Fill up or extract brake fluid to the MAX

correct if necessary. mark on the brake fluid reservoir in order to guarantee faultless function of the brake system. General brake fluid Sheet 330.1 BB00.40-P-0330-01A

Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40-P-0331-00A

Test values for rear brake disks Number Designation Model 454.0 with code 30Y BE42.10-P-1001-09F Brake disk thickness New mm 10 Wear limit mm 8 Check values for rear brake pad Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.10-p-0170fg, Replacing and installing brake pads MODEL 454.0 with CODE (30Y) Disk brakes on rear axle Rear axle

SI42.10-P-0001SM

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1837 · Applies to: 453 · AR: SI42.10-P-0001SM, AR42.10-P-0010SM, AR42.10-P-0010RR, AR42.10-P-0010FF, AR42.00-P-0017FF (+4 more)

Service Information: Brake lines 20.3.06 MODEL 450, 452, 454 Modification notes 8.8.05 Procedure for establishing brake line threaded connection changed Brake line repair concept changed Reuse of screw connections on brake line procedure: Mark union nut on brake line in question after first reuse of screw connection with yellow As part of the continuous product and repair optimizations, it is locking paint. permissible on all smart model series to reuse the screw connections Mark union nut on brake line in question after second reuse of screw connection with red on brake lines as from July 2005. locking paint. The previous procedure, whereby brake lines generally had to be The specified sequence of color codings (yellow-red) must always be adhered to. replaced once they had been undone can be dispensed with under the following conditions: The use of different colors is not permissible. Brake lines with red color coding are to be replaced once the screwed connection has been released. Maximum 2 repeat screw connections (see section on "Reuse

of screw connections procedure"). Replaced brake lines are not to be color coded following the first fitting. Provide color coding according to number of screw

Wherever doubt exists about the number of reuses of a connection reuses on brake line (see section on "Reuse of

screwed connection, always replace the brake line. screw connections procedure"). Brake system leaktightness test (see section on "Revised

workshop documentation").

---

When retightening the brake lines, the torques contained in the Specifications for performing leaktightness test on the brake system WIS documentation are valid. are available in the WIS documentation at: Every time the hydraulic brake circuit is undone, a leaktightness smart fortwo 450.3/4 (see AR42.10-P-0100-01SM, test must be performed on the brake system. e.g. in the WIS document AR42.10-P-0010SM "Bleed brake smart hereby expressly states that framework conditions such as system"). cleanliness must be upheld. smart roadster/roadster coupe 452.3/4 (see AR42.10-P-0100-01RR, e.g. in the WIS document AR42.10-P-0010RR "Bleed brake system"). Revised workshop documentation: The WIS documentation has been revised in accordance with the smart forfour 454.0 (see AR42.10-P-0100-01FF, e.g. in the WIS document AR42.10-P-0010FF "Bleed brake system"). above-mentioned procedure. The WIS documentation has been updated for the following model series: An example for a revised specification for brake line color coding is available in the WIS documentation at: smart fortwo 450.3/4 (WIS update 08/05 in German, WIS update 09/05 in all languages). smart forfour 454.0 (see AR42.10-P-0013-05SM, e.g. in the WIS document AR42.00-P-0017FF "Remove/install brake lines". smart roadster/roadster coupe 452.3/4 (WIS update 08/05 in German, WIS update 09/05 in all languages). smart forfour 454.0 (WIS update 07/05 in German, WIS update 08/05 in all languages).

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Modified working hours: Example of altered working hours: The altered work procedure when removing components in the brake smart forfour 454.0 (e.g. operation item (42-8590) Replace system means that the corresponding working hours in ASRA and Electronic Stability Program (ESP) hydraulic unit in brake system). DMS are reduced. Previous time: 37 WU or 3.1 h The altered working hours have been updated for the following Altered time: 22 WU or 1.8 h model series: smart fortwo 450.3/4 (ASRA and DMS update 09/05 in all languages) smart roadster/roadster coupe 452.3/4 (ASRA and DMS update 09/05 in all languages). smart forfour 454.0. (ASRA and DMS update 07/05 in all languages). Bleed brake system for model 450.3/4 AR42.10-P-0010SM

Bleed brake system for model 452.3/4 AR42.10-P-0010RR

Bleed brake system On model 454.0 with code (30Y) Disk brakes AR42.10-P-0010FF

on rear axle Bleed brake system On model 454.0 without code (30Y) Disk AR42.10-P-0010FG

brakes on rear axle Remove/install brake lines On model 454.0 front axle AR42.10-P-0017FF

Remove/install brake lines On model 454.0 rear axle AR42.10-P-0017FG

Remove/install brake lines On model 454.0 with engine 639.9 and code AR42.10-P-0017FH

(RHD) Right-hand drive vehicle Brake line from master brake cylinder to hydraulic unit Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, si42.10-p-0001sm, Service Information: Brake lines MODEL 450, 452, 454

Remove/install brake lines

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1838 · Applies to: 453 · AR: AR42.10-P-0017FI, AR42.10-P-0017FJ, AR42.10-P-0017FK

Model 454.0 with engine 134.9, 135.9 and AR42.10-P-0017FI

code (RHD) Right-hand drive vehicle Brake line from master brake cylinder to hydraulic unit Remove/install brake lines Model 454.0 without code (30Y) Disk brakes AR42.10-P-0017FJ

on rear axle Brake line to wheel brake cylinder Remove/install brake lines Model 454.0 with code (LHD) Left-hand drive AR42.10-P-0017FK

vehicle Brake line from master brake cylinder to hydraulic unit "Yellow" locking paint *BR00.45-Z-1027-07A

"Red" safety paint *BR00.45-Z-1028-07A Repair materials Number Designation Order number BR00.45-Z-1028-07A "Red" safety paint Lackfabrik Bäder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 BR00.45-Z-1027-07A "Yellow" locking paint Lackfabrik Bäder GmbH & Co. KG Dieselstrasse 34 73734 Esslingen Germany Tel. +49 711 381607 Fax +49 711 383092 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, si42.10-p-0001sm, Service Information: Brake lines MODEL 450, 452, 454

AR42.20-P-0540FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1839 · Applies to: 453 · AR: AR42.20-P-0540FF, AR68.20-P-2025FF

Adjust parking brake 20.3.06 MODEL 454.0 1 Beverage holder 2 Handbrake lever 3 Cover 4 Nut P42.20-2184-04 Adjust 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 below the lifting platform support points specified by the vehicle manufacturer. 1 Lift up the vehicle until the wheels rotate freely 2.1 Lift cover (3) at rear and pull out beverage On vehicles without code (S29) Multifunction holder (1) armrest (DFO/FFO) 2.2 Remove center armrest On vehicles with code (S29) Multifunction AR68.20-P-2025FF armrest (DFO/FFO) 3 Adjust parking brake by turning the nut (4) It must no longer be possible to turn the rear wheels by hand after the hand brake lever (2) has been moved to the 3rd detent. The rear wheels must turn freely when the hand brake lever (2) is released. 4 Operate the hand brake lever (2) several times and release again 5 Check the parking brake adjustment 6.1 Insert beverage holder (1) and clip in cover (3)On vehicles without code (S29) Multifunction armrest (DFO/FFO) 6.2 Install center armrest On vehicles with code (S29) Multifunction AR68.20-P-2025FF armrest (DFO/FFO) Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.20-p-0540ff, Adjust parking brake MODEL 454.0

AR42.20-P-0540SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1840 · Applies to: 453 · AR: AR42.20-P-0540SR, AR42.10-P-1010SR, AR42.20-P-0545SR

Adjust parking brake 07.10.2016 Model 453 Modification notes 07.10.2016 Adjusting nut (3) must always be replaced. See SI42.20-P-0004A 12.01.2016 Document revised completely. 1 Parking brake lever 2 Cover 3 Adjusting nut P42.20-2675-04 Adjust 1 Unclip cover (2) 2 Remove adjusting nut (3) and screw new nut onto thread. Lower parking brake lever (1) fully SI42.20-P-0004A

Nut must always be replaced.

The thread must fit flush with the nut (3).

3 Check condition of brake system on rear AR42.10-P-1010SR axle, reset brake shoes and position again using the adjustment Lower vehicle far enough so that the

wheels can still turn. 4 Adjust free travel on parking brake lever (1) A noticeable free travel of approx. 2 to

using nut (3) 3 mm must be given, before the brake cables can be tightened. 5 Turn wheels on rear axle The wheels must turn freely.

If brake shoes are making contact Check brake cables for unobstructed movement and adjust free travel again AR42.20-P-0545SR 6 Tighten parking brake lever (1) up to third notch 7 Turn wheels on rear axle The wheels must turn with a noticeable

braking effect. If there is hardly any or no noticeable braking effect Tighten parking brake lever (1) up to fourth notch and turn wheels again 8 Correct adjustment of nut (3) on thread, taking If the braking effect is still hardly or not free travel into consideration perceptible at all in the fourth notch. 9 Tighten parking brake lever (1) up to fifth notch 10 Turn wheels on rear axle It should no longer be possible to turn the

wheels. If the wheels still turn. Tighten parking brake lever (1) up to seventh notch and turn wheels again 11 Correct adjustment of nut (3) on thread, taking If the wheels still turn, even in the seventh free travel into consideration notch. 12 Tighten parking brake lever (1) then release it again, several times in succession 13 Check the parking brake adjustment If adjustment changed Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar42.20-p-0540sr, Adjust parking brake Model 453

Correct adjustment of nut (3) on thread, taking

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1841 · Applies to: 453 · AR: AP42.00-P-4290MCC

free travel into consideration 14 Lower vehicle with vehicle lift 15 Clip in cover (2) Check

16 Carry out brake test on the test stand AP42.00-P-4290MCC

Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar42.20-p-0540sr, Adjust parking brake Model 453

SM42.20-P-0019A

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1842 · Applies to: 453 · AR: AR42.20-P-0540SR

Check adjusting nut of hand-operated parking brake (code: 1707P42B76) 25.10.2017 Model 453 Operation no. of the operation texts or standard texts and flat rates Category Op. no. Operation text Time Acc. no. Code C 02-2014 Check nut on brake cable C 02-2015 Replace nut on brake cable (after check) 3 Adjusting nut P42.20-2675-04 Check

1 Check whether vehicle is affected by measure. Model 453 as of 000107 up to 021597 SM42.20-P-0019-01AAA Model 453 as of 021598 up to 042833 SM42.20-P-0019-01AAB Model 453 as of 042834 up to 079579 SM42.20-P-0019-01AAC Affected vehicles: Check adjusting nut of SM42.20-P-0019-01AAD hand-operated parking brake (code: 1707P42B76)Model 453 as of 079580 up to 080221 2 Check whether the adjusting nut (3) on the Findings

from the scope of testing must hand-operated parking brake is a Polystopp or be recorded in written form on the a microencapsulated nut. workshop order and then stored in a tamperproof manner. Polystopp nut installed. End the measure. Microencapsulated nut installed. Continue with operation step 3. Install

3 Replace microencapsulated nut on hand- operated parking brake with Polystopp nut. 4 Adjust parking brake AR42.20-P-0540SR

Do not perform operation step 3 in AR.

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, sm42.20-p-0019a, Check adjusting nut of hand-operated parking brake (code: 1707P42B76) Model 453

AR42.20-P-0545FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1844 · Applies to: 453 · AR: AR42.20-P-0545FF, AR68.20-P-2000FF, AR40.10-P-1100FF, AR42.20-P-0540FF

Parking brake cable removal and installation 20.3.06 MODEL 454.0 with CODE (30Y) Disk brakes on rear axle P42.20-2204-09 Shown on right-hand hand brake cable 1 Handbrake cable 5 Handbrake lever 9 Electrical line 2 Hand brake lever rocker 6 Wire 10 Grommet 3 Bracket 7 Brake caliper 11 Bracket 4 Nut 8 Bracket 12 Bracket Remove/install

1 Remove center console AR68.20-P-2000FF 2 Release handbrake lever (5) 3 Undo nut (4), detach left or right hand brake cable (1) from rocker of hand brake lever (2) and pull out of bracket (3) 4 Attach suitable wire (6) to hand brake cable (1) 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 below the lifting platform support points specified by the vehicle manufacturer. 5 Raise vehicle 6.1 Detach right rear wheel Only when removing the right-hand hand AR40.10-P-1100FF brake cable (1). 7 Unhook hand brake cable (1) from brake caliper (7) 8 Pull electrical line (9) out of the brackets (8, 11) 9 Detach brackets (8, 11, 12) Installation: Replace bracket bolts (8, 11, 12). 10 Remove grommet (10) Installation: Only insert grommet (10) after attaching hand brake cable (1) to rocker of hand brake lever (2). 11 Carefully pull the hand brake cable (1) The wire (6) remains in the vehicle. outwards and remove wire (6) from the hand brake cable (1) Installation: Assistant required. Attach wire (6) to hand brake cable (1). Push hand brake cable (1) into interior and guide hand brake cable (1) by simultaneously pulling on wire (6). 12 Install in the reverse order 13 Adjust parking brake AR42.20-P-0540FF Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.20-p-0545ff, Parking brake cable removal and installation MODEL 454.0 with CODE (30Y) Disk brakes on rear axle

AR42.20-P-0545FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1845 · Applies to: 453 · AR: AR42.20-P-0545FG, AR68.20-P-2000FF, AR42.10-P-0165FF, AR42.20-P-0540FF

Parking brake cable removal and installation 20.3.06 MODEL 454.0 except CODE (30Y) Disk brakes on rear axle P42.20-2278-09 Shown on right-hand hand brake cable 1 Handbrake cable 5 Handbrake lever 9 Electrical line 2 Hand brake lever rocker 6 Wire 10 Grommet 3 Bracket 7 Brake anchor plate 11 Bracket 4 Nut 8 Bracket 12 Bracket Remove/install

1 Remove center console AR68.20-P-2000FF 2 Release handbrake lever (5) 3 Undo nut (4), detach left or right hand brake cable (1) from rocker of hand brake lever (2) and pull out of bracket (3) 4 Attach suitable wire (6) to hand brake cable (1) 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 below the lifting platform support points specified by the vehicle manufacturer. 5 Raise vehicle 6 Remove brake shoes at rear axle. AR42.10-P-0165FF 7 Detach hand brake cable (1) from brake Hand brake cable (1) is clipped into brake carrier plate (7) carrier plate with three catches (arrow). 8 Pull electrical line (9) out of the brackets (8, 11) 9 Detach brackets (8, 11, 12) Install new bolts for brackets (8, 11, 12). 10 Remove grommet (10) Installation: Only insert grommet (10) after attaching hand brake cable (1) to rocker of hand brake lever (2). 11 Carefully pull the hand brake cable (1) The wire (6) remains in the vehicle. outwards and remove wire (6) from the hand brake cable (1) Installation: An assistant is required. Attach wire (6) to hand brake cable (1). Push hand brake cable (1) into interior and guide hand brake cable (1) by simultaneously pulling on wire (6). 12 Install in the reverse order 13 Adjust parking brake AR42.20-P-0540FF Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.20-p-0545fg, Parking brake cable removal and installation MODEL 454.0 except CODE (30Y) Disk brakes on rear axle

AR42.20-P-0545SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1846 · Applies to: 453 · AR: AR42.20-P-0545SR, AR68.20-P-2000SR, AR42.20-P-0540SR

Parking brake cable removal and installation 28.01.2016 Model 453 Modification notes 12.01.2016 Document revised completely. 1 Left brake cable 2 Right brake cable 3 Adjusting nut 4 Parking brake lever 5 Cover 6 Fuse 7 Rocker 8 Guide tube 9 Guide tube P42.20-2670-06 Shown on left side of vehicle 1 Left brake cable 10 Rubber grommet 11 Axle tube 12 Brake cover plate 13 Guide 14 Guide P42.20-2669-06 Remove/install

1 Remove center console AR68.20-P-2000SR 2 Unclip cover (5) 3 Unscrew adjusting nut (3) up to end of thread AR42.20-P-0540SR and fully lower parking brake lever (4) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.20-p-0545sr, Parking brake cable removal and installation Model 453

The thread must fit flush with the adjusting

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1847 · Applies to: 453 · AR: AR42.10-P-0165SR, AP42.00-P-4290MCC

nut (3). Installation:

Adjust parking brake. 4 Unclip retainer (6) from rocker (7) 5 Unhook left brake cable (1) or right brake cable (2) from rocker (7) 6 Remove corresponding brake shoes AR42.10-P-0165SR 7 Unhook rubber grommet (10) from bracket on axle tube (11) 8 Pull left brake cable (1) or right brake cable (2) from corresponding guide tube (8, 9) 9 Push catch hooks (arrows) together and route the left brake cable(1) or the right brake cable (2) out of the brake cover plate (12) 10 Pull left brake cable (1) or right brake cable (2) out of guides (13, 14) 11 Install in the reverse order Check

12 Carry out brake test on the test stand AP42.00-P-4290MCC

Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.20-p-0545sr, Parking brake cable removal and installation Model 453

AR42.20-P-0500SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1848 · Applies to: 453 · AR: AR42.20-P-0500SR, AR68.20-P-2000SR

Removing and installing hand brake lever 04.08.2014 MODEL 453 1 Parking brake lever 2 Cap 3 Brake cables 4 Adjusting nut 5 Retainer 6 Rocker P42.20-2673-06 1 Parking brake lever 7 Retaining clip 8 Electrical connector 9 Nuts 10 Guide tubes P42.20-2674-06 Remove/install

1 Remove center console AR68.20-P-2000SR 2 Pull parking brake lever (1) 3 Remove cap (2) from parking brake lever (1) 4 Release brake cables (3) by slackening Installation: Check free travel of parking

adjusting nut (4) on parking brake lever (1) brake. It must no longer be possible to turn the rear wheels by hand after the parking brake lever (1) has been moved to the 2nd detent. The rear wheels must turn freely when the parking brake lever (1) is released. If this is not the case: Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.20-p-0500sr, Removing and installing hand brake lever MODEL 453

Adjust parking brake.

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1849 · Applies to: 453 · AR: AR42.20-P-0540SR

AR42.20-P-0540SR 5 Release parking brake lever (1) 6 Unclip retainer (5) from rocker (6) 7 Detach brake cables (3) from side of rocker (6) 8 Unclip retaining clip (7) 9 Disconnect electrical connector (8) 10 Unscrew nuts (9) *BA42.20-P-1001-01N Nut, parking brake lever to body 11 Detach parking brake lever (1) from guide tubes (10) and remove 12 Install in the reverse order Parking brake Number Designation MODEL 453 BA42.20-P-1001-01N Nut, parking brake lever to body Nm 21 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.20-p-0500sr, Removing and installing hand brake lever MODEL 453

AR42.20-P-0500FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1850 · Applies to: 453 · AR: AR42.20-P-0500FF, AR68.20-P-2000FF, AR42.20-P-0540FF

Removing and installing handbrake lever 6.6.03 MODELS 454.0 1 Hand brake lever 2 Connector 3 Nut 4 Hand brake cables 5 Bolts S12 Parking brake indicator switch P42.20-2183-06 Remove/Install

1 Remove center console AR68.20-P-2000FF 2 Release handbrake lever (1) 3 Disconnect connector 4 Loosen nut (3) and unhook hand brake cable (4) 5 Unscrew bolts (5) Installation: Replace bolts (5). *BA42.20-P-1001-01E

6 Remove hand brake lever (1) 7.1 Detach parking brake indicator switch (S12) Only when replacing the hand brake lever (1). from hand brake lever (1) 8 Install in the reverse order 9 Adjust parking brake AR42.20-P-0540FF Parking brake

Number Designation Model 454.0 BA42.20-P-1001-01E Bolt, hand brake lever to body Nm 18 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.20-p-0500ff, Removing and installing handbrake lever MODELS 454.0

AR42.20-P-0501FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1851 · Applies to: 453 · AR: AR42.20-P-0501FF, AR68.20-P-2000FF

Removing and installing parking brake indicator switch 6.6.03 MODELS 454.0 1 Connector 2 Hand brake lever S12 Parking brake indicator switch P42.20-2182-04 Remove/Install

1 Remove center console AR68.20-P-2000FF 2 Unplug connector (1) 3 Push the floor covering to one side and detach parking brake indicator switch (S12) from hand brake lever (2) 4 Install in the reverse order 5 Carry out function check of parking brake indicator switch (S12) Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.20-p-0501ff, Removing and installing parking brake indicator switch MODELS 454.0

SI42.20-P-0004A

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1853 · Applies to: 453 · AR: AR42.20-P-0540SR

Service Information: Parking brake adjustment operations 29.09.2016 Model 453 During adjustment operations on the parking brake, the adjusting nut (2) must always be replaced by a new nut (N 000 000 008 272). The document AR42.20-P-0540SR will immediately be supplemented with a corresponding note. 1 Parking brake lever 2 Adjusting nut P42.20-2733-02 Parts ordering note Part no. Designation Quantity N 000 000 008 272 Nut Adjust parking brake AR42.20-P-0540SR Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, si42.20-p-0004a, Service Information: Parking brake adjustment operations Model 453

PE42.20-P-2000BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1856 · Applies to: 453 · AR: PE42.20-P-2000BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of parking brake 11.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Wiring diagram of parking brake PE42.20-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, pe42.20-p-2000bba, Wiring diagram of parking brake Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020

AR42.30-P-8550FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1857 · Applies to: 453 · AR: AR42.30-P-8550FF, AR54.00-P-0002FF

Remove/install ABS control unit 20.3.06 MODEL 454.0 except CODE (V33) ESP 1 Locking clamp 2 Electrical connector 3 Hydraulic unit 4 Fuel lines 5 Bolts 6 Plug connection 7 Coil N47-7 ABS control unit P42.30-2127-06 Remove/install

Notes on avoiding damage to electronic AH54.00-P-0001-01A

components due to electrostatic discharge 1 Remove battery tray AR54.00-P-0002FF 2 Unlock locking clamp (1) of electrical connector (2) and disconnect electrical connector (2) 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 below the lifting platform support points specified by the vehicle manufacturer. 3.1 Raise vehicle with lifting platform Only with transmission 717.474/475 4 Remove bolts (5) With transmission 717.474/475, the bolts (5) are only accessible from underneath. With all other transmission variants the bolts (5) are accessible from above. *BA42.30-P-1005-03B

*452589039901

*WH58.30-Z-1067-06A

5.1 Lower vehicle Only with transmission 717.474/475 6 Push fuel lines (4) slightly to right and remove Push fuel lines (4) to the right carefully in ABS control unit (N47-7) downward from order to avoid damage due to kinking. hydraulic unit (3) Installation:

Position the ABS control unit (N47-7) straight and with care, otherwise the connector (6) and coils (7) could be damaged. 7 Install in the reverse order 8 Read out fault memory and program ABS The ABS control unit (N47-7) is only control unit (N47-7) programmed when it is replaced. Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Hydraulic unit

Number Designation Model 454.0 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.30-p-8550ff, Remove/install ABS control unit MODEL 454.0 except CODE (V33) ESP

AR42.30-P-0705FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1859 · Applies to: 453 · AR: AR42.30-P-0705FF, AR83.25-P-1402FF, AR54.00-P-0002FF

Remove/install ABS hydraulic unit 10.11.11 MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle except CODE (V33) ESP Shown on vehicle with engine 135.9 1 Brake lines 2 Locking clamp 3 Electrical connector 4 Hydraulic unit 9 Left front brake line 10 Right front brake line 11 Brake line, rear left 12 Brake line, right rear P42.30-2126-05 4 Hydraulic unit 5 Hydraulic unit bracket 6 Nuts 7 Rubber bushing 8 Rubber bushing N47-7 ABS control unit P42.30-2123-02 Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A

brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge 1 Check bolted connection of brake lines (1, 9, AR42.10-P-0013-05SM Installation:

Mark brake lines (1, 9, 10, 10, 11, 12) for color coding 11, 12) accordingly. "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 2 Remove water collector AR83.25-P-1402FF 3 Remove battery tray AR54.00-P-0002FF 4 Extract brake fluid from brake fluid reservoir Brake fluid change unit gotis://B_42/43.2_01 5 Detach left rear brake line (11) and right rear Collect brake fluid which runs out in a brake line (12) from the hydraulic unit (4) suitable container. Seal openings of left rear brake line (11) and right rear brake line (12) and hydraulic unit (4) with suitable plugs. *BA42.10-P-1005-04G

Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.30-p-0705ff, Remove/install ABS hydraulic unit MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle except CODE (V33) ESP

Installation:

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1860 · Applies to: 453 · AR: AR42.10-P-0017FG, AR42.10-P-0017FF, AR42.10-P-0017FK, AR42.10-P-0010FG

Replace the left rear brake line (11) and right rear brake line (12) if initial color coding testing color coding. See: Remove/install rear axle brake lines AR42.10-P-0017FG 6 Detach left front brake line (9) and right front Collect brake fluid which runs out in a brake line (10) from hydraulic unit (4) suitable container. Seal openings of left front brake line (9) and right front brake line (10) and hydraulic unit (4) with suitable plugs. *BA42.10-P-1005-04G

Installation:

Replace the left front brake line (9) and right front brake line (10) if initial color coding testing makes this necessary color coding. See: Remove/install front axle brake lines AR42.10-P-0017FF 7 Detach brake lines (1) from the hydraulic unit Collect brake fluid which runs out in a (4) suitable container. Seal openings of brake lines (1) and hydraulic unit (4) with suitable plugs. *BA42.10-P-1005-04G

Installation:

Replace the brake lines (1), if necessary after initial testing of the color coding. See: Remove/install brake lines from the master AR42.10-P-0017FK brake cylinder to the hydraulic unit 8 Unlock locking clamp (2) of electrical connector (3) and disconnect electrical connector (3) 9 Unscrew nuts (6) Replace self-locking nuts (6). *BA42.30-P-1004-03B

10 Remove hydraulic unit (4) from the hydraulic unit bracket (5) 11.1 Detach rubber mounts (7, 8) from the Only when replacing the hydraulic unit (4). hydraulic unit (4) 12.1 Detach ABS control unit (N47-7) from the Only when replacing the hydraulic unit (4). hydraulic unit (4) *BA42.30-P-1005-03B

13 Install in the reverse order 14 Bleed brake system AR42.10-P-0010FG 15 Carry out transposition test Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Brake lines, brake hoses

Number Designation Model 454.0 without code 30Y BA42.10-P-1005-04G Brake line to hydraulic unit Nm 15 Hydraulic unit

Number Designation Model 454.0 BA42.30-P-1004-03B Nut, hydraulic unit to bracket Nm 9 BA42.30-P-1005-03B Bolt, ABS control unit to hydraulic unit Nm 3 Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.30-p-0705ff, Remove/install ABS hydraulic unit MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle except CODE (V33) ESP

AR42.30-P-0712FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1862 · Applies to: 453 · AR: AR42.30-P-0712FF

Remove/install left front or right rpm sensor 29.8.07 MODEL 454.0 1 Screw 2 Electrical line 3 Clip 4 Bracket 5 Bracket L6/1 Left front rpm sensor L6/1x1 Rpm sensor connector L6/2 Right front rpm sensor L6/2x1 Rpm sensor connector P42.30-2112-06 6 Screw 7 Nut 8 Front axle shaft 9 Bolts 10 Nuts 11 Suspension strut 12 Steering knuckle 13 Rubber boot L6/1 Left front rpm sensor L6/2 Right front rpm sensor P42.30-2128-06 Modification notes 8.11.06 Treating the contact areas on the rpm sensor as well as the Operation step 7 brake paste required for this added Removing

Risk of death Danger! caused by vehicle slipping or Align vehicle between columns of vehicle lift AS00.00-Z-0010-01A toppling off of the lifting platform. and position four support plates at vehicle lift support points specified by vehicle manufacturer. 1 Raise vehicle with vehicle lift 2 Disconnect rpm sensor connector (L6/1x1 or L6/2x1) on inner longitudinal member Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.30-p-0712ff, Remove/install left front or right rpm sensor MODEL 454.0

AR42.30-P-0714FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1865 · Applies to: 453 · AR: AR42.30-P-0714FF, AR40.10-P-1100FF

Remove/install rear axle rpm sensor 3.3.04 MODEL 454.0 Illustrated on model 454.031 1 Bolt 2 Clip 3 Electrical line 4 Bracket L6/3 Left rear rpm sensor L6/3x1 Rpm sensor connector L6/4 Right rear rpm sensor L6/4x1 Rpm sensor connector P42.30-2113-06 Remove/Install

1 Remove wheels from rear axle AR40.10-P-1100FF 2 Separate the rpm sensor connector (L6/3x1) or rpm sensor connector (L6/4x1) 3 Remove electrical line (3) of left rear rpm sensor (L6/3) and right rear rpm sensor (L6/4) from bracket (4) 4 Remove clip (2) 5 Remove bolt (1) from left rear rpm sensor Replace bolt (1). (L6/3) and right rear rpm sensor (L6/4) *BA42.30-P-1001-02E

6 Remove left rear rpm sensor (L6/3) or right Installation: Install new sealing ring for

rear rpm sensor (L6/4) left rear rpm sensor (L6/3) and right rear rpm sensor (L6/4). 7 Install in the reverse order Rear axle rpm sensor

Number Designation Model 454.0 BA42.30-P-1001-02E Bolt, rpm sensor support to Nm 8 wheel carrier Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.30-p-0714ff, Remove/install rear axle rpm sensor MODEL 454.0

PE42.30-P-2001ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1866 · Applies to: 453 · AR: PE42.30-P-2001ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+4 more)

Wiring diagram for ABS trailer socket 14.4.05 MODELS 454 as of 11.4.05 PE42.30-P-2001-99ZA Wiring diagram for ABS trailer socket PE42.30-P-2001-99ZA PE42.30-P-2001-60ZA Legend of wiring diagram for ABS trailer PE42.30-P-2001-60ZA socket 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) PE07.00-P-1100ZA Further wiring diagrams PE07.00-P-1100ZA PE42.00-P-1100ZA Further wiring diagrams PE42.00-P-1100ZA PE46.00-P-1100ZA Further wiring diagrams PE46.00-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe42.30-p-2001za, Wiring diagram for ABS trailer socket MODELS 454 as of 11.4.05

PE42.30-P-2000ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1867 · Applies to: 453 · AR: PE42.30-P-2000ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram of antilock brake system (ABS) 22.2.05 MODEL 454 as of 11.4.05 up to 2.4.06 PE42.30-P-2000-99ZA Wiring diagram of antilock brake system PE42.30-P-2000-99ZA (ABS) PE42.30-P-2000-60ZA Legend of wiring diagram for anti-lock brake PE42.30-P-2000-60ZA system (ABS) 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) PE00.19-P-1100ZA Further wiring diagrams PE00.19-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe42.30-p-2000za, Wiring diagram of antilock brake system (ABS) MODEL 454 as of 11.4.05 up to 2.4.06

PE42.30-P-2000ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1868 · Applies to: 453 · AR: PE42.30-P-2000ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+3 more)

Wiring diagram of antilock brake system (ABS) 8.3.06 MODEL 454 from 3.4.06 PE42.30-P-2000-99ZB Wiring diagram of antilock brake system PE42.30-P-2000-99ZB (ABS) PE42.30-P-2000-60ZB Legend of wiring diagram for anti-lock brake PE42.30-P-2000-60ZB system (ABS) 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) PE00.19-P-1100ZA Further wiring diagrams PE00.19-P-1100ZA PE15.00-P-1100ZA Further wiring diagrams PE15.00-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe42.30-p-2000zb, Wiring diagram of antilock brake system (ABS) MODEL 454 from 3.4.06

AR42.40-P-0816FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1869 · Applies to: 453 · AR: AR42.40-P-0816FF, AR83.25-P-1402FF, AR54.00-P-0002FF

Remove/install ETS/ASR/ESP hydraulic unit 10.11.11 MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle with CODE (V33) ESP Shown on vehicle with engine 135.9 1 Brake lines 2 Locking clamp 3 Electrical connector 4 Hydraulic unit 5 Hydraulic unit bracket 9 Left front brake line 10 Right front brake line 11 Brake line, rear left 12 Brake line, right rear P42.40-2023-05 4 Hydraulic unit 5 Hydraulic unit bracket 6 Nuts 7 Rubber bushing 8 Rubber bushing N47-5 ESP control unit P42.45-2446-02 Modification notes 15.6.05 Check brake line for reuse added Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A

brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge 1 Check bolted connection of brake lines (1, 9, AR42.10-P-0013-05SM 10, 11, 12) for color coding Installation:

Identify brake line (1, 9, 10, 11, 12) accordingly. See: Mark brake lines AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 2 Remove water collector AR83.25-P-1402FF 3 Remove battery tray AR54.00-P-0002FF Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.40-p-0816ff, Remove/install ETS/ASR/ESP hydraulic unit MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle with CODE (V33) ESP

Extract brake fluid from brake fluid reservoir

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1870 · Applies to: 453 · AR: AR42.10-P-0017FG, AR42.10-P-0017FF, AR42.10-P-0017FK, AR42.10-P-0010FF, AR42.10-P-0010FG

4 Extract brake fluid from brake fluid reservoir Brake fluid change unit gotis://B_42/43.2_01 5 Detach left rear brake line (11) and right rear Collect brake fluid which runs out in a brake line (12) from the hydraulic unit (4) suitable container. Seal the openings on the left rear brake line (11), right rear brake line (12) and hydraulic unit (4) with suitable plugs. *BA42.10-P-1005-04G

Installation:

Replace the left rear brake line (11) and right rear brake line (12) if initial color coding testing makes this necessary color coding. See: Remove/install rear axle brake lines AR42.10-P-0017FG 6 Detach left front brake line (9) and right front Collect brake fluid which runs out in a brake line (10) from hydraulic unit (4) suitable container. Seal the openings on the left front brake line (9), right front brake line (10) and on the hydraulic unit (4) with suitable plugs. *BA42.10-P-1005-04G

Installation:

Replace the left front brake line (9) and right front brake line (10) if initial color coding testing color coding. See: Remove/install front axle brake lines AR42.10-P-0017FF 7 Detach brake lines (1) from the hydraulic unit Collect brake fluid which runs out in a (4) suitable container. Seal openings on the brake lines (1) and hydraulic unit (4) with suitable plugs. *BA42.10-P-1005-04G

Installation:

Replace the brake lines (1), if necessary after initial testing of the color coding. See: Remove/install brake lines from the master AR42.10-P-0017FK brake cylinder to the hydraulic unit 8 Unlock locking clamp (2) of electrical connector (3) and disconnect electrical connector (3) 9 Unscrew nuts (6) Replace self-locking nuts (6). *BA42.45-P-1001-01G

10 Remove hydraulic unit (4) from the hydraulic unit bracket (5) 11.1 Detach rubber mounts (7, 8) from the Only when replacing the hydraulic unit (4). hydraulic unit (4) 12.1 Detach ESP control unit (N47-5) from the Only when replacing the hydraulic unit (4). hydraulic unit (4) *BA42.45-P-1004-01G

13 Install in the reverse order 14 Bleed brake system On vehicles with code (30Y) Disk brakes on AR42.10-P-0010FF rear axle On vehicles without code (30Y) Disk brakes AR42.10-P-0010FG on rear axle 15 Carry out transposition test Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Brake lines, brake hoses

Number Designation Model Model 454.0 with 454.0 code 30Y without code 30Y BA42.10-P-1005-04G Brake line to hydraulic unit Nm 15 15 Electronic Stability Program (ESP)

Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.40-p-0816ff, Remove/install ETS/ASR/ESP hydraulic unit MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle with CODE (V33) ESP

AR42.40-P-0816FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1872 · Applies to: 453 · AR: AR42.40-P-0816FG, AR83.25-P-1402FF, AR54.00-P-0002FF, AR42.10-P-0017FI, AR42.10-P-0017FH

Remove/install ETS/ASR/ESP hydraulic unit 10.11.11 MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle with CODE (V33) ESP P42.40-2019-08 Shown on engine 135.930 1 Brake lines 4 Locking clamp 7 Hydraulic unit 2 Brake lines 5 Electrical connector 3 Brake line 6 Nuts N47-5 ESP control unit Modification notes 13.6.05 Check brake line for reuse added Remove/install

Risk of poisoning Danger! caused by swallowing Only pour brake fluid into suitable and AS42.50-Z-0001-01A

brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge 1 Check bolted connections of brake lines (1, 2, AR42.10-P-0013-05SM 3) for color coding Installation:

Identify brake lines (1, 2, 3) accordingly. See: Mark brake lines AR42.10-P-0013-05SM "Yellow" locking paint BR00.45-Z-1027-07A "Red" safety paint BR00.45-Z-1028-07A 2 Remove water collector AR83.25-P-1402FF 3 Remove battery tray AR54.00-P-0002FF 4 Extract brake fluid from brake fluid reservoir Brake fluid change unit gotis://B_42/43.2_01 5 Detach brake lines (1) from the hydraulic unit Collect brake fluid which runs out in a (7) suitable container. Seal openings on the brake lines (1) and hydraulic unit (7) with suitable plugs. *BA42.10-P-1005-04G

Installation:

Replace the brake lines (1), if necessary after initial testing of the color coding. See: Engine 134.9/135.9 AR42.10-P-0017FI Engine 639.9 AR42.10-P-0017FH 6 Detach rear axle brake lines (2) Collect brake fluid which runs out in a suitable container. Seal openings on the brake lines (2) and hydraulic unit (7) with suitable plugs. Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.40-p-0816fg, Remove/install ETS/ASR/ESP hydraulic unit MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle with CODE (V33) ESP

*BA42.10-P-1005-04G

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1873 · Applies to: 453 · AR: AR42.10-P-0017FG, AR42.10-P-0017FF, AR42.10-P-0010FF, AR42.10-P-0010FG

Installation:

Replace the brake lines (2), if necessary after initial testing of the color coding. See: Remove/install rear axle brake lines AR42.10-P-0017FG 7 Detach front axle brake lines (3) Collect brake fluid which runs out in a suitable container. Seal openings on the brake lines (3) and hydraulic unit (7) with suitable plugs. *BA42.10-P-1005-04G

Installation:

Replace the brake lines (3), if necessary after initial testing of the color coding. See: Remove/install front axle brake lines AR42.10-P-0017FF 8 Unlock locking clamp (4) of electrical connector (5) and disconnect electrical connector (5) 9 Unscrew nuts (6) Replace self-locking nuts (6). *BA42.45-P-1001-01G

10 Remove hydraulic unit (7) 11.1 Detach rubber mount on the hydraulic unit (7) Only when replacing the hydraulic unit (7). 12.1 Detach ESP control unit (N47-5) from the Only when replacing the hydraulic unit (7). hydraulic unit (7) *BA42.45-P-1004-01G

13 Install in the reverse order 14 Bleed brake system On vehicles with code (30Y) Disk brakes on AR42.10-P-0010FF rear axle On vehicles without code (30Y) Disk brakes AR42.10-P-0010FG on rear axle 15 Carry out transposition test Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Brake lines, brake hoses

Number Designation Model Model 454.0 with 454.0 code 30Y without code 30Y BA42.10-P-1005-04G Brake line to hydraulic unit Nm 15 15 Electronic Stability Program (ESP)

Number Designation Model 454.0 BA42.45-P-1001-01G Nut, hydraulic unit to bracket Nm 9 BA42.45-P-1004-01G Bolt, ESP control unit to Nm 3 hydraulic unit Repair materials Number Designation Order number Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.40-p-0816fg, Remove/install ETS/ASR/ESP hydraulic unit MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle with CODE (V33) ESP

AR42.40-P-9801SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1875 · Applies to: 453 · AR: AR42.40-P-9801SR, AR40.10-P-1100SR

Remove/install left/right front axle rpm sensor 04.08.2014 MODEL 453 P42.30-2195-09 Shown on left side of vehicle 1 Screw 5 Bracket L6/1 Left front axle rpm sensor 2 Steering knuckle 6 Retaining clip L6/1x1 Left front axle rpm sensor electrical connector 3 Electrical line 7 Fender liner L6/2 Right front axle rpm sensor 4 Grommets 8 Electrical connector L6/2x1 Right front axle rpm sensor electrical connector 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. Remove/install

1 Switch off ignition 2 Remove left or right front wheel and tire AR40.10-P-1100SR assembly 3 Remove screw/bolt (1) *BA42.30-P-1001-01L Bolt, rpm sensor on front axle to steering knuckle 4 Pull left front axle rpm sensor (L6/1) or right front axle rpm sensor (L6/2) out of steering knuckle (2) 5 Remove rubber grommets (4) of electrical line (3) from bracket 6 Remove retaining clip (6) 7 Pull fender liner (7) to one side in area of left front axle rpm sensor electrical connector (L6/1x1) or right front axle rpm sensor electrical connector (L6/2x1) 8 Disconnect left front axle rpm sensor electrical connector (L6/1x1) or right front axle rpm sensor electrical connector (L6/2x1) 9 Unclip electrical connector (8) from bracket (5) and remove left front axle rpm sensor (L6/1) or right front axle rpm sensor (L6/2) 10 Install in the reverse order 11 Connect diagnostic system, read out fault memory and erase if necessary Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.40-p-9801sr, Remove/install left/right front axle rpm sensor MODEL 453

AR42.40-P-9807SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1877 · Applies to: 453 · AR: AR42.40-P-9807SR

Remove/install left/right rear axle rpm sensor 13.08.2014 MODEL 453 1 Bolt 2 Axle tube 3 Bracket 4 Electrical line 5 Electrical line L6/3 Left rear axle rpm sensor P42.30-2196-06 P42.30-2197-09 2 Axle tube 7 Electrical connector L6/3x1 Left rear axle rpm sensor electrical connector 4 Electrical line 8 Electrical connector L6/4x1 Right rear axle rpm sensor electrical connector 5 Electrical line 9 Bolt 6 Bracket L6/4 Right rear axle rpm sensor Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.40-p-9807sr, Remove/install left/right rear axle rpm sensor MODEL 453

PE42.45-P-2001ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1879 · Applies to: 453 · AR: PE42.45-P-2001ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+4 more)

Block diagram of electronic stability program (ESP) 16.12.03 MODELS 454 PE42.45-P-2001-99ZA Block diagram of electronic stability program PE42.45-P-2001-99ZA (ESP) PE42.45-P-2001-60ZA Legend of block diagram of electronic stability PE42.45-P-2001-60ZA program (ESP) 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) PE07.00-P-1100ZA Further wiring diagrams PE07.00-P-1100ZA PE42.00-P-1100ZA Further wiring diagrams PE42.00-P-1100ZA PE46.00-P-1100ZA Further wiring diagrams PE46.00-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe42.45-p-2001za, Block diagram of electronic stability program (ESP) MODELS 454

AR42.45-P-0820SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1880 · Applies to: 453 · AR: AR42.45-P-0820SR, AR42.45-P-0817SR

Remove/install Electronic Stability Program (ESP(R)) control unit 06.03.2020 Model 453 Modification notes 28.02.2017 If, when replacing the control unit, several control units are shown in the EPC, an XSF ticket must be created to enable the part number to be accurately identified. P42.45-2777-07 1 Hydraulic unit 4 Bolts 2 Nuts N30/4 Electronic Stability Program control unit 3 Bracket Remove/install

1 Remove hydraulic unit (1) AR42.45-P-0817SR 2 Loosen nuts (2) *BA42.45-P-1002-01P Nut, bracket to hydraulic unit 3 Remove hydraulic unit (1) from bracket (3) in direction of arrow 4 Remove screws (4) Installation: Replace screws/bolts (4).

*BA42.45-P-1003-01P Bolt, ESP® control unit to hydraulic unit 5 Detach Electronic Stability Program control If, when replacing the control unit, several unit (N30/4) from hydraulic unit (1) control units are shown in the EPC. Create XSF ticket for correct part number identification. Clean

6 Clean sealing surface on hydraulic unit (1) Assembly cleaner *BR00.45-Z-1028-04A 7 Install in the reverse order 8 Carry out calibration of the Electronic Stability When replacing Electronic Stability Program Program control unit (N30/4) with diagnostic control unit (N30/4). system AD00.00-P-2000-06SR

Electronic Stability Program (ESP®) Number Designation Model 453 BA42.45-P-1002-01P Nut, bracket to hydraulic unit Nm 8 Electronic Stability Program (ESP®) Number Designation Model 453 BA42.45-P-1003-01P Bolt, ESP® control unit to hydraulic unit Nm 8 Repair materials Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar42.45-p-0820sr, Remove/install Electronic Stability Program (ESP(R)) control unit Model 453

AR42.45-P-0817SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1882 · Applies to: 453 · AR: AR42.45-P-0817SR, AR42.10-P-0034SR, AR33.10-P-0100SR

Remove/install Electronic Stability Program (ESP(R)) hydraulic unit 10.07.2018 Model 453 P42.45-2776-09 1 Hydraulic unit 4 Electrical connector 7 Bracket 2 Brake lines 5 Bracket 8 Nuts 3 Brake lines 6 Electrical wiring harness 9 Nuts Risk of poisoning Caution from swallowing brake Only pour brake fluid into suitable and AS42.50-Z-0001-01A

fluid. Risk of injury from skin and eye contact appropriately marked containers. Wear with brake fluid protective clothing and eye protection when handling brake fluid. Topical note Notes on repairs to brake system AH42.00-P-0003-01A Topical note Brake fluid notes AH42.50-P-0001-01A Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Remove/install

1 Switch off ignition 2 Insert brake pedal jack with adapter for brake

pedal jack between brake pedal and driver's Cover driver seat. seat, and press brake pedal approx. 2 cm Otherwise the driver's seat may be soiled or damaged. 000589183100 Brake pedal jack 211589003100 Adapter for brake pedal winch 3 Mark brake lines (2, 3) with corresponding connections 4 Detach brake lines (2) from master brake AR42.10-P-0034SR cylinder leading to hydraulic unit (1) 5 Unscrew brake lines (3) from hydraulic unit (1) Installation: Observe marking of the brake

and seal lines (3). BA42.10-P-1004-04SR Retaining screw, brake line to hydraulic unit 129589009100 Record plug 6 Release and disconnect electrical connection (4) 7 Remove front axle AR33.10-P-0100SR 8 Unclip brake lines (3) from brackets (5) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.45-p-0817sr, Remove/install Electronic Stability Program (ESP(R)) hydraulic unit Model 453

AR42.45-P-0820FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1884 · Applies to: 453 · AR: AR42.45-P-0820FF, AR54.00-P-0002FF

Remove/install electronic stability program (ESP) control unit 20.3.06 MODEL 454.0 with CODE (V33) ESP 1 Electrical connector 2 Hydraulic unit 3 Bolts 4 Pressure sensor 5 Fuel lines 6 Plug connection 7 Coil N47-5 ESP control unit P42.10-2413-06 Remove/install

Notes on avoiding damage to electronic AH54.00-P-0001-01A

components due to electrostatic discharge 1 Remove battery tray AR54.00-P-0002FF 2 Unlock locking clip of electrical connector (1) and separate electrical connector (1) 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 below the lifting platform support points specified by the vehicle manufacturer. 3.1 Raise vehicle with lifting platform Only with transmission 717.474/475 4 Remove bolts (3) In vehicles with transmission 717.474/475, the bolts (3) are only accessible from underneath. With all other transmission variants the bolts (3) are accessible from above. *BA42.45-P-1004-01G

*452589039901

*WH58.30-Z-1067-06A

5.1 Lower vehicle Only with transmission 717.474/475 6 Press fuel lines (5) slightly to the right and Push fuel lines (5) to the right carefully in remove ESP control unit (N47-5) downwards order to avoid damage due to kinking. off the hydraulic unit (2) Installation:

Carefully position the ESP control unit (N47-5) straight, otherwise there is a risk of damage to the pressure sensor (4), the connector (6) and the coils (7). 7 Install in the reverse order 8 Read out fault memory and program ESP The ESP control unit (N47-5) is only control unit (N47-5) programmed when it is replaced. Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Electronic stability program (ESP)

Number Designation Model 454.0 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.45-p-0820ff, Remove/install electronic stability program (ESP) control unit MODEL 454.0 with CODE (V33) ESP

AR42.45-P-0841FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1886 · Applies to: 453 · AR: AR42.45-P-0841FF, AR68.20-P-2000FF

Remove/install yaw rate and lateral acceleration sensor 20.3.06 MODEL 454.0 with CODE (V33) ESP P42.45-2445-07 1 Floor mat 3 Electrical connector B24/15 Yaw rate and lateral acceleration sensor 2 Clip 4 Nut Remove/install

1 Remove center console AR68.20-P-2000FF 2 Cut up floor covering (1) at the marking 3 Remove clip (2) 4 Disconnect electrical connector (3) 5 Unscrew nuts (4) *BA42.45-P-1003-01G

6 Remove yaw rate and lateral acceleration sensor (B24/15) 7 Install in the reverse order 8 Read out fault memory Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Electronic stability program (ESP)

Number Designation Model 454.0 BA42.45-P-1003-01G Nut, yaw rate and lateral acceleration sensor Nm 6 to body Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar42.45-p-0841ff, Remove/install yaw rate and lateral acceleration sensor MODEL 454.0 with CODE (V33) ESP

PE42.45-P-2000ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1888 · Applies to: 453 · AR: PE42.45-P-2000ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram - electronic stability program (ESP) 16.12.03 MODEL 454 up to 2.4.06 PE42.45-P-2000-99ZA Wiring diagram - electronic stability program PE42.45-P-2000-99ZA (ESP) PE42.45-P-2000-60ZA electronic stability program PE42.45-P-2000-60ZA 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) PE00.19-P-1100ZA Further wiring diagrams PE00.19-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe42.45-p-2000za, Wiring diagram - electronic stability program (ESP) MODEL 454 up to 2.4.06

PE42.45-P-2000BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1897 · Applies to: 453 · AR: PE42.45-P-2000BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of Electronic Stability Program (ESP) 11.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Wiring diagram of Electronic Stability Program PE42.45-P-2000-97BBA (ESP) 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, pe42.45-p-2000bba, Wiring diagram of Electronic Stability Program (ESP) Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020

PE42.45-P-2000ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1898 · Applies to: 453 · AR: PE42.45-P-2000ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+3 more)

Wiring diagram of Electronic Stability Program (ESP) 8.3.06 MODEL 454 from 3.4.06 PE42.45-P-2000-99ZB Wiring diagram of Electronic Stability Program PE42.45-P-2000-99ZB (ESP) PE42.45-P-2000-60ZB electronic stability program PE42.45-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) PE00.19-P-1100ZA Further wiring diagrams PE00.19-P-1100ZA PE15.00-P-1100ZA Further wiring diagrams PE15.00-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe42.45-p-2000zb, Wiring diagram of Electronic Stability Program (ESP) MODEL 454 from 3.4.06

PE42.47-P-2050BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1899 · Applies to: 453 · AR: PE42.47-P-2050BBA

Electrical function schematic for Adaptive Brake (ABR) 10.03.2017 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) Electrical function schematic for Adaptive PE42.47-P-2050-97BBA Brake (ABR) Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe42.47-p-2050bba, Electrical function schematic for Adaptive Brake (ABR) Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491)

GF42.47-P-9997KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1900 · Applies to: 453 · AR: GF42.47-P-9997KJ

Overview of system components, Adaptive Brake (ABR) 10.03.2017 Model 453.0/3/4 P42.47-2097-79 Shown on model 453.0 (valid for model 453 except 453.091/391/491) A1 Instrument cluster L6/1 Left front axle rpm sensor S9/1 Stop lamp switch A1e7 Brake fluid and parking brake L6/2 Right front axle rpm sensor S11 Brake fluid level switch warning lamp A1e17 Anti-lock braking system L6/3 Left rear axle rpm sensor S12 Parking brake indicator switch indicator lamp A1e41 Electronic Stability Program L6/4 Right rear axle rpm sensor S29/5 Backup lamp activation/idle warning lamp recognition switch (with code 410 (Manual transmission, 5- speed)) A90 Distance warning function N2/10 Supplemental restraint system S40/3 Clutch pedal switch (for code controller unit with active control unit 410 (5-speed manual intervention by the brake system transmission)) (vehicles with code 258 (Active Brake Assist)) B37 Accelerator pedal sensor N3/10 ME-SFI [ME] control unit S56/1 Gear recognition sensor (with code 429 (twinamic)) B64/1 Brake vacuum sensor N10/10 Center SAM control unit U24 Valid for manual transmission E3 Left rear lamp unit N10/11 Driver SAM control unit U25 Valid for automatic transmission E4 Right rear lamp unit N15/13 Dual clutch transmission control X11/4 Diagnostic connector unit (with code 429 (Twinamic)) E21 Center stop lamp N30/4 Electronic Stability Program control unit L5 Crankshaft position sensor N49 Steering wheel angle sensor Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, gf42.47-p-9997kj, Overview of system components, Adaptive Brake (ABR) Model 453.0/3/4

GF42.47-P-0999KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1903 · Applies to: 453 · AR: GF42.47-P-0999KJ, GF42.47-P-0001KJ, GF42.47-P-9997KJ

Table of contents for function description, adaptive brake (ABR) 10.03.2017 Model 453.0/3/4 Adaptive brake (ABR), function GF42.47-P-0001KJ Overview of system components, Adaptive GF42.47-P-9997KJ Brake (ABR) Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf42.47-p-0999kj, Table of contents for function description, adaptive brake (ABR) Model 453.0/3/4

AR43.10-P-0350FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1914 · Applies to: 453 · AR: AR43.10-P-0350FF, AR42.40-P-0816FF, AR42.30-P-0705FF

Remove/install brake booster 21.11.05 MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle Shown on vehicle with engine 639 1 Brake booster 2 Brake booster vacuum line 3 Bracket 4 Connector 5 Brake fluid reservoir 9 Fuel filter (on engine 639.9) 10 Bracket 11 Bracket (on engine 639.9) P43.10-2059-04 P43.10-2042-07 1 Brake booster 7 Pin 8 Nuts 6 Fuse Remove/install

Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Push down brake pedal several times To reduce any vacuum. 2.1 Remove ESP hydraulic unit On vehicles with code (V33) ESP (FFO) AR42.40-P-0816FF 2.2 Remove ABS hydraulic unit On vehicles without code (V33) ESP (FFO) AR42.30-P-0705FF 3 Remove bracket (3) *BA42.30-P-1004-03B

*BA42.45-P-1001-01G

4 Pull vacuum line of brake booster (2) out of Installation:

Check rubber seal on brake brake booster (1) booster (1), replace if necessary. 5 Unplug connector (4) 6.1 Detach hose of clutch master cylinder on Transmission 717.470/471/ 473/478 brake fluid reservoir (5) using suitable pliers Replace seal in hose of clutch master cylinder. 7.1 Pull activated charcoal canister upward out of With engine 122.9, 134.9, 135.9 bracket (10) and place aside 7.2 Open bracket (11) and detach fuel filter (9) Engine 639.9: from bracket (10) and place aside 8 Remove bracket (10) from bulkhead 9 Remove locking device (6) and pull out bolt (7) 10 Unscrew nuts (8) and remove brake booster Replace self-locking nuts (8). (1) with master brake cylinder and brake fluid reservoir (5) *BA43.10-P-1001-01E

11.1 Modify master brake cylinder Only when replacing the brake booster (1). Replace nuts of master brake cylinder. Installation: Replace sealing ring of

master brake cylinder. *BA42.10-P-1001-05E

12 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar43.10-p-0350ff, Remove/install brake booster MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle

Push down brake pedal several times

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1917 · Applies to: 453 · AR: AR42.10-P-0300FG

1 Push down brake pedal several times In order to eliminate any vacuum present. 2 Remove brake master cylinder AR42.10-P-0300FG 3 Pull off retainer (1) and pull out pin (2) Installation:

Apply a thin coating of grease to the pin (2). 4 Unscrew nuts (3). Install new self-locking nuts (3). *BA43.10-P-1001-01E

5 Pull vacuum line of brake booster (5) out of brake booster (4) 6 Remove filler neck (7) with bracket Installation:

Replace the sealing ring of the filler neck (7). 7 Remove screws (9) 8 Use a suitable jack to support the engine Use a suitable support of wood or rubber to prevent damage to the engine. Ensure that the jack is securely positioned to prevent it from slipping. 9 Unscrew nut (8) *BA22.10-P-1003-01Q

10 Unscrew nuts (10). *BA22.10-P-1006-01Q

11 Remove bracket (6) 12 Lower the right front of the engine until the Pull the engine forward carefully in order brake booster (4) can be removed to have more space for removal. Helper required 13 Remove brake booster (4). 14 Install in the reverse order Pneumatic brake booster

Number Designation Model 454.0 BA43.10-P-1001-01E Brake booster nut to splash wall Nm 14 Engine mounts, engine supports

Number Designation Engine 639.9 BA22.10-P-1003-01Q Nut of engine bracket to engine mount Nm 48 BA22.10-P-1006-01Q Nut of engine bracket to bracket Nm 45 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar43.10-p-0350fg, Remove/install brake booster MODEL 454.0## 2# with ENGINE 639.939 with CODE (RHD) Right-hand drive vehicle

AR25.20-P-0070FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2042 · Applies to: 453 · AR: AR25.20-P-0070FF, AP42.10-P-4210FF

Bleed clutch operating system 5.12.03 MODELS 454.0 with TRANSMISSION 717.470 /471 /473 /478 P25.20-2030-07 Shown on vehicle with transmission 717.471 1 Brake fluid reservoir 3 Bleed valve 5 Brake fluid receptacle 2 Cap 4 Slave cylinder Bleeding Risk of poisoning Danger! caused by swallowing Pour brake fluid only into suitable and AS42.50-Z-0001-01A

brake fluid. Risk of injury caused by brake appropriately marked containers. Wear fluid coming into contact with skin and eyes. protective clothing and eye protection when handling brake fluid. Brake fluid notes AH42.50-P-0001-01A

Notes on repairs to brake system AH42.00-P-0003-01A

1 Unscrew cap (2) of brake fluid reservoir (1) 2 Connect brake fluid changing unit to brake Observe owner's manual of brake fluid fluid reservoir (1) and switch on replacement unit. General brake fluid Sheet 330.1 BB00.40-P-0330-01A

Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40-P-0331-00A

Brake fluid replacement unit WE58.40-Z-1001-07A 454589019100

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 below the hoist support points specified by the vehicle manufacturer. 3 Raise vehicle. 4 Remove dust cap from vent valve (3), connect hose of brake fluid receptacle (5) to vent valve (3) of slave cylinder (4) and open vent valve (3) 5 Close vent valve (3), detach hose of brake Only close the vent valve (3) when the fluid receptacle (5) and press dust cap onto brake fluid escapes free of bubbles and the vent valve (3) without contamination (brake fluid is light in color). *BA25.20-P-1005-01D

6 Lower vehicle 7 Switch off brake fluid replacement unit and Observe owner's manual of brake fluid

disconnect replacement unit. Brake fluid replacement unit WE58.40-Z-1001-07A 454589019100

8 Check brake fluid level and correct if necessary Brake system - inspect fluid level AP42.10-P-4210FF

9 Screw on cap (2) of brake fluid reservoir (1) 10 Check function of clutch operator 11 Check leaktightness of brake system AR42.10-P-0100-01FF If a test trip is carried out after a repair to the hydraulic system, the brakes are to be applied with an ABS control. Clutch mechanism Number Designation Model 454.0 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar25.20-p-0070ff, Bleed clutch operating system MODELS 454.0 with TRANSMISSION 717.470 /471 /473 /478