2014-2024 Smart Fortwo 453 Workshop Manual.pdf

475 excerpts.

OV00.01-P-1909BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 111 · Applies to: 453 · AR: OV00.01-P-1909BBA, PE47.40-P-2101BBA, PE54.30-P-2101BBA, PE00.19-P-2800BBB, PE54.15-P-2001BBB (+5 more)

Search aid for all electrical components 12.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Short designation Component Notes Wiring diagram A1 Instrument cluster Model 453.0 (except 453.091), 453.3 (except PE47.40-P-2101BBA 453.391), 453.4 (except 453.491) up to model year 2020 A1 Instrument cluster 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 A15 Additional instruments Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBB 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 A15 Additional instruments 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 A15 Additional instruments 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 A15 Additional instruments Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBD 453.391), 453.4 (except 453.491) up to model year 2020 Sheet4 A15 Additional instruments 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 A15 Additional instruments Model 453.0 (except 453.091), 453.3 (except PE82.20-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 A16 Knock sensor Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBB year 2020 Plug AC A2 Radio 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 A2 Radio 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 A2 Radio Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBD 453.391), 453.4 (except 453.491) up to model year 2020 Sheet4 A2 Radio Model 453.0 (except 453.091), 453.3 (except PE82.60-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 537 (smart audio system) except code 535 (smart media system) except code 561 (61C - PREMIUM radio without DAB with PREMIUM SOUND)
except code 562 (62C - R0 radio with DAB and PREMIUM SOUND) except code C08 (Pre-installation for radio) A2 Radio Model 453.0 (except 453.091), 453.3 (except PE82.60-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code 535 (smart media system) except code 537 (smart audio system) except code 556 (56A MM2012 radio with DAB and PREMIUM SOUND) except code 557 (57A MM2012 radio without DAB) except code C08 (Pre-installation for radio) A2 Radio Model 453.0 (except 453.091), 453.3 (except PE82.60-P-2000BBC 453.391), 453.4 (except 453.491) up to model year 2020 with code 535 (smart media system) with code 556 (56A MM2012 radio with DAB and PREMIUM SOUND) with code 557 (57A MM2012 radio without DAB) except code 537 (smart audio system) except code C08 (Pre-installation for radio) with sound system A2 Radio Model 453.0 (except 453.091), 453.3 (except PE82.60-P-2000BBE 453.391), 453.4 (except 453.491) up to model year 2020 with code 537 (smart audio system) with code 561 (61C - PREMIUM radio without DAB with PREMIUM SOUND) with code 562 (62C - R0 radio with DAB and PREMIUM SOUND) except code 535 (smart media system) except code C08 (Pre- installation for radio) Page 1 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

A50/5

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 113 · Applies to: 453 · AR: PE00.19-P-2800BBC, PE54.15-P-2001BBB, PE82.85-P-2008BBA, PE00.19-P-2150BBD, PE77.39-P-2202BBA (+5 more)

Card reader on windshield 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 A50/5 Card reader on windshield 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 A50/5 Card reader on windshield Model 453.0 (except 453.091), 453.3 (except PE82.85-P-2008BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code P02 (car2go) A50/6 Windshield reader system access electronic Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2150BBD key box 453.391), 453.4 (except 453.491) up to model year 2020 Multimedia A50/6 Windshield reader system access electronic Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBC key box 453.391), 453.4 (except 453.491) up to model year 2020 W1/3 A50/6 Windshield reader system access electronic Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBB key box 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AA A50/6 Windshield reader system access electronic Model 453.0 (except 453.091), 453.3 (except PE82.85-P-2008BBA key box 453.391), 453.4 (except 453.491) up to model year 2020 with code P02 (car2go) A52 Soft top control drive unit Model 453.4 (except 453.491) up to model PE77.39-P-2202BBA year 2020 A53 Driver head/thoraxbag sensor Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBA 453.391), 453.4 (except 453.491) up to model year 2020 Plug BB A54 Passenger head/thoraxbag sensor Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBB 453.391), 453.4 (except 453.491) up to model year 2020 Plug BA-BC A67 Inside rearview mirror Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBB 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 A67 Inside rearview mirror 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 A67 Inside rearview mirror Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBE 453.391), 453.4 (except 453.491) up to model year 2020 Sheet5 A67 Inside rearview mirror Model 453.0 (except 453.091), 453.3 (except PE68.49-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code V35 (Automatically dimming inside rearview mirror) except code 494 (USA version) A71 Front passenger airbag warning indicator 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 A71 Front passenger airbag warning indicator Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBC 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AB to AE A71 Front passenger airbag warning indicator Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBE 453.391), 453.4 (except 453.491) up to model year 2020 Sheet5 A71 Front passenger airbag warning indicator Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBA 453.391), 453.4 (except 453.491) up to model year 2020 Plug BB A89 Controller unit for distance warning function Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2150BBB with radar sensor 453.391), 453.4 (except 453.491) up to model year 2020 Cruise control A89 Controller unit for distance warning function Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBB with radar sensor 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 A89 Controller unit for distance warning function Model 453.0 (except 453.091), 453.3 (except PE30.30-P-2105BBA with radar sensor 453.391), 453.4 (except 453.491) up to model year 2020 with code 252 (Distance warning function) except code 258 (Active Brake Assist) A89 Controller unit for distance warning function Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBB with radar sensor 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AA A9 Refrigerant compressor Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 A9 Refrigerant compressor Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBA year 2020 Plug AA A9 Refrigerant compressor 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 Page 3 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

E17/16

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 118 · Applies to: 453 · AR: PE00.19-P-2800BBC, PE82.20-P-2000BBA, PE54.15-P-2001BBC, PE00.19-P-2800BBA, PE54.18-P-2300BBB (+5 more)

Left front footwell lamp 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 E17/16 Left front footwell lamp Model 453.0 (except 453.091), 453.3 (except PE82.20-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 E18/1 Load compartment lamp Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBC 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AB to AE E18/1 Load compartment lamp Model 453.0 (except 453.091), 453.3 (except PE82.20-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 E19/1 Left license plate lamp Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 E19/1 Left license plate lamp 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 E19/2 Right license plate lamp Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 E2 Right front lamp unit 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 E21 Center high-mounted stop lamp Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 E22/1 Left additional turn signal lamp Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBB 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 E22/1 Left additional turn signal lamp Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) E22/1 Left additional turn signal lamp Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2200BBA 453.391), 453.4 (except 453.491) up to model year 2020 E22/2 Right additional turn signal lamp Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBB 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 E22/2 Right additional turn signal lamp Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) E22/2 Right additional turn signal lamp Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2200BBA 453.391), 453.4 (except 453.491) up to model year 2020 E3 Left taillamp Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 E4 Right taillamp Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 E4 Right taillamp Model 453.0/3/4 with transmission 700.4 up to PE27.19-P-2102BBA model year 2020 with code 429 (twinamic) E4 Right taillamp 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 E4 Right taillamp 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 E4 Right taillamp Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) E4 Right taillamp 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 E4 Right taillamp Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2200BBA 453.391), 453.4 (except 453.491) up to model year 2020 E4 Right taillamp Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2300BBA 453.391), 453.4 (except 453.491) up to model year 2020 E43/1 Left cockpit ambiance illumination Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBD 453.391), 453.4 (except 453.491) up to model year 2020 W1/5 Page 8 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

M14/9

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 125 · Applies to: 453 · AR: PE00.19-P-2800BBA, PE54.18-P-2300BBD, PE80.20-P-2000BBA, PE80.20-P-2000BBB, PE80.50-P-2000BBB (+5 more)

Right rear central locking actuator Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 M14/9 Right rear central locking actuator Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBD 453.391), 453.4 (except 453.491) up to model year 2020 Sheet4 M14/9 Right rear central locking actuator Model 453.0 (except 453.091), 453.3 (except PE80.20-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Except UK M14/9 Right rear central locking actuator Model 453.0 (except 453.091), 453.3 (except PE80.20-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 UK version M14/9 Right rear central locking actuator Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) M15 Clutch actuator 2 Transmission 700.4 in model 453.0/3/4 up to PE27.19-P-2106BBA model year 2020 with code 429 (twinamic) M16/6 Throttle valve actuator Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBB year 2020 Plug AC M16/6 Throttle valve actuator Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBC year 2020 Plug AB M16/7 Boost pressure control flap actuator Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBB year 2020 Plug AC M16/7 Boost pressure control flap actuator Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBC year 2020 Plug AB M2 Blower motor Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBD 453.391), 453.4 (except 453.491) up to model year 2020 W1/5 M2 Blower motor Model 453.0 (except 453.091), 453.3 (except PE83.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code I01 (Air conditioning PLUS) except code I77 (Manual air conditioning) M2 Blower motor Model 453.0 (except 453.091), 453.3 (except PE83.30-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code I77 (Manual air conditioning) except code I01 (Air conditioning PLUS) M2/14 Blending air flap actuator motor Model 453.0 (except 453.091), 453.3 (except PE83.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code I01 (Air conditioning PLUS) except code I77 (Manual air conditioning) M2/15 Footwell flap actuator motor Model 453.0 (except 453.091), 453.3 (except PE83.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code I01 (Air conditioning PLUS) except code I77 (Manual air conditioning) M2/5 Fresh air/air recirculation flap actuator motor Model 453.0 (except 453.091), 453.3 (except PE83.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code I01 (Air conditioning PLUS) except code I77 (Manual air conditioning) M21/1 Left electrically adjustable and heated outside Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBC mirror 453.391), 453.4 (except 453.491) up to model year 2020 W1/3 M21/1 Left electrically adjustable and heated outside Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBC mirror 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AB to AE M21/1 Left electrically adjustable and heated outside Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBC mirror 453.391), 453.4 (except 453.491) up to model year 2020 Sheet3 M21/1 Left electrically adjustable and heated outside Model 453.0 (except 453.091), 453.3 (except PE88.79-P-2000BBA mirror 453.391), 453.4 (except 453.491) up to model year 2020 with code V21 (Electrically adjustable and heated outside mirrors (FFO)) M21/2 Right electrically adjustable and heated Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBD outside mirror 453.391), 453.4 (except 453.491) up to model year 2020 W1/5 M21/2 Right electrically adjustable and heated Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBC outside mirror 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AB to AE M21/2 Right electrically adjustable and heated Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBC outside mirror 453.391), 453.4 (except 453.491) up to model year 2020 Sheet3 M21/2 Right electrically adjustable and heated Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBD outside mirror 453.391), 453.4 (except 453.491) up to model year 2020 Sheet4 Page 15 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

M6/1

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 127 · Applies to: 453 · AR: PE00.19-P-2800BBB, PE54.21-P-2127BBA, PE82.30-P-2000BBA, PE00.19-P-2800BBA, PE54.18-P-2300BBB (+5 more)

Wiper motor Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBB 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 M6/1 Wiper motor 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 M6/1 Wiper motor Model 453.0 (except 453.091), 453.3 (except PE82.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 M6/4 Tailgate wiper motor Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 M6/4 Tailgate wiper motor 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 M6/4 Tailgate wiper motor 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 M6/4 Tailgate wiper motor 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 M6/4 Tailgate wiper motor Model 453.0 (except 453.091), 453.3 (except PE82.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 N10/10 SAM control unit Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2150BBA 453.391), 453.4 (except 453.491) up to model year 2020 Interior compartment and suspension N10/10 SAM control unit 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 N10/10 SAM control unit 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 N10/10 SAM control unit 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 N10/10 SAM control unit Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBD 453.391), 453.4 (except 453.491) up to model year 2020 Sheet4 N10/10 SAM control unit 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 N10/10 SAM control unit 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 N10/10 SAM control unit 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 N10/10 SAM control unit 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 N10/10 SAM control unit Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) N10/10 SAM control unit 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 N10/10 SAM control unit Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2200BBA 453.391), 453.4 (except 453.491) up to model year 2020 N10/11 Driver SAM control unit 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 N10/11 Driver SAM control unit 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 N10/11 Driver SAM control unit 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 N10/11 Driver SAM control unit 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 N110 Weight Sensing System (WSS) control unit 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 Page 17 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

Parking system control unit

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 130 · Applies to: 453 · AR: PE00.19-P-2800BBA, PE54.65-P-2101BBA, PE00.19-P-2150BBA, PE15.00-P-2101BBA, PE46.35-P-2000BBA (+5 more)

N62 Parking system control unit Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 N62 Parking system control unit Model 453.0 (except 453.091), 453.3 (except PE54.65-P-2101BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 220 (Rear parking assist) N68 Steering assist control unit Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2150BBA 453.391), 453.4 (except 453.491) up to model year 2020 Interior compartment and suspension N68 Steering assist control unit Model 453.0 (except 453.091), 453.3 (except PE15.00-P-2101BBA 453.391), 453.4 (except 453.491) up to model year 2020 N68 Steering assist control unit Model 453.0 (except 453.091), 453.3 (except PE46.35-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 N68 Steering assist control unit 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 N70/1 Sliding roof control unit Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 N70/1 Sliding roof control unit 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 N70/1 Sliding roof control unit Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBC 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AB to AE N70/1 Sliding roof control unit Model 453.0 (except 453.091) up to model PE77.20-P-2200BBA year 2020 N76/1 Blower regulator Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBD 453.391), 453.4 (except 453.491) up to model year 2020 W1/5 N76/1 Blower regulator Model 453.0 (except 453.091), 453.3 (except PE83.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code I01 (Air conditioning PLUS) except code I77 (Manual air conditioning) N93/1 Audio gateway control unit Model 453.0 (except 453.091), 453.3 (except PE82.60-P-2102BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 535 (smart media system) N93/2 Distance warning function gateway Model 453.0 (except 453.091), 453.3 (except PE30.30-P-2105BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 252 (Distance warning function) except code 258 (Active Brake Assist) R1 Heated rear window Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 R1 Heated rear window 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 R12/13 Driver airbag ignition squib 1 Model 453.0 (except 453.091), 453.3 (except PE82.25-P-2100BBA 453.391), 453.4 (except 453.491) up to model year 2020 R12/13 Driver airbag ignition squib 1 Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBB 453.391), 453.4 (except 453.491) up to model year 2020 Plug BA-BC R12/14 Driver airbag ignition squib 2 Model 453.0 (except 453.091), 453.3 (except PE82.25-P-2100BBA 453.391), 453.4 (except 453.491) up to model year 2020 R12/14 Driver airbag ignition squib 2 Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBB 453.391), 453.4 (except 453.491) up to model year 2020 Plug BA-BC R12/22 Left windowbag squib 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 R12/23 Right windowbag squib Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBD 453.391), 453.4 (except 453.491) up to model year 2020 Sheet4 R12/24 Front passenger kneebag squib Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBB 453.391), 453.4 (except 453.491) up to model year 2020 Plug BA-BC R12/25 Driver kneebag squib Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBB 453.391), 453.4 (except 453.491) up to model year 2020 Plug BA-BC R12/26 Right front belt force limiter Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBA 453.391), 453.4 (except 453.491) up to model year 2020 Plug BB Page 20 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

X132/2

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 140 · Applies to: 453 · AR: PE00.19-P-2150BBA, PE00.19-P-2800BBA, PE54.15-P-2001BBC, PE77.39-P-2202BBA, PE54.15-P-2001BBB (+5 more)

Soft top electrical connector Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2150BBA 453.391), 453.4 (except 453.491) up to model year 2020 Interior compartment and suspension X132/2 Soft top electrical connector Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 X132/2 Soft top electrical connector Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBC 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AB to AE X132/2 Soft top electrical connector Model 453.4 (except 453.491) up to model PE77.39-P-2202BBA year 2020 X133/2 Sliding roof electrical connector Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 X133/2 Sliding roof electrical connector 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 X133/2 Sliding roof electrical connector Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBC 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AB to AE X133/2 Sliding roof electrical connector Model 453.0 (except 453.091) up to model PE77.20-P-2200BBA year 2020 X18/3 Vehicle interior/fuel tank electrical connector Model 453.0 (except 453.091), 453.3 (except PE47.40-P-2101BBA 453.391), 453.4 (except 453.491) up to model year 2020 X18/42 Vehicle interior/restraint systems electrical Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBB connector 453.391), 453.4 (except 453.491) up to model year 2020 Plug BA-BC X18/48 Vehicle interior/rear end electrical connector Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 X18/48 Vehicle interior/rear end electrical connector 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 X18/48 Vehicle interior/rear end electrical connector Model 453.0 (except 453.091), 453.3 (except PE54.65-P-2101BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 220 (Rear parking assist) X18/48 Vehicle interior/rear end electrical connector 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 X18/49 Right vehicle interior/seat electrical connector Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBD 453.391), 453.4 (except 453.491) up to model year 2020 W1/5 X18/49 Right vehicle interior/seat electrical connector 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 X18/49 Right vehicle interior/seat electrical connector Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBA 453.391), 453.4 (except 453.491) up to model year 2020 Plug BB X18/49 Right vehicle interior/seat electrical connector Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBB 453.391), 453.4 (except 453.491) up to model year 2020 Plug BA-BC X18/50 Left vehicle interior/seat electrical connector 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 X18/50 Left vehicle interior/seat electrical connector 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 X18/50 Left vehicle interior/seat electrical connector Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBA 453.391), 453.4 (except 453.491) up to model year 2020 Plug BB X18/50 Left vehicle interior/seat electrical connector Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBB 453.391), 453.4 (except 453.491) up to model year 2020 Plug BA-BC X18/53 Instrument panel/ATA electrical connector 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 X18/53 Instrument panel/ATA electrical connector Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBB 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 X18/53 Instrument panel/ATA electrical connector Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 except code V19 (Anti-theft alarm system) X19 Rear window heater electrical connector Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 Page 30 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

Z37/21

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 152 · Applies to: 453 · AR: PE00.19-P-2150BBA, PE07.61-P-2101BBA, PE42.45-P-2000BBA, PE46.35-P-2000BBA, PE54.21-P-2127BBB (+5 more)

CAN bus (low) connector sleeve Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2150BBA 453.391), 453.4 (except 453.491) up to model year 2020 Interior compartment and suspension Z37/21 CAN bus (low) connector sleeve Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBA year 2020 Plug AA Z37/21 CAN bus (low) connector sleeve Model 453.0 (except 453.091), 453.3 (except PE42.45-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z37/21 CAN bus (low) connector sleeve Model 453.0 (except 453.091), 453.3 (except PE46.35-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z37/21 CAN bus (low) connector sleeve 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 Z37/21 CAN bus (low) connector sleeve Model 453.4 (except 453.491) up to model PE77.39-P-2202BBA year 2020 Z37/21 CAN bus (low) connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.85-P-2105BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 535 (smart media system) with code P02 (car2go) Z37/21 CAN bus (low) connector sleeve Model 453.0 (except 453.091), 453.3 (except PE83.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code I01 (Air conditioning PLUS) except code I77 (Manual air conditioning) Z37/21 CAN bus (low) connector sleeve Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBA 453.391), 453.4 (except 453.491) up to model year 2020 Plug BB Z37/22 CAN databus (high) connector sleeve Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2150BBA 453.391), 453.4 (except 453.491) up to model year 2020 Interior compartment and suspension Z37/22 CAN databus (high) connector sleeve Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBA year 2020 Plug AA Z37/22 CAN databus (high) connector sleeve Model 453.0 (except 453.091), 453.3 (except PE42.45-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z37/22 CAN databus (high) connector sleeve Model 453.0 (except 453.091), 453.3 (except PE46.35-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z37/22 CAN databus (high) connector sleeve 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 Z37/22 CAN databus (high) connector sleeve Model 453.4 (except 453.491) up to model PE77.39-P-2202BBA year 2020 Z37/22 CAN databus (high) connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.85-P-2105BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 535 (smart media system) with code P02 (car2go) Z37/22 CAN databus (high) connector sleeve Model 453.0 (except 453.091), 453.3 (except PE83.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code I01 (Air conditioning PLUS) except code I77 (Manual air conditioning) Z37/22 CAN databus (high) connector sleeve Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBA 453.391), 453.4 (except 453.491) up to model year 2020 Plug BB Z37/43 Audio + signal connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.62-P-2101BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 810 (Premium sound system) Z37/52 Audio - signal connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.62-P-2101BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 810 (Premium sound system) Z38 Backup lamp connector sleeve Model 453.0/3/4 with transmission 700.4 up to PE27.19-P-2102BBA model year 2020 with code 429 (twinamic) Z38 Backup lamp connector sleeve 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 Z38 Backup lamp connector sleeve 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 Z38 Backup lamp connector sleeve 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 Z40 Stop lamp signal connector sleeve Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBA year 2020 Plug AA Page 42 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

Z6/153

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 158 · Applies to: 453 · AR: PE00.19-P-2800BBC, PE15.00-P-2103BBA, PE30.30-P-2000BBA, PE54.65-P-2101BBA, PE77.20-P-2200BBA (+5 more)

Ground connection connector sleeve 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 Z6/153 Ground connection connector sleeve 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 Z6/153 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE30.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/153 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE54.65-P-2101BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 220 (Rear parking assist) Z6/153 Ground connection connector sleeve Model 453.0 (except 453.091) up to model PE77.20-P-2200BBA year 2020 Z6/153 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.00-P-2600BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/153 Ground connection connector sleeve 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 Z6/153 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.20-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/153 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.25-P-2100BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/154 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBD 453.391), 453.4 (except 453.491) up to model year 2020 Sheet4 Z6/155 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBD 453.391), 453.4 (except 453.491) up to model year 2020 W1/5 Z6/155 Ground connection connector sleeve Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBC year 2020 Plug AB Z6/155 Ground connection connector sleeve 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 Z6/155 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE54.22-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/155 Ground connection connector sleeve 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 Z6/155 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.20-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/155 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBA 453.391), 453.4 (except 453.491) up to model year 2020 Plug BB Z6/157 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBB 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 Z6/157 Ground connection connector sleeve Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBA year 2020 Plug AA Z6/157 Ground connection connector sleeve Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBC year 2020 Plug AB Z6/157 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBA 453.391), 453.4 (except 453.491) up to model year 2020 F1 Z6/157 Ground connection connector sleeve 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 Z6/157 Ground connection connector sleeve 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 Z6/157 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) Z6/157 Ground connection connector sleeve 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 Z6/157 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2200BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/157 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.25-P-2005BBA 453.391), 453.4 (except 453.491) up to model year 2020 Page 48 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

Z6/158

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 159 · Applies to: 453 · AR: PE00.19-P-2800BBB, PE07.61-P-2101BBA, PE07.61-P-2101BBC, PE54.15-P-2001BBB, PE54.18-P-2300BBB (+5 more)

Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBB 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 Z6/158 Ground connection connector sleeve Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBA year 2020 Plug AA Z6/158 Ground connection connector sleeve Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBC year 2020 Plug AB Z6/158 Ground connection connector sleeve 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 Z6/158 Ground connection connector sleeve 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 Z6/158 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) Z6/158 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2200BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/158 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.25-P-2005BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/160 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBB 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 Z6/160 Ground connection connector sleeve 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 Z6/160 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) Z6/160 Ground connection connector sleeve 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 Z6/160 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2200BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/161 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBB 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 Z6/161 Ground connection connector sleeve Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBC year 2020 Plug AB Z6/161 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBC 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AB to AE Z6/161 Ground connection connector sleeve 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 Z6/161 Ground connection connector sleeve 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 Z6/161 Ground connection connector sleeve 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 Z6/161 Ground connection connector sleeve 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 Z6/161 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 except code V19 (Anti-theft alarm system) Z6/161 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) Z6/161 Ground connection connector sleeve 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 Z6/161 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2200BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/161 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/162 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBB 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 Page 49 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

Z6/162

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 160 · Applies to: 453 · AR: PE07.61-P-2101BBC, PE54.15-P-2001BBC, PE54.18-P-2300BBB, PE54.21-P-2127BBC, PE54.30-P-2101BBA (+5 more)

Ground connection connector sleeve Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBC year 2020 Plug AB Z6/162 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBC 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AB to AE Z6/162 Ground connection connector sleeve 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 Z6/162 Ground connection connector sleeve 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 Z6/162 Ground connection connector sleeve 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 Z6/162 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 except code V19 (Anti-theft alarm system) Z6/162 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) Z6/162 Ground connection connector sleeve 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 Z6/162 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2200BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/163 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE47.40-P-2101BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/166 Circuit 31 end sleeve Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 Z6/166 Circuit 31 end sleeve 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 Z6/167 Circuit 31 end sleeve Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 Z6/167 Circuit 31 end sleeve Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) Z6/168 Circuit 31 end sleeve Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 Z6/168 Circuit 31 end sleeve 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 Z6/168 Circuit 31 end sleeve 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 Z6/168 Circuit 31 end sleeve Model 453.0 (except 453.091), 453.3 (except PE67.29-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/168 Circuit 31 end sleeve 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 Z6/168 Circuit 31 end sleeve 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 Z6/168 Circuit 31 end sleeve Model 453.0 (except 453.091), 453.3 (except PE80.50-P-2000BBB 453.391), 453.4 (except 453.491) up to model year 2020 with code V19 (Anti-theft alarm system) Z6/168 Circuit 31 end sleeve Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2300BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/168 Circuit 31 end sleeve Model 453.0 (except 453.091), 453.3 (except PE82.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 Z6/169 Circuit 31 end sleeve 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 Z6/170 Ground connection connector sleeve Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2800BBA 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 Page 50 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

OV00.01-P-1909BEA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 166 · Applies to: 453 · AR: OV00.01-P-1909BEA, PE54.30-P-2101BEA, PE54.15-P-2001BEB, PE82.20-P-2000BEA, PE82.60-P-2000BEA (+5 more)

Search aid for all electrical components 12.08.2019 Model 453.091/391/491 up to model year 2020 Short designation Component Notes Wiring diagram A1 Instrument cluster Model 453.091/391/491 up to model year PE54.30-P-2101BEA 2020 A15 Additional instruments Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA A15 Additional instruments Model 453.091/391/491 up to model year PE54.30-P-2101BEA 2020 A15 Additional instruments Model 453.091/391/491 up to model year PE82.20-P-2000BEA 2020 A2 Radio Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA A2 Radio Model 453.091/391/491 up to model year PE82.60-P-2000BEA 2020 with code 537 (smart audio system)
except code 535 (smart media system) except code 561 (61C - PREMIUM radio without DAB with PREMIUM SOUND) except code 562 (62C - R0 radio with DAB and PREMIUM SOUND) except code C08 (Pre-installation for radio) A2 Radio Model 453.091/391/491 up to model year PE82.60-P-2000BEB 2020 with code 535 (smart media system) except code 537 (smart audio system) except code 556 (56A MM2012 radio with DAB and PREMIUM SOUND) except code 557 (57A MM2012 radio without DAB) except code C08 (Pre-installation for radio) A2 Radio Model 453.091/391/491 up to model year PE82.60-P-2000BEC 2020 with code 535 (smart media system) with code 556 (56A MM2012 radio with DAB and PREMIUM SOUND) with code 557 (57A MM2012 radio without DAB) except code 537 (smart audio system) except code C08 (Pre- installation for radio) with sound system A2 Radio Model 453.091/391/491 up to model year PE82.60-P-2000BED 2020 with code C08 (Pre-installation for radio) except code 535 (smart media system)
except code 537 (smart audio system) A2 Radio Model 453.091/391/491 up to model year PE82.60-P-2000BEE 2020 with code 537 (smart audio system) with code 561 (61C - PREMIUM radio without DAB with PREMIUM SOUND) with code 562 (62C - R0 radio with DAB and PREMIUM SOUND) except code 535 (smart media system) except code C08 (Pre-installation for radio) A2/13 Sound amplifier Model 453.091/391/491 up to model year PE82.62-P-2101BEA 2020 with code 810 (Premium sound system) A2/134 FM, AM and DAB antenna Model 453.091/391/491 up to model year PE82.60-P-2000BEA 2020 with code 537 (smart audio system)
except code 535 (smart media system) except code 561 (61C - PREMIUM radio without DAB with PREMIUM SOUND) except code 562 (62C - R0 radio with DAB and PREMIUM SOUND) except code C08 (Pre-installation for radio) A2/134 FM, AM and DAB antenna Model 453.091/391/491 up to model year PE82.60-P-2000BEB 2020 with code 535 (smart media system) except code 537 (smart audio system) except code 556 (56A MM2012 radio with DAB and PREMIUM SOUND) except code 557 (57A MM2012 radio without DAB) except code C08 (Pre-installation for radio) A2/134 FM, AM and DAB antenna Model 453.091/391/491 up to model year PE82.60-P-2000BEC 2020 with code 535 (smart media system) with code 556 (56A MM2012 radio with DAB and PREMIUM SOUND) with code 557 (57A MM2012 radio without DAB) except code 537 (smart audio system) except code C08 (Pre- installation for radio) with sound system Page 1 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

A9/6

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 168 · Applies to: 453 · AR: PE20.00-P-2001BEA, PE43.05-P-2000BEA, PE54.00-P-2001BEA, PE54.21-P-2154BEA, PE54.21-P-2154BEB (+5 more)

Electric refrigerant compressor Engine 780.997 in model 453.091/391/491 up PE20.00-P-2001BEA to model year 2020 A9/6 Electric refrigerant compressor Model 453.091/391/491 up to model year PE43.05-P-2000BEA 2020 A9/6 Electric refrigerant compressor Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 A9/6 Electric refrigerant compressor Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) A9/6 Electric refrigerant compressor Model 453.091/391/491 up to model year PE54.21-P-2154BEB 2020 with code 908 (22 kW on-board charger) A9/6 Electric refrigerant compressor Model 453.091/391/491 up to model year PE83.55-P-2000BEA 2020 A9/6 Electric refrigerant compressor Model 453.091/391/491 up to model year PE83.70-P-2102BEA 2020 A90 Controller unit for distance warning function Model 453.091/391/491 up to model year PE00.19-P-2150BEB with active brake intervention 2020 Cruise control A90 Controller unit for distance warning function Model 453.091/391/491 up to model year PE30.30-P-2105BEB with active brake intervention 2020 with code 258 (Active Brake Assist) except code 252 (Distance warning function) A90 Controller unit for distance warning function Model 453.091/391/491 up to model year PE54.15-P-2001BEC with active brake intervention 2020 F2 Plug AB-AE A90 Controller unit for distance warning function Model 453.091/391/491 up to model year PE54.21-P-2127BEB with active brake intervention 2020 N10/10 A90/5 Multimedia connection unit Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA A90/5 Multimedia connection unit Model 453.091/391/491 up to model year PE82.60-P-2000BEB 2020 with code 535 (smart media system) except code 537 (smart audio system) except code 556 (56A MM2012 radio with DAB and PREMIUM SOUND) except code 557 (57A MM2012 radio without DAB) except code C08 (Pre-installation for radio) A90/5 Multimedia connection unit Model 453.091/391/491 up to model year PE82.60-P-2000BEC 2020 with code 535 (smart media system) with code 556 (56A MM2012 radio with DAB and PREMIUM SOUND) with code 557 (57A MM2012 radio without DAB) except code 537 (smart audio system) except code C08 (Pre- installation for radio) with sound system A90/5 Multimedia connection unit Model 453.091/391/491 up to model year PE82.85-P-2200BEA 2020 with code 535 (smart media system) A91b1 Electric power steering torque sensor Model 453.091/391/491 up to model year PE46.35-P-2000BEA 2020 A91m1 Electric power steering actuator motor Model 453.091/391/491 up to model year PE46.35-P-2000BEA 2020 B10/6 Evaporator temperature sensor 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) B150/1 Brake booster vacuum sensor Model 453.091/391/491 up to model year PE43.05-P-2000BEA 2020 B25/12 Hands-free system microphone Model 453.091/391/491 up to model year PE82.60-P-2000BEA 2020 with code 537 (smart audio system)
except code 535 (smart media system) except code 561 (61C - PREMIUM radio without DAB with PREMIUM SOUND) except code 562 (62C - R0 radio with DAB and PREMIUM SOUND) except code C08 (Pre-installation for radio) B25/12 Hands-free system microphone Model 453.091/391/491 up to model year PE82.60-P-2000BEE 2020 with code 537 (smart audio system) with code 561 (61C - PREMIUM radio without DAB with PREMIUM SOUND) with code 562 (62C - R0 radio with DAB and PREMIUM SOUND) except code 535 (smart media system) except code C08 (Pre-installation for radio) B25/12 Hands-free system microphone Model 453.091/391/491 up to model year PE82.85-P-2200BEA 2020 with code 535 (smart media system) B3 Driver seat adjustment detection sensor Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 B3/1 Right front seat position sensor Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 B33 Tow-away protection sensor Model 453.091/391/491 up to model year PE80.50-P-2000BEA 2020 except code V19 (Anti-theft alarm system) B37 Accelerator pedal sensor Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 Page 3 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

W49/2

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 185 · Applies to: 453 · AR: PE20.00-P-2001BEA, PE54.00-P-2001BEA, PE54.10-P-2003BEA, PE54.21-P-2154BEA, PE54.21-P-2154BEB (+5 more)

Drivetrain ground point 2 Engine 780.997 in model 453.091/391/491 up PE20.00-P-2001BEA to model year 2020 W49/2 Drivetrain ground point 2 Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 W49/2 Drivetrain ground point 2 Model 453.091/391/491 up to model year PE54.10-P-2003BEA 2020 W49/2 Drivetrain ground point 2 Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) W49/2 Drivetrain ground point 2 Model 453.091/391/491 up to model year PE54.21-P-2154BEB 2020 with code 908 (22 kW on-board charger) W51/14 Right rear frame ground connection Engine 780.997 in model 453.091/391/491 up PE20.00-P-2001BEA to model year 2020 W51/14 Right rear frame ground connection Model 453.091/391/491 up to model year PE54.10-P-2109BEA 2020 W51/14 Right rear frame ground connection Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) W51/14 Right rear frame ground connection Model 453.091/391/491 up to model year PE54.21-P-2154BEB 2020 with code 908 (22 kW on-board charger) W51/14 Right rear frame ground connection Model 453.091 up to model year 2020 PE77.20-P-2200BEA W51/14 Right rear frame ground connection Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK W51/14 Right rear frame ground connection Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version W51/14 Right rear frame ground connection Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) W51/14 Right rear frame ground connection Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 W51/14 Right rear frame ground connection Model 453.091/391/491 up to model year PE82.10-P-2200BEA 2020 W51/14 Right rear frame ground connection Model 453.091/391/491 up to model year PE82.10-P-2300BEA 2020 W51/14 Right rear frame ground connection Model 453.091 up to model year 2020 except PE91.30-P-2000BEB code 873 (Seat heater for driver's seat at left and right) W83 Ground (transmission tunnel) Engine 780.997 in model 453.091/391/491 up PE20.00-P-2001BEA to model year 2020 W83 Ground (transmission tunnel) Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 W9 Ground (left front, at lamp unit) Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 W98/1 Shielding ground point Model 453.091/391/491 up to model year PE46.35-P-2000BEA 2020 X11/4 Data link connector Model 453.091/391/491 up to model year PE54.22-P-2000BEA 2020 X112/3 Car2Go main wiring harness/wiring harness Model 453.091/391/491 up to model year PE00.19-P-2150BED electrical connection 2020 Multimedia X112/3 Car2Go main wiring harness/wiring harness Model 453.091/391/491 up to model year PE54.15-P-2001BEB electrical connection 2020 F2 Plug AA X112/3 Car2Go main wiring harness/wiring harness Model 453.091/391/491 up to model year PE54.22-P-2000BEA electrical connection 2020 X112/3 Car2Go main wiring harness/wiring harness Model 453.091/391/491 up to model year PE82.85-P-2008BEA electrical connection 2020 with code P02 (car2go) X112/3 Car2Go main wiring harness/wiring harness Model 453.091/391/491 up to model year PE82.85-P-2105BEA electrical connection 2020 with code 535 (smart media system)
with code P02 (car2go) X112/4 Main wiring harness/windshield reader system Model 453.091/391/491 up to model year PE00.19-P-2150BED wiring harness electrical connector 2020 Multimedia X112/4 Main wiring harness/windshield reader system Model 453.091/391/491 up to model year PE54.15-P-2001BEB wiring harness electrical connector 2020 F2 Plug AA X112/4 Main wiring harness/windshield reader system Model 453.091/391/491 up to model year PE82.85-P-2008BEA wiring harness electrical connector 2020 with code P02 (car2go) X132/2 Soft top electrical connector Model 453.091/391/491 up to model year PE00.19-P-2150BEA 2020 Interior compartment and suspension X132/2 Soft top electrical connector Model 453.491 up to model year 2020 PE77.39-P-2202BEA X133/2 Sliding roof electrical connector Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA X133/2 Sliding roof electrical connector Model 453.091/391/491 up to model year PE54.15-P-2001BEC 2020 F2 Plug AB-AE X133/2 Sliding roof electrical connector Model 453.091 up to model year 2020 PE77.20-P-2200BEA X18/41 Vehicle interior/optional restraint systems Model 453.091/391/491 up to model year PE91.60-P-2105BEA electrical connector 2020 X18/42 Vehicle interior/restraint systems electrical Model 453.091/391/491 up to model year PE91.60-P-2105BEA connector 2020 X18/48 Vehicle interior/rear end electrical connector Model 453.091/391/491 up to model year PE54.65-P-2101BEA 2020 with code 220 (Rear parking assist) Page 20 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

Z35/32

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 192 · Applies to: 453 · AR: PE00.19-P-2131BEA, PE00.19-P-2150BED, PE08.20-P-2000BEA, PE54.10-P-2109BEA, PE82.60-P-2000BEA (+5 more)

Diagnostic CAN (low) connector sleeve, Model 453.091/391/491 up to model year PE00.19-P-2131BEA multimedia 2020 Z35/32 Diagnostic CAN (low) connector sleeve, Model 453.091/391/491 up to model year PE00.19-P-2150BED multimedia 2020 Multimedia Z35/32 Diagnostic CAN (low) connector sleeve, Engine 780.997 in model 453.091/391/491 up PE08.20-P-2000BEA multimedia to model year 2020 Z35/32 Diagnostic CAN (low) connector sleeve, Model 453.091/391/491 up to model year PE54.10-P-2109BEA multimedia 2020 Z35/32 Diagnostic CAN (low) connector sleeve, Model 453.091/391/491 up to model year PE82.60-P-2000BEA multimedia 2020 with code 537 (smart audio system)
except code 535 (smart media system) except code 561 (61C - PREMIUM radio without DAB with PREMIUM SOUND) except code 562 (62C - R0 radio with DAB and PREMIUM SOUND) except code C08 (Pre-installation for radio) Z35/32 Diagnostic CAN (low) connector sleeve, Model 453.091/391/491 up to model year PE82.60-P-2000BEB multimedia 2020 with code 535 (smart media system) except code 537 (smart audio system) except code 556 (56A MM2012 radio with DAB and PREMIUM SOUND) except code 557 (57A MM2012 radio without DAB) except code C08 (Pre-installation for radio) Z35/32 Diagnostic CAN (low) connector sleeve, Model 453.091/391/491 up to model year PE82.60-P-2000BEC multimedia 2020 with code 535 (smart media system) with code 556 (56A MM2012 radio with DAB and PREMIUM SOUND) with code 557 (57A MM2012 radio without DAB) except code 537 (smart audio system) except code C08 (Pre- installation for radio) with sound system Z35/32 Diagnostic CAN (low) connector sleeve, Model 453.091/391/491 up to model year PE82.60-P-2000BEE multimedia 2020 with code 537 (smart audio system) with code 561 (61C - PREMIUM radio without DAB with PREMIUM SOUND) with code 562 (62C - R0 radio with DAB and PREMIUM SOUND) except code 535 (smart media system) except code C08 (Pre-installation for radio) Z35/32 Diagnostic CAN (low) connector sleeve, Model 453.091/391/491 up to model year PE82.62-P-2101BEA multimedia 2020 with code 810 (Premium sound system) Z35/32 Diagnostic CAN (low) connector sleeve, Model 453.091/391/491 up to model year PE82.85-P-2008BEA multimedia 2020 with code P02 (car2go) Z35/32 Diagnostic CAN (low) connector sleeve, Model 453.091/391/491 up to model year PE82.85-P-2105BEA multimedia 2020 with code 535 (smart media system)
with code P02 (car2go) Z35/32 Diagnostic CAN (low) connector sleeve, Model 453.091/391/491 up to model year PE82.85-P-2200BEA multimedia 2020 with code 535 (smart media system) Z35/33 Diagnostic CAN (high) connector sleeve, Model 453.091/391/491 up to model year PE00.19-P-2131BEA multimedia 2020 Z35/33 Diagnostic CAN (high) connector sleeve, Model 453.091/391/491 up to model year PE00.19-P-2150BED multimedia 2020 Multimedia Z35/33 Diagnostic CAN (high) connector sleeve, Engine 780.997 in model 453.091/391/491 up PE08.20-P-2000BEA multimedia to model year 2020 Z35/33 Diagnostic CAN (high) connector sleeve, Model 453.091/391/491 up to model year PE54.10-P-2109BEA multimedia 2020 Z35/33 Diagnostic CAN (high) connector sleeve, Model 453.091/391/491 up to model year PE82.60-P-2000BEA multimedia 2020 with code 537 (smart audio system)
except code 535 (smart media system) except code 561 (61C - PREMIUM radio without DAB with PREMIUM SOUND) except code 562 (62C - R0 radio with DAB and PREMIUM SOUND) except code C08 (Pre-installation for radio) Z35/33 Diagnostic CAN (high) connector sleeve, Model 453.091/391/491 up to model year PE82.60-P-2000BEB multimedia 2020 with code 535 (smart media system) except code 537 (smart audio system) except code 556 (56A MM2012 radio with DAB and PREMIUM SOUND) except code 557 (57A MM2012 radio without DAB) except code C08 (Pre-installation for radio) Z35/33 Diagnostic CAN (high) connector sleeve, Model 453.091/391/491 up to model year PE82.60-P-2000BEC multimedia 2020 with code 535 (smart media system) with code 556 (56A MM2012 radio with DAB and PREMIUM SOUND) with code 557 (57A MM2012 radio without DAB) except code 537 (smart audio system) except code C08 (Pre- installation for radio) with sound system Page 27 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

Z37/21

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 194 · Applies to: 453 · AR: PE00.19-P-2131BEA, PE00.19-P-2150BEA, PE42.45-P-2000BEA, PE46.35-P-2000BEA, PE54.00-P-2001BEA (+5 more)

CAN bus (low) connector sleeve Model 453.091/391/491 up to model year PE00.19-P-2131BEA 2020 Z37/21 CAN bus (low) connector sleeve Model 453.091/391/491 up to model year PE00.19-P-2150BEA 2020 Interior compartment and suspension Z37/21 CAN bus (low) connector sleeve Model 453.091/391/491 up to model year PE42.45-P-2000BEA 2020 Z37/21 CAN bus (low) connector sleeve Model 453.091/391/491 up to model year PE46.35-P-2000BEA 2020 Z37/21 CAN bus (low) connector sleeve Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 Z37/21 CAN bus (low) connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z37/21 CAN bus (low) connector sleeve Model 453.491 up to model year 2020 PE77.39-P-2202BEA Z37/21 CAN bus (low) connector sleeve Model 453.091/391/491 up to model year PE82.85-P-2105BEA 2020 with code 535 (smart media system)
with code P02 (car2go) Z37/21 CAN bus (low) connector sleeve 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) Z37/21 CAN bus (low) connector sleeve Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 Z37/22 CAN databus (high) connector sleeve Model 453.091/391/491 up to model year PE00.19-P-2131BEA 2020 Z37/22 CAN databus (high) connector sleeve Model 453.091/391/491 up to model year PE00.19-P-2150BEA 2020 Interior compartment and suspension Z37/22 CAN databus (high) connector sleeve Model 453.091/391/491 up to model year PE42.45-P-2000BEA 2020 Z37/22 CAN databus (high) connector sleeve Model 453.091/391/491 up to model year PE46.35-P-2000BEA 2020 Z37/22 CAN databus (high) connector sleeve Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 Z37/22 CAN databus (high) connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z37/22 CAN databus (high) connector sleeve Model 453.491 up to model year 2020 PE77.39-P-2202BEA Z37/22 CAN databus (high) connector sleeve Model 453.091/391/491 up to model year PE82.85-P-2105BEA 2020 with code 535 (smart media system)
with code P02 (car2go) Z37/22 CAN databus (high) connector sleeve 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) Z37/22 CAN databus (high) connector sleeve Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 Z37/23 Electric drive CAN (low) end sleeve Model 453.091/391/491 up to model year PE00.19-P-2131BEA 2020 Z37/23 Electric drive CAN (low) end sleeve Model 453.091/391/491 up to model year PE27.19-P-2102BEA 2020 Z37/23 Electric drive CAN (low) end sleeve Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 Z37/23 Electric drive CAN (low) end sleeve Model 453.091/391/491 up to model year PE54.10-P-2005BEA 2020 Z37/23 Electric drive CAN (low) end sleeve Model 453.091/391/491 up to model year PE54.10-P-2104BEA 2020 Z37/23 Electric drive CAN (low) end sleeve Model 453.091/391/491 up to model year PE54.10-P-2109BEA 2020 Z37/23 Electric drive CAN (low) end sleeve Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 Z37/24 Electric drive CAN (high) end sleeve Model 453.091/391/491 up to model year PE00.19-P-2131BEA 2020 Z37/24 Electric drive CAN (high) end sleeve Model 453.091/391/491 up to model year PE27.19-P-2102BEA 2020 Z37/24 Electric drive CAN (high) end sleeve Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 Z37/24 Electric drive CAN (high) end sleeve Model 453.091/391/491 up to model year PE54.10-P-2005BEA 2020 Z37/24 Electric drive CAN (high) end sleeve Model 453.091/391/491 up to model year PE54.10-P-2104BEA 2020 Z37/24 Electric drive CAN (high) end sleeve Model 453.091/391/491 up to model year PE54.10-P-2109BEA 2020 Z37/24 Electric drive CAN (high) end sleeve Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 Z37/43 Audio + signal connector sleeve Model 453.091/391/491 up to model year PE82.62-P-2101BEA 2020 with code 810 (Premium sound system) Z37/52 Audio - signal connector sleeve Model 453.091/391/491 up to model year PE82.62-P-2101BEA 2020 with code 810 (Premium sound system) Page 29 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

Z37/6

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 195 · Applies to: 453 · AR: PE00.19-P-2131BEA, PE54.00-P-2001BEA, PE54.10-P-2003BEA, PE54.21-P-2154BEA, PE27.19-P-2102BEA (+5 more)

CAN databus (high) connector sleeve Model 453.091/391/491 up to model year PE00.19-P-2131BEA 2020 Z37/6 CAN databus (high) connector sleeve Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 Z37/6 CAN databus (high) connector sleeve Model 453.091/391/491 up to model year PE54.10-P-2003BEA 2020 Z37/6 CAN databus (high) connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) Z37/7 CAN bus (low) connector sleeve Model 453.091/391/491 up to model year PE00.19-P-2131BEA 2020 Z37/7 CAN bus (low) connector sleeve Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 Z37/7 CAN bus (low) connector sleeve Model 453.091/391/491 up to model year PE54.10-P-2003BEA 2020 Z37/7 CAN bus (low) connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) Z38 Backup lamp connector sleeve Model 453.091/391/491 up to model year PE27.19-P-2102BEA 2020 Z38 Backup lamp connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z38 Backup lamp connector sleeve Model 453.091/391/491 up to model year PE54.65-P-2101BEA 2020 with code 220 (Rear parking assist) Z38 Backup lamp connector sleeve Model 453.391/491 up to model year 2020
PE68.49-P-2200BEA with code 494 (USA version) Z38 Backup lamp connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z40 Stop lamp signal connector sleeve Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 Z40 Stop lamp signal connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z40 Stop lamp signal connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2300BEA 2020 Z40/3 Stop lamp connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEA 2020 N10/11 Z40/3 Stop lamp connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z40/3 Stop lamp connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2300BEA 2020 Z50/41 Voltage supply connector sleeve Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA Z50/41 Voltage supply connector sleeve Model 453.091/391/491 up to model year PE54.15-P-2001BEC 2020 F2 Plug AB-AE Z50/41 Voltage supply connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2135BEA 2020 Z50/43 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE30.30-P-2000BEA 2020 Z50/43 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE30.30-P-2105BEA 2020 with code 252 (Distance warning function) except code 258 (Active Brake Assist) Z50/43 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE30.30-P-2105BEB 2020 with code 258 (Active Brake Assist) except code 252 (Distance warning function) Z50/43 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA Z50/43 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE54.15-P-2001BEC 2020 F2 Plug AB-AE Z50/43 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2129BEA 2020 Z50/43 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE54.65-P-2101BEA 2020 with code 220 (Rear parking assist) Z50/43 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE68.49-P-2000BEA 2020 with code V35 (Automatically dimming inside rearview mirror) except code 494 (USA version) Z50/43 Circuit 15 (fused) connector sleeve Model 453.391/491 up to model year 2020
PE68.49-P-2200BEA with code 494 (USA version) Z50/43 Circuit 15 (fused) connector sleeve Model 453.091 up to model year 2020 PE77.20-P-2200BEA Z50/43 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z50/43 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE82.25-P-2100BEA 2020 Z50/43 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE91.30-P-2000BEA 2020 with code 873 (Seat heater for driver's seat at left and right) Page 30 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

OV00.01-P-1901-09A

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 219 · Applies to: 453 · AR: PE07.08-Q-2101XXB, PE91.29-Q-2059XXA

Use of electrical function schematics Model all Wiring diagrams PE07.08-Q-2101XXB The function schematic is assigned to the function groups 00-91 under Function schematics the information type "PE", e.g.: The control units and electrical components involved in one function PE91.29-Q-2059XXA are illustrated with pictographs. The functional connections between the components and the control units are shown as a direct line or data bus line. Function schematics a Data bus line b Direct line c Pictograph (component, control unit) d Reference to further wiring diagrams P00.19-3084-01 Example of CAN bus illustration CAN B Interior CAN CAN C Drive train CAN CAN D Diagnostic CAN CAN EHB Electrohydraulic brake CAN P00.01-3557-01 Example of LIN bus illustration LIN B8 Climate control LIN LIN C1 Drive train LIN P00.01-3558-01 MOST bus presentation MOST Media Oriented System Transport P00.01-3091-01 Vehicle or major assembly model designation Variants Vehicle identification end number The function schematic can contain variants that are framed to identify them as variants and are given a validity element. The validity elements "U ..." or "Code ..." are listed in the legend. The following validity elements can be used: Logical combinations of variants are represented as follows: U texts AND/OR combination Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ov00.01-p-1901-09a, Use of electrical function schematics Model all

OV00.01-P-1901-03BBA Use of wiring diagrams

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 221 · Applies to: 453 · AR: PE07.61-P-2101BBA, PE07.61-P-2101BBB, OV00.01-P-1909BBA, OV00.01-P-1909BEA, PE54.21-P-2154BEA (+1 more)

Model 453 up to model year 2020 GF00.19-P-1000BBALocation and assignment of line and plug Wiring diagrams connectors The wiring diagrams are assigned to the familiar function groups GF00.19-P-2000BBALocation and assignment of ground points 00-91. GF00.19-P-3000BBALocation and assignment of Z connector The circuit diagrams are filed according to PE number in each function group, e.g.: sleeves (wiring and plug connectors in wiring harness) PE07.61-P-2101BBA All electrical components are sorted alphabetically and listed according to the abbreviations in the "Search aid for all electrical components" PE07.61-P-2101BBB OV00.01-P-1909BBA or OV00.01-P-1909BEA. A reference is made to The locations of electrical connectors, ground points and Z-end the wiring diagrams in which the relevant component is explained sleeves are shown in the following 3 documents: completely. Variants of a component or the subdivision of a component into several wiring diagrams are stated in the third column. Example: M14/4 Charge socket lock, model 453.091/391/491 except code 908 (22 kW on-board charger) PE54.21-P-2154BEA M14/4 Charge socket lock, model 453.091/391/491 with code 908 (22 kW on-board charger) PE54.21-P-2154BEB Wiring diagram number a Information type b Function group c Function subgroup d Producer ID e Record number f Information unit number g Validity letter (s) P00.19-0401-01 Function/system diagrams Kinds of wiring diagrams The wiring diagrams are prepared as function schematics, function/ All the components that are relevant to a function or system are system diagrams, control unit diagrams or Z-end sleeve wiring shown in the wiring diagram. diagrams, ground wiring diagrams and connector wiring diagrams. Control unit diagrams Function schematics Control units are represented complete with all connected The control units and electrical components required for the components. Control units with many connections can be function are shown as symbols. The functional connections are subdivided into several wiring diagrams. realized by direct lines or by the data bus. Solder point wiring diagrams, ground wiring diagrams and connector wiring diagrams Solder points, ground points and electrical connections, which are not shown completely in any control unit diagram, are shown here complete with all connected components. Function schematic c Symbols (components, control units) a Data bus interface d Reference to further wiring diagrams b Direct interface P00.19-3084-01 Wire Identification b Base color a Conductor cross section in mm c Identification color 2 Page 1 of 4 © Mercedes-Benz AG, 5/22/18, L/07/20, ov00.01-p-1901-03bba, Use of wiring diagrams Model 453 up to model year 2020

GF00.19-P-1005BMA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 245 · Applies to: 453 · AR: GF00.19-P-1005BMA

Arrangement of electrical connectors 13.11.2019 Model 453.091/391/491 as of model year 2020 L6/1x1 Left front axle rpm sensor electrical connector GF00.19-P-1005-02BMA L6/2x1 Right front axle rpm sensor electrical GF00.19-P-1005-02BMA connector L6/3x1 Left rear axle rpm sensor electrical connector GF00.19-P-1005-26BMA L6/4x1 Right rear axle rpm sensor electrical connector GF00.19-P-1005-26BMA X4/24 Vehicle interior/daytime running lights GF00.19-P-1005-08BMA electrical connector X8/4 Trunk lid electrical connector GF00.19-P-1005-26BMA X11/4 Diagnostic connector GF00.19-P-1005-14BMA X18/48 Vehicle interior/rear end electrical connector GF00.19-P-1005-26BMA X18/49 Right vehicle interior/seat electrical connector GF00.19-P-1005-15BMA X18/50 Left vehicle interior/seat electrical connector GF00.19-P-1005-14BMA X18/53 Instrument panel/ATA electrical connector GF00.19-P-1005-11BMA X19 Rear window heater electrical connector GF00.19-P-1005-26BMA X25/2 Engine compartment/vehicle interior electrical GF00.19-P-1005-26BMA connector X26 Vehicle interior/engine wiring harness GF00.19-P-1005-26BMA electrical connector X26/10 Engine compartment/vehicle socket electrical GF00.19-P-1005-26BMA connector X31/3 Dome lamp electrical connector GF00.19-P-1005-14BMA X35/1 Left front door electrical connector GF00.19-P-1005-17BMA X35/2 Right front door electrical connector GF00.19-P-1005-18BMA X35/3 Left rear door electrical connector Model 453.091 GF00.19-P-1005-14BMA X35/4 Right rear door electrical connector Model 453.091 GF00.19-P-1005-15BMA X35/66 Driver's door front door electrical connector GF00.19-P-1005-17BMA X35/67 Front passenger door front door electrical GF00.19-P-1005-18BMA connector X42/37 ATA alarm siren electrical connector GF00.19-P-1005-02BMA X54/12 Front seat heater electrical connector, driver GF00.19-P-1005-21BMA X54/13 Front seat heater electrical connector, front GF00.19-P-1005-22BMA passenger X54/37 Front seat backrest heater pad electrical GF00.19-P-1005-21BMA connector, driver side X54/38 Front seat backrest heater pad electrical GF00.19-P-1005-22BMA connector, passenger side X55/3 Driver seat connector block GF00.19-P-1005-14BMA X55/4 Front passenger seat connector block GF00.19-P-1005-15BMA X58/10 Rear luggage carrier electrical connector GF00.19-P-1005-26BMA X58/23 Charger feed-in socket GF00.19-P-1005-26BMA X85/5 Cockpit/air conditioning electrical connector GF00.19-P-1005-10BMA X85/18 Vehicle interior/vehicle front electrical GF00.19-P-1005-02BMA connector X99/3 Vehicle interior/vehicle front electrical GF00.19-P-1005-02BMA connector X112/3 Car2Go main wiring harness/wiring harness GF00.19-P-1005-10BMA electrical connection X132/2 Soft top electrical connector Model 453.491 GF00.19-P-1005-26BMA X218 Left rear seat electrical connector Model 453.091 GF00.19-P-1005-14BMA X218/1 Right rear seat electrical connector Model 453.091 GF00.19-P-1005-14BMA Location of electrical connectors - Engine Model 453.091/391/491 GF00.19-P-1005-02BMA compartment as of model year 2020 Location of electrical connectors - Front Model 453.091/391/491 GF00.19-P-1005-08BMA bumper as of model year 2020 Location of electrical connectors - Instrument Model 453.091/391/491 GF00.19-P-1005-10BMA panel as of model year 2020 Location of electrical connectors - Center Model 453.091/391/491 GF00.19-P-1005-11BMA console as of model year 2020 Location of electrical connectors - Left vehicle Model 453.091/391/491 GF00.19-P-1005-14BMA interior as of model year 2020 Location of electrical connectors - Right Model 453.091/391/491 GF00.19-P-1005-15BMA vehicle interior as of model year 2020 Location of electrical connectors - Left front Model 453.091/391/491 GF00.19-P-1005-17BMA door as of model year 2020 Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, gf00.19-p-1005bma, Arrangement of electrical connectors Model 453.091/391/491 as of model year 2020

GF00.19-P-3000BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 256 · Applies to: 453 · AR: GF00.19-P-3000BBA

Location and assignment of Z connector sleeves (wiring and plug connectors in 09.08.2019 wiring harness) Model 453 up to model year 2020 Location Z3/3 Circuit 15 connector sleeve, ignition coil 1 to 3 GF00.19-P-3001-02BBA Z3/4 Tml. 15 connector sleeve GF00.19-P-3001-03BBA Z6z14 Ground connection connector sleeve GF00.19-P-3001-03BBA Z6z16 Ground connection connector sleeve GF00.19-P-3001-03BBA Z6z17z1 Ground connection connector sleeve GF00.19-P-3001-12BBA Z6z17z2 Ground connection connector sleeve GF00.19-P-3001-12BBA Z6 Ground connection connector sleeve GF00.19-P-3001-10BBA Z6/150 Ground connection connector sleeve GF00.19-P-3001-04BBA Z6/151 Ground connection connector sleeve GF00.19-P-3001-03BBA Z6/152 Ground connection connector sleeve GF00.19-P-3001-04BBA Z6/153 Ground connection connector sleeve GF00.19-P-3001-04BBA Z6/154 Ground connection connector sleeve GF00.19-P-3001-05BBA Z6/155 Ground connection connector sleeve GF00.19-P-3001-03BBA Z6/157 Ground connection connector sleeve GF00.19-P-3001-10BBA Z6/158 Ground connection connector sleeve GF00.19-P-3001-10BBA Z6/160 Ground connection connector sleeve GF00.19-P-3001-20BBA Z6/161 Ground connection connector sleeve GF00.19-P-3001-11BBA Z6/162 Ground connection connector sleeve GF00.19-P-3001-11BBA Z6/163 Ground connection connector sleeve GF00.19-P-3001-05BBA Z6/166 Circuit 31 splice GF00.19-P-3001-04BBA Z6/167 Circuit 31 splice GF00.19-P-3001-04BBA Z6/168 Circuit 31 splice GF00.19-P-3001-22BBA Z6/169 Circuit 31 splice GF00.19-P-3001-08BBA Z6/170 Ground connection connector sleeve GF00.19-P-3001-22BBA Z6/171 Ground connection connector sleeve 453.0 (except 453.091), 453.3 (except GF00.19-P-3001-02BBA 453.391), 453.4 (except 453.491) Z6/171 Ground connection connector sleeve Model 453.091/391/491 GF00.19-P-3001-02BBA Z6/172 Ground connection connector sleeve Model 453.091/391/491 GF00.19-P-3001-02BBA Z6/174 Ground connection connector sleeve GF00.19-P-3001-04BBA Z6/175 Ground connection connector sleeve GF00.19-P-3001-04BBA Z6/176 Ground connection connector sleeve GF00.19-P-3001-05BBA Z6/177 Ground connection connector sleeve GF00.19-P-3001-01BBA Z7/3 Circuit 87 connector sleeve, injection valve 1 GF00.19-P-3001-05BBA to 3 Z7/89 Line signal connector sleeve GF00.19-P-3001-03BBA Z7/110 Circuit 87 end sleeve GF00.19-P-3001-02BBA Z7/111 Circuit 87 end sleeve 453.0 (except 453.091), 453.3 (except GF00.19-P-3001-05BBA 453.391), 453.4 (except 453.491) Z7/111 Circuit 87 end sleeve Model 453.091/391/491 GF00.19-P-3001-23BBA Z7/112 Circuit 87 end sleeve GF00.19-P-3001-02BBA Z8 Circuit 50 connector sleeve GF00.19-P-3001-03BBA Z16/4 Passenger-side power window motor "RAISE" GF00.19-P-3001-12BBA signal connector sleeve Z16/7 Passenger-side power window motor GF00.19-P-3001-12BBA "LOWER" signal connector sleeve Z24 ATA [EDW] engine hood connector sleeve GF00.19-P-3001-10BBA Z28/19 Circuit 15R end sleeve GF00.19-P-3001-03BBA Z30/1 Left turn signal indicator connector sleeve GF00.19-P-3001-09BBA Z30/2 Right turn signal indicator connector sleeve GF00.19-P-3001-10BBA Z30/7 Hazard warning system connector sleeve GF00.19-P-3001-03BBA Z35/31 Telematics wake-up signal connector sleeve GF00.19-P-3001-03BBA Z35/32 Diagnostic CAN (low) connector sleeve, GF00.19-P-3001-04BBA multimedia Z35/33 Diagnostic CAN (high) connector sleeve, GF00.19-P-3001-04BBA multimedia Z36/1 Rear parking system sensors ground line GF00.19-P-3001-22BBA connector sleeve Z36/14 Headlamp range adjustment signal connector GF00.19-P-3001-10BBA sleeve Z37/6 Charging CAN (high) connector sleeve Model 453.091/391/491 GF00.19-P-3001-02BBA Page 1 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, gf00.19-p-3000bba, Location and assignment of Z connector sleeves (wiring and plug connectors in wiring harness) Model 453 up to model year 2020

Z158/8

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 258 · Applies to: 453 · AR: OV00.01-P-1909BBA, OV00.01-P-1909BEA

Central locking front passenger door signal (-) GF00.19-P-3001-12BBA connector sleeve Z158/9 Central locking driver door signal (-) connector GF00.19-P-3001-12BBA sleeve Z232/30 Central locking trunk lid signal connector GF00.19-P-3001-04BBA sleeve Z232/31 Ambiance illumination power supply connector GF00.19-P-3001-09BBA sleeve Z300/21 Clutch pedal switch signal connector sleeve GF00.19-P-3001-05BBA 453.0 (except 453.091), 453.3 (except OV00.01-P-1909BBA 453.391), 453.4 (except 453.491) Model 453.091/391/491 OV00.01-P-1909BEA Location of Z-connector sleeves (line Model 453 GF00.19-P-3001-01BBA connections in wiring harness) - left of engine up to model year 2020 compartment Location of Z-connector sleeves (line Model 453 GF00.19-P-3001-02BBA connections in wiring harness) - engine up to model year 2020 compartment, right Location of Z-connector sleeves (line Model 453 GF00.19-P-3001-03BBA connections in wiring harness) - cockpit up to model year 2020 Location of Z-connector sleeves (line Model 453 GF00.19-P-3001-04BBA connections in wiring harness) - interior up to model year 2020 compartment, left Location of Z-connector sleeves (line Model 453 GF00.19-P-3001-05BBA connections in wiring harness) - interior up to model year 2020 compartment, right Location and assignment of Z connector Model 453 GF00.19-P-3001-08BBA sleeves (line connectors in wiring harness) - up to model year 2020 Rear end Location of Z-connector sleeves (line Model 453 GF00.19-P-3001-09BBA connections in wiring harness) - center up to model year 2020 console Location and assignment of Z connector Model 453 GF00.19-P-3001-10BBA sleeves (line connectors in wiring harness) - up to model year 2020 Front section, right Location and assignment of Z connector Model 453 GF00.19-P-3001-11BBA sleeves (line connectors in wiring harness) - up to model year 2020 Front section, left Location and assignment of Z connector Model 453 GF00.19-P-3001-12BBA sleeves (line connectors in wiring harness) - up to model year 2020 Doors Location of Z-connector sleeves (line Model 453 GF00.19-P-3001-20BBA connections in wiring harness) - front bumper up to model year 2020 Location of Z-connector sleeves (line Model 453 GF00.19-P-3001-22BBA connections in wiring harness) - rear bumper up to model year 2020 Location of Z-connector sleeves (line Model 453 GF00.19-P-3001-23BBA connections in wiring harness) - underfloor up to model year 2020 Page 3 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, gf00.19-p-3000bba, Location and assignment of Z connector sleeves (wiring and plug connectors in wiring harness) Model 453 up to model year 2020

GF00.19-P-2000BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 259 · Applies to: 453 · AR: GF00.19-P-2000BBA, OV00.01-P-1909BBA, OV00.01-P-1909BEA

Location and assignment of ground points 09.08.2019 Model 453 up to model year 2020 Location W1/1 Cockpit frame ground point GF00.19-P-2001-03BBA W1/3 Left cockpit ground point GF00.19-P-2001-03BBA W1/5 Right cockpit ground point GF00.19-P-2001-03BBA W2 Right front ground point GF00.19-P-2001-08BBA W9 Left front ground point (at lamp unit) GF00.19-P-2001-08BBA W10 Battery ground point GF00.19-P-2001-11BBA W11 Combustion engine ground point GF00.19-P-2001-21BBA W11/10 Refrigerant compressor ground point 453.0 (except 453.091), 453.3 (except GF00.19-P-2001-01BBA 453.391), 453.4 (except 453.491) W11/16w1 Combustion engine ground point 2 GF00.19-P-2001-05BBA W11/16w2 Combustion engine ground point 2 GF00.19-P-2001-21BBA W11/9 Left rear ground point GF00.19-P-2001-21BBA W12 Ground point (center console) GF00.19-P-2001-03BBA W15/9 Ground point / PTC heater booster Vehicle with electric drive GF00.19-P-2001-05BBA W16/8 Major assembly compartment ground point 453.0 (except 453.091), 453.3 (except GF00.19-P-2001-01BBA (body) 453.391), 453.4 (except 453.491) W16/9 Major assembly compartment ground point 453.0 (except 453.091), 453.3 (except GF00.19-P-2001-01BBA (transmission) 453.391), 453.4 (except 453.491) W16/10 Major assembly compartment ground point 453.0 (except 453.091), 453.3 (except GF00.19-P-2001-01BBA 453.391), 453.4 (except 453.491) W22 Ground point GF00.19-P-2001-03BBA W26 Transmission tunnel ground point GF00.19-P-2001-26BBA W43/1 ABS ground point (LHD) GF00.19-P-2001-11BBA W43/1 ABS ground point (RHD) GF00.19-P-2001-11BBA W49 Transmission ground point 453.0 (except 453.091), 453.3 (except GF00.19-P-2001-21BBA 453.391), 453.4 (except 453.491) W49/2 Drivetrain ground point 2 Model 453.091/391/491 GF00.19-P-2001-21BBA W51/14 Right rear frame ground connection GF00.19-P-2001-05BBA W83 Transmission tunnel ground connection GF00.19-P-2001-33BBA W98/1 Shielding ground point (LHD) GF00.19-P-2001-11BBA W98/1 Shielding ground point (RHD) Model 453.0 (except 453.091), 453.3 (except OV00.01-P-1909BBA 453.391), 453.4 (except 453.491) Model 453.091/391/491 OV00.01-P-1909BEA Location of ground points - engine Model 453.0 (except 453.091), 453.3 (except GF00.19-P-2001-01BBA compartment, left 453.391), 453.4 (except 453.491) up to model year 2020 Location of ground points - cockpit Model 453 GF00.19-P-2001-03BBA up to model year 2020 Location of ground points - interior Model 453 GF00.19-P-2001-05BBA compartment, right up to model year 2020 Location of ground points - frame Model 453 GF00.19-P-2001-08BBA up to model year 2020 Location and assignment of ground points - Model 453 GF00.19-P-2001-11BBA Front section, right up to model year 2020 Location of ground points - rear end Model 453 GF00.19-P-2001-21BBA up to model year 2020 Location of ground points - center console Model 453 GF00.19-P-2001-26BBA up to model year 2020 Location of ground points - underfloor Model 453 GF00.19-P-2001-33BBA up to model year 2020 Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, gf00.19-p-2000bba, Location and assignment of ground points Model 453 up to model year 2020

GF00.19-P-1000BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 262 · Applies to: 453 · AR: GF00.19-P-1000BBA, OV00.01-P-1909BBA, OV00.01-P-1909BEA

Location and assignment of line and plug connectors 09.08.2019 Model 453 up to model year 2020 Location X4/24 Vehicle interior/daytime running lights GF00.19-P-1001-38BBA electrical connector X8/4 Trunk lid electrical connector GF00.19-P-1001-22BBA X11/4 Diagnostic connector GF00.19-P-1001-13BBA X18/3 Vehicle interior/fuel tank electrical connector GF00.19-P-1001-24BBA X18/48 Vehicle interior/rear end electrical connector GF00.19-P-1001-22BBA X18/49 Vehicle interior/right seat electrical connector GF00.19-P-1001-05BBA X18/50 Vehicle interior/left seat electrical connector GF00.19-P-1001-04BBA X18/53 Instrument panel/ATA electrical connector GF00.19-P-1001-28BBA X19 Rear window heater electrical connector GF00.19-P-1001-22BBA X22 Engine compartment and combustion engine 453.0 (except 453.091), 453.3 (except GF00.19-P-1001-02BBA electrical connector 453.391), 453.4 (except 453.491) X25/2 Engine compartment/vehicle interior electrical GF00.19-P-1001-22BBA connector X26 Vehicle interior/engine wiring harness GF00.19-P-1001-22BBA electrical connector X26/8 Instrument panel/engine compartment 453.0 (except 453.091), 453.3 (except GF00.19-P-1001-02BBA electrical connector 453.391), 453.4 (except 453.491) X26/10 Engine compartment/vehicle socket electrical Model 453.091/391/491 GF00.19-P-1001-02BBA connector X31/3 Dome lamp electrical connector GF00.19-P-1001-04BBA X35/1 Driver front door electrical connector GF00.19-P-1001-21BBA X35/2 Front passenger front door electrical GF00.19-P-1001-21BBA connector X35/3 Left rear door electrical connector Model 453.0 GF00.19-P-1001-04BBA X35/4 Right rear door electrical connector Model 453.0 GF00.19-P-1001-05BBA X35/65 Vehicle interior/front crossmember electrical GF00.19-P-1001-38BBA connector X35/66 Driver door electrical connector GF00.19-P-1001-21BBA X35/67 Front passenger door electrical connector GF00.19-P-1001-21BBA X42/37 ATA alarm siren electrical connector GF00.19-P-1001-39BBA X54/12 Front seat heater electrical connector, driver GF00.19-P-1001-17BBA X54/13 Front seat heater electrical connector, front GF00.19-P-1001-18BBA passenger X54/37 Front seat backrest heater pad electrical GF00.19-P-1001-17BBA connector, driver side X54/38 Front seat backrest heater pad electrical GF00.19-P-1001-18BBA connector, passenger side X55/3 Driver seat connector block GF00.19-P-1001-04BBA X55/4 Front passenger seat connector block GF00.19-P-1001-05BBA X58/10 Rear luggage carrier electrical connector GF00.19-P-1001-22BBA X58/23 Charger feed-in socket Model 453.091/391/491 GF00.19-P-1001-22BBA X85/5 Cockpit/air conditioning electrical connector GF00.19-P-1001-03BBA X99/3 Vehicle interior/vehicle front electrical Model 453.091/391/491 GF00.19-P-1001-39BBA connector X112/3 Car2Go main wiring harness/wiring harness GF00.19-P-1001-03BBA electrical connection X132/2 Soft top electrical connector MODEL 453.4 GF00.19-P-1001-22BBA X218 Left rear seat electrical connector Model 453.0 GF00.19-P-1001-04BBA X218/1 Right rear seat electrical connector Model 453.0 GF00.19-P-1001-04BBA Assignment Vehicle with combustion engine OV00.01-P-1909BBA Vehicle with electric drive OV00.01-P-1909BEA Location of line and plug connectors - engine Model 453 GF00.19-P-1001-02BBA compartment, right up to model year 2020 Location of line and plug connectors - cockpit Model 453 GF00.19-P-1001-03BBA up to model year 2020 Location of line and plug connectors - interior Model 453 GF00.19-P-1001-04BBA compartment, left up to model year 2020 Location of line and plug connectors - interior Model 453 GF00.19-P-1001-05BBA compartment, right up to model year 2020 Location of line and plug connectors, footwell, Model 453 GF00.19-P-1001-13BBA left up to model year 2020 Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, gf00.19-p-1000bba, Location and assignment of line and plug connectors Model 453 up to model year 2020

GF00.19-P-3005BMA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 294 · Applies to: 453 · AR: GF00.19-P-3005BMA

Location of end sleeves 13.11.2019 Model 453.091/391/491 as of model year 2020 Z107/1 Charger feed-in socket PP signal connector GF00.19-P-3005-26BMA sleeve Z111/18 Rear standing lights connector sleeve GF00.19-P-3005-10BMA Z111/3 Brake light actuation connector sleeve GF00.19-P-3005-10BMA Z111/6 Terminal 58 connector sleeve GF00.19-P-3005-10BMA Z111/7 Terminal 58 connector sleeve GF00.19-P-3005-09BMA Z114/1 Left front speaker connector sleeve (+) GF00.19-P-3005-14BMA Z114/2 Left front speaker connector sleeve (-) GF00.19-P-3005-14BMA Z115/1 Right front speaker connector sleeve (+) GF00.19-P-3005-14BMA Z115/2 Right front speaker connector sleeve (-) GF00.19-P-3005-14BMA Z158/5 Central locking electric motors power supply GF00.19-P-3005-15BMA connector sleeve Z158/6 Central locking electric motors power supply GF00.19-P-3005-10BMA connector sleeve Z158/7 Central locking Superlocking signal connector GF00.19-P-3005-10BMA sleeve Z158/8 Central locking front passenger door signal (-) GF00.19-P-3005-18BMA connector sleeve Z158/9 Central locking driver door signal (-) connector GF00.19-P-3005-17BMA sleeve Z16/6 Front power window motor central closing GF00.19-P-3005-10BMA signal end sleeve Z232/30 Ambiance illumination power supply connector GF00.19-P-3005-11BMA sleeve Z232/31 Ambiance illumination power supply connector GF00.19-P-3005-11BMA sleeve Z3/4 Tml. 15 connector sleeve GF00.19-P-3005-10BMA Z3/70 Tml. 15 connector sleeve GF00.19-P-3005-10BMA Z30/7 Hazard warning system connector sleeve GF00.19-P-3005-10BMA Z35/100 Diagnostic CAN (low) connector sleeve, GF00.19-P-3005-02BMA multimedia Z35/31 Telematics wake-up signal connector sleeve GF00.19-P-3005-10BMA Z35/32 Diagnostic CAN (low) connector sleeve, GF00.19-P-3005-10BMA multimedia Z35/33 Diagnostic CAN (high) connector sleeve, GF00.19-P-3005-10BMA multimedia Z35/99 Diagnostic CAN (high) connector sleeve, GF00.19-P-3005-02BMA multimedia Z36/1 Rear parking system sensors ground line GF00.19-P-3005-09BMA connector sleeve Z37/17 CAN bus (low) connector sleeve GF00.19-P-3005-10BMA Z37/18 CAN databus (high) connector sleeve GF00.19-P-3005-10BMA Z37/19 CAN bus (low) connector sleeve GF00.19-P-3005-10BMA Z37/20 CAN databus (high) connector sleeve GF00.19-P-3005-10BMA Z37/21z2 CAN bus (low) connector sleeve GF00.19-P-3005-10BMA Z37/22z2 CAN databus (high) connector sleeve GF00.19-P-3005-10BMA Z37/23 Electric drive CAN (low) connector sleeve GF00.19-P-3005-15BMA Z37/24 Electric drive CAN (high) connector sleeve GF00.19-P-3005-15BMA Z37/43 Audio + signal connector sleeve GF00.19-P-3005-10BMA Z37/52 Audio - signal connector sleeve GF00.19-P-3005-10BMA Z37/6 Charging CAN (high) connector sleeve GF00.19-P-3005-26BMA Z37/7 Charging CAN (low) connector sleeve GF00.19-P-3005-26BMA Z38 Backup lamp connector sleeve GF00.19-P-3005-10BMA Z40 Stop lamp signal connector sleeve GF00.19-P-3005-10BMA Z50/41 Voltage supply connector sleeve GF00.19-P-3005-10BMA Z50/43 Circuit 15 (fused) connector sleeve GF00.19-P-3005-10BMA Z50/44 Circuit 15 (fused) connector sleeve GF00.19-P-3005-10BMA Z50/48 Circuit 15 (fused) connector sleeve GF00.19-P-3005-10BMA Z50/49 Circuit 30 (fused) end sleeve GF00.19-P-3005-10BMA Z50/49z2 Circuit 30 (fused) end sleeve GF00.19-P-3005-10BMA Z50/50 Circuit 30 (fused) end sleeve GF00.19-P-3005-10BMA Z50/51 Circuit 30 (fused) end sleeve GF00.19-P-3005-10BMA Z50/51z1 Circuit 30 (fused) end sleeve GF00.19-P-3005-10BMA Page 1 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, gf00.19-p-3005bma, Location of end sleeves Model 453.091/391/491 as of model year 2020

GF00.19-P-2002BMA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 314 · Applies to: 453 · AR: GF00.19-P-2002BMA

Location of ground points 13.11.2019 Model 453.091/391/491 as of model year 2020 W1/1 Cockpit frame ground point GF00.19-P-2001-30BMA W1/3 Left cockpit ground point GF00.19-P-2001-30BMA W1/5 Right cockpit ground point GF00.19-P-2001-30BMA W2 Right front ground point GF00.19-P-2001-32BMA W9 Left front ground point (at lamp unit) GF00.19-P-2001-32BMA W10 Battery ground point GF00.19-P-2001-17BMA W11 Combustion engine ground point GF00.19-P-2001-34BMA W11/10 Refrigerant compressor ground point GF00.19-P-2001-34BMA W11/9 Left rear ground point GF00.19-P-2001-34BMA W12 Ground point (center console) GF00.19-P-2001-30BMA W15/9 Ground point / PTC heater booster GF00.19-P-2001-25BMA W22 Ground point GF00.19-P-2001-30BMA W26 Transmission tunnel ground point GF00.19-P-2001-29BMA W43/1 Ground point (ABS) GF00.19-P-2001-17BMA W49/1 Drivetrain ground point 1 GF00.19-P-2001-25BMA W49/2 Drivetrain ground point 2 GF00.19-P-2001-34BMA W51/14 Right rear frame ground connection GF00.19-P-2001-25BMA W83 Transmission tunnel ground connection GF00.19-P-2001-33BMA W98/1 Shielding ground point GF00.19-P-2001-17BMA Location of ground points - Engine Model 453.091/391/491 GF00.19-P-2001-17BMA compartment as of model year 2020 Location of ground points - vehicle interior, Model 453.091/391/491 GF00.19-P-2001-25BMA right as of model year 2020 Location of ground points - center console Model 453.091/391/491 GF00.19-P-2001-29BMA as of model year 2020 Location of ground points - instrument panel Model 453.091/391/491 GF00.19-P-2001-30BMA as of model year 2020 Location of ground points - frame Model 453.091/391/491 GF00.19-P-2001-32BMA as of model year 2020 Location of ground points - underfloor Model 453.091/391/491 GF00.19-P-2001-33BMA as of model year 2020 Location of ground points - rear end Model 453.091/391/491 GF00.19-P-2001-34BMA as of model year 2020 Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, gf00.19-p-2002bma, Location of ground points Model 453.091/391/491 as of model year 2020

GF00.19-P-0999KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 345 · Applies to: 453 · AR: GF00.19-P-0999KJ, GF00.19-P-0001KJ, GF00.19-P-9997KJ

Overall network (GVN) function description table of contents 19.11.15 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) Overall network (GVN) function GF00.19-P-0001KJ Overview of system components for overall GF00.19-P-9997KJ network (GVN) Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf00.19-p-0999kj, Overall network (GVN) function description table of contents Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491)

GF00.19-P-9997KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 346 · Applies to: 453 · AR: GF00.19-P-9997KJ

Overview of system components for overall network (GVN) 06.06.2017 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) P00.19-5687-79 Overall network, model 453.3/4 shown on model 453.4 A1 Instrument cluster N10/10 Center SAM control unit A2 Radio N10/11 Driver SAM control unit A2/13 Sound system amplifier control unit (vehicles with code N15/5 Electronic selector lever module control unit (vehicles 810 (Sound system)) with transmission 700.4 (with code 429 (twinamic))) A15 Additional instruments (vehicles with code V31 N15/13 Dual-clutch transmission control unit (vehicles with (Additional instruments (cockpit clock and tachometer))) transmission 700.4 (with code 429 (twinamic))) A40/3 Smart Radio Multimedia Navigator (Vehicles with code N20 Air conditioning control unit (Vehicles with code I01 535 (Smart Media System)) (Automatic air conditioning)) A40/11 Multifunction camera (vehicles with code 238 (Lane N22/1 Air conditioning control unit (Vehicles with code I01 Keeping Assist)) (Automatic air conditioning)) A50/5 Card reader (vehicles with code P02 (car2go) or with N24 Multimedia operating unit (vehicles with code 535 (smart code 45P (Line package rental model)) media system)) A50/6 Windshield reader system access electronic key box N30/4 Electronic Stability Program control unit (vehicles as of model year 2018 with code P02 (car2go) or with code 45P (Line package for rental model)) A52n1 Soft top control control unit (model 453.4) N49 Steering wheel angle sensor A89 Controller unit for distance warning function with radar N68 Electrical power steering control unit sensor (vehicles with code 252 (Distance warning function)) A90 Distance warning function controller unit with active N93/1 Audio gateway control unit intervention by the brake system (vehicles with code 258 (Active Brake Assist)) B38/2 Rain/light sensor (vehicles with code V54 (Rain/light N93/2 Distance warning function gateway (vehicles with code sensor)) 252 (Distance warning function)) B95 Battery sensor N110 Weight Sensing System (WSS) control unit (vehicles with code 494 (USA version) G2 Alternator N112/2 Telematics services communications module (vehicles with code 535 (smart media system) or with code P02 (car2go)) N2/10 Supplemental restraint system control unit N112/3 Windshield reader system control unit (vehicles with code P02 (car2go) or with code 45P (Line package for rental model) or with code 45P (Line package for rental model)) N3/10 ME-SFI [ME] control unit X11/4 Diagnostic connector Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, gf00.19-p-9997kj, Overview of system components for overall network (GVN) Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491)

AR00.19-P-0130SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 349 · Applies to: 453 · AR: AR00.19-P-0130SR

Remove contacts from plugs and connector sockets 12.03.2018 Model 453 Engine wiring harness P00.19-6751-79 P00.19-6752-79 Page 1 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, ar00.19-p-0130sr, Remove contacts from plugs and connector sockets Model 453 Engine wiring harness

AR00.19-P-0120A

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 354 · Applies to: 453 · AR: AR00.19-P-0130SR

Removing contacts from plugs and connectors 09.12.2019 Model 414 Model all (4xWD, CAR, smart) Modification notes 09.01.2018 Removing contacts from plugs and connector sockets, Operation step 1 added Topical note General information on handling vehicles with AH00.00-Z-0300-01A high-voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system Topical note Notes on replacement of safety-relevant and AH00.19-P-1000-08A special components Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Topical note Notes on battery AH54.10-P-0001-01A Notes regarding plug connections AH00.19-P-1000-06A Remove

1 Remove contacts from plugs and connector Model 453 sockets. AR00.19-P-0130SR 2.1 Remove contacts from micro quadlock system With micro quadlock system plug variant 1. plug variant 1. AR00.19-P-0120-03A 000589139900 Wiring harness repair kit, basic 220589019950 Blade holder with clamping pliers 220589019960 MQS blade 220589049900 New passenger car wiring harness repair kit 2.2 Remove contacts from micro quadlock system With micro quadlock system plug variant 2. plug variant 2. AR00.19-P-0120-03B 000589139900 Wiring harness repair kit, basic 220589019950 Blade holder with clamping pliers 220589019960 MQS blade 220589049900 New passenger car wiring harness repair kit 2.3 Remove contacts from nano micro quadlock With nano micro quadlock system plug. system plug. AR00.19-P-0100-13A 220589049937 NanoMQS release tool 220589049938 NanoMQS release tool 2.4 Remove contacts from micro quadlock system For micro quadlock system coupling variant 1. coupling variant 1. AR00.19-P-0120-04A 000589139900 Wiring harness repair kit, basic 220589019950 Blade holder with clamping pliers 220589019960 MQS blade 220589049900 New passenger car wiring harness repair kit 2.5 Remove contacts from micro quadlock system With micro quadlock system connector variant coupling variant 2. 2. AR00.19-P-0120-04B 000589139900 Wiring harness repair kit, basic 220589019950 Blade holder with clamping pliers 220589019960 MQS blade 220589049900 New passenger car wiring harness repair kit 2.6 Remove contacts from E 95 coupling. With E 95 connectors. AR00.19-P-0120-05A Page 1 of 6 © Mercedes-Benz AG, 5/21/18, L/07/20, ar00.19-p-0120a, Removing contacts from plugs and connectors Model 414 Model all (4xWD, CAR, smart)

PE00.19-P-2200ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 361 · Applies to: 453 · AR: PE00.19-P-2200ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+5 more)

Wiring diagram CAN bus engine 16.12.03 MODEL 454 up to 2.4.06 PE00.19-P-2200-99ZA Wiring diagram CAN bus engine PE00.19-P-2200-99ZA PE00.19-P-2200-60ZA Legend of wiring diagram for CAN bus - PE00.19-P-2200-60ZA engine 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 PE82.00-P-1100ZA Further wiring diagrams PE82.00-P-1100ZA PE83.00-P-1100ZA Further wiring diagrams PE83.00-P-1100ZA PE91.00-P-1100ZA Further wiring diagrams PE91.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe00.19-p-2200za, Wiring diagram CAN bus engine MODEL 454 up to 2.4.06

PE00.19-P-2200ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 362 · Applies to: 453 · AR: PE00.19-P-2200ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+5 more)

Wiring diagram CAN bus engine 8.3.06 MODEL 454 as from 3.4.06 PE00.19-P-2200-99ZB Wiring diagram CAN bus engine PE00.19-P-2200-99ZB PE00.19-P-2200-60ZB Legend of wiring diagram for CAN bus - PE00.19-P-2200-60ZB engine 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 PE82.00-P-1100ZA Further wiring diagrams PE82.00-P-1100ZA PE83.00-P-1100ZA Further wiring diagrams PE83.00-P-1100ZA PE91.00-P-1100ZA Further wiring diagrams PE91.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe00.19-p-2200zb, Wiring diagram CAN bus engine MODEL 454 as from 3.4.06

PE00.19-P-2300ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 363 · Applies to: 453 · AR: PE00.19-P-2300ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Wiring diagram CAN bus interior 4.11.03 MODEL 454 up to 10.4.05 PE00.19-P-2300-99ZA Wiring diagram CAN bus interior PE00.19-P-2300-99ZA PE00.19-P-2300-60ZA Legend of wiring diagram for CAN bus - PE00.19-P-2300-60ZA interior compartment 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) PE82.00-P-1100ZA Further wiring diagrams PE82.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe00.19-p-2300za, Wiring diagram CAN bus interior MODEL 454 up to 10.4.05

PE00.19-P-2300ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 364 · Applies to: 453 · AR: PE00.19-P-2300ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Wiring diagram CAN bus interior 10.3.05 MODEL 454 as of 11.4.05 up to 2.4.06 PE00.19-P-2300-99ZB Wiring diagram CAN bus interior PE00.19-P-2300-99ZB PE00.19-P-2300-60ZB Legend for wiring diagram of CAN bus - PE00.19-P-2300-60ZB interior compartment 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) PE82.00-P-1100ZA Further wiring diagrams PE82.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe00.19-p-2300zb, Wiring diagram CAN bus interior MODEL 454 as of 11.4.05 up to 2.4.06

PE00.19-P-2300ZC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 365 · Applies to: 453 · AR: PE00.19-P-2300ZC, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Wiring diagram CAN bus interior 8.3.06 MODEL 454 as from 3.4.06 PE00.19-P-2300-99ZC Wiring diagram CAN bus interior PE00.19-P-2300-99ZC PE00.19-P-2300-60ZC Legend for wiring diagram of CAN bus - PE00.19-P-2300-60ZC interior compartment 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) PE82.00-P-1100ZA Further wiring diagrams PE82.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe00.19-p-2300zc, Wiring diagram CAN bus interior MODEL 454 as from 3.4.06

PE00.19-P-2400ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 366 · Applies to: 453 · AR: PE00.19-P-2400ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+5 more)

Wiring diagram for LIN bus 16.12.03 MODEL 454 up to 2.4.06 PE00.19-P-2400-99ZA Wiring diagram for LIN bus PE00.19-P-2400-99ZA PE00.19-P-2400-60ZA Legend of wiring diagram for LIN bus PE00.19-P-2400-60ZA 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) PE07.00-P-1100ZA Further wiring diagrams PE07.00-P-1100ZA PE15.00-P-1100ZA Further wiring diagrams PE15.00-P-1100ZA PE46.00-P-1100ZA Further wiring diagrams PE46.00-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE77.00-P-1100ZA Further wiring diagrams PE77.00-P-1100ZA PE80.00-P-1100ZA Further wiring diagrams PE80.00-P-1100ZA PE82.00-P-1100ZA Further wiring diagrams PE82.00-P-1100ZA PE83.00-P-1100ZA Further wiring diagrams PE83.00-P-1100ZA PE91.00-P-1100ZA Further wiring diagrams PE91.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe00.19-p-2400za, Wiring diagram for LIN bus MODEL 454 up to 2.4.06

PE00.19-P-2400ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 367 · Applies to: 453 · AR: PE00.19-P-2400ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+5 more)

Wiring diagram for LIN bus 8.3.06 MODEL 454 as from 3.4.06 PE00.19-P-2400-99ZB Wiring diagram for LIN bus PE00.19-P-2400-99ZB PE00.19-P-2400-60ZB Legend of wiring diagram for LIN bus PE00.19-P-2400-60ZB 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) PE07.00-P-1100ZA Further wiring diagrams PE07.00-P-1100ZA PE15.00-P-1100ZA Further wiring diagrams PE15.00-P-1100ZA PE46.00-P-1100ZA Further wiring diagrams PE46.00-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE77.00-P-1100ZA Further wiring diagrams PE77.00-P-1100ZA PE80.00-P-1100ZA Further wiring diagrams PE80.00-P-1100ZA PE82.00-P-1100ZA Further wiring diagrams PE82.00-P-1100ZA PE83.00-P-1100ZA Further wiring diagrams PE83.00-P-1100ZA PE91.00-P-1100ZA Further wiring diagrams PE91.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe00.19-p-2400zb, Wiring diagram for LIN bus MODEL 454 as from 3.4.06

PE00.19-P-2150BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 396 · Applies to: 453 · AR: PE00.19-P-2150BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of CAN bus 09.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Interior compartment and suspension Wiring diagram for CAN bus PE00.19-P-2150-97BBA 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, pe00.19-p-2150bba, Wiring diagram of CAN bus Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Interior compartment and suspension

PE00.19-P-2150BBB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 397 · Applies to: 453 · AR: PE00.19-P-2150BBB, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of CAN bus 09.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Cruise control Wiring diagram for CAN bus PE00.19-P-2150-97BBB Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe00.19-p-2150bbb, Wiring diagram of CAN bus Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Cruise control

PE00.19-P-2150BBC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 398 · Applies to: 453 · AR: PE00.19-P-2150BBC, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of CAN bus 09.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Automatic transmission Wiring diagram for CAN bus PE00.19-P-2150-97BBC Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe00.19-p-2150bbc, Wiring diagram of CAN bus Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Automatic transmission

PE00.19-P-2150BBD

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 399 · Applies to: 453 · AR: PE00.19-P-2150BBD, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of CAN bus 09.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Multimedia Wiring diagram for CAN bus PE00.19-P-2150-97BBD 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, pe00.19-p-2150bbd, Wiring diagram of CAN bus Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Multimedia

PE00.19-P-2800BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 427 · Applies to: 453 · AR: PE00.19-P-2800BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of ground cabling 09.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8 Wiring diagram for ground wiring PE00.19-P-2800-97BBA 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, pe00.19-p-2800bba, Wiring diagram of ground cabling Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 W11, W11/9, W51/4, W12, W16/8

PE00.19-P-2800BBB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 428 · Applies to: 453 · AR: PE00.19-P-2800BBB, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of ground cabling 09.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9 Wiring diagram for ground wiring PE00.19-P-2800-97BBB Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe00.19-p-2800bbb, Wiring diagram of ground cabling Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 W1/1, W2, W9

PE00.19-P-2800BBC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 429 · Applies to: 453 · AR: PE00.19-P-2800BBC, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of ground cabling 09.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 W1/3 Wiring diagram for ground wiring PE00.19-P-2800-97BBC Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe00.19-p-2800bbc, Wiring diagram of ground cabling Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 W1/3

PE00.19-P-2800BBD

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 430 · Applies to: 453 · AR: PE00.19-P-2800BBD, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of ground cabling 09.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 W1/5 Wiring diagram for ground wiring PE00.19-P-2800-97BBD 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, pe00.19-p-2800bbd, Wiring diagram of ground cabling Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 W1/5

PE00.19-P-2600BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 450 · Applies to: 453 · AR: PE00.19-P-2600BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of soldered points / Z connector sleeves 09.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Wiring diagram solder points/Z-connector PE00.19-P-2600-97BBA sleeves 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, pe00.19-p-2600bba, Wiring diagram of soldered points / Z connector sleeves Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020

PE00.19-P-1050ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 451 · Applies to: 453 · AR: PE00.19-P-1050ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+5 more)

Wiring diagrams, contents 18.8.03 MODELS 454 OV00.01-P-1701-01ZA Preface to wiring diagrams Model 454 OV00.01-P-1701-01ZA OV00.01-P-1901-03ZA Use of wiring diagrams Model 454 OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups Model 454 OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams Model 454 OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit Model 454 OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Arrangement and assignment of the wiring Model 454 GF00.19-P-1000ZA and plug connectors GF00.19-P-2000ZA Arrangement and assignment of ground Model 454 GF00.19-P-2000ZA points GF00.19-P-3000ZA Arrangement and assignment of Z connector Model 454 GF00.19-P-3000ZA sleeves (wiring connections in wiring harness) PE00.19-P-1100ZA Overview of wiring diagrams covering all Model 454 PE00.19-P-1100ZA function groups PE07.00-P-1100ZA Overview of wiring diagrams for mixture Engine 639.939, 134.910, 135.930 /950 in PE07.00-P-1100ZA formation Model 454 Overview of wiring diagrams for electrical PE15.00-P-1100ZA Model Series 454 PE15.00-P-1100ZA

system, engine PE31.00-P-1100ZA Survey of wiring diagrams of trailer coupling PE31.00-P-1100ZA PE42.00-P-1100ZA Overview of wiring diagrams for brakes - Model 454 PE42.00-P-1100ZA hydraulic and mechanical systems PE46.00-P-1100ZA Overview of wiring diagrams for steering Model 454 PE46.00-P-1100ZA PE54.00-P-1100ZA Overview of wiring diagrams for electrical Model 454 PE54.00-P-1100ZA system, equipment and instruments PE67.00-P-1100ZA Survey of electric wiring diagrams, screens Model 454 PE67.00-P-1100ZA and windows PE72.00-P-1100ZA Overview of wiring diagrams of doors Model 454 PE72.00-P-1100ZA PE77.00-P-1100ZA Overview of wiring diagrams sliding roof, soft Model 454 PE77.00-P-1100ZA top PE80.00-P-1100ZA Overview of wiring diagrams central locking, Model 454 PE80.00-P-1100ZA convenience hydraulics PE82.00-P-1100ZA Overview of wiring diagrams for electrical Model 454 PE82.00-P-1100ZA system, body PE83.00-P-1100ZA Overview of wiring diagrams for climate Model 454 PE83.00-P-1100ZA control PE88.00-P-1100ZA Overview of wiring diagrams detachable body Model 454 PE88.00-P-1100ZA components, outside mirrors PE91.00-P-1100ZA Overview of wiring diagrams for seats, bunks, Model 454 PE91.00-P-1100ZA restraint systems Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe00.19-p-1050za, Wiring diagrams, contents MODELS 454

AP00.20-P-0000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 458 · Applies to: 453 · AR: AP00.20-P-0000FF, AP00.20-P-0001SN, AP00.20-P-0001RR, AP00.20-P-0001FF, AP00.20-P-0011SM (+5 more)

Maintenance 08.02.2019 Model 450.3/4, 452.3/4, 454.0 Notes on position of chassis number Model 450.3/4, 452.3/4, 454.0 AH00.00-P-0002-01RR Notes on position of engine number AH01.00-P-0001-01FF Notes on position of transmission number AH26.00-P-0001-01FF Safety notes/warning notes AP00.20-P-0000-02FF Service intervals/work sheets general AP00.20-P-0000-04FF information SERVICE SHEET for Active Service System Model 450 as of 03.01.03 as of AP00.20-P-0001SN (ASSYST) WME4503001J000001, fortwo 2nd generation Model 452 AP00.20-P-0001RR Model 454 AP00.20-P-0001FF Maintenance service Model 450 up to 3.1.03 or chassis number AP00.20-P-0011SM WME01MCO2H106037 Safety precautions for new vehicles that are AP00.70-P-1000SM being put in storage Perform check of vehicles in stock every 90 Model 450 except 450.418 AR00.20-P-0001SM days Model 450.418 AR00.20-P-0001CR Model 452 AR00.20-P-0001RR Model 454 AR00.20-P-0001FF Perform check of vehicles in stock every 270 Model 454.0 AR00.20-P-0002SM days Model 450.418 AR00.20-P-0002CR Model 452 AR00.20-P-0002RR Model 454 AR00.20-P-0002FF Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-0000ff, Maintenance Model 450.3/4, 452.3/4, 454.0

AP00.20-P-0050FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 459 · Applies to: 453 · AR: AP00.20-P-0050FF

Major assemblies - check tightness and condition 1.10.03 MODELS 454.0 Check 1 Engine and transmission: visually inspect for Slightly damp sealing areas are harmless. damage and leaks If there are leaks present that lead to continuous loss of oil: Repair the cause of the leaks and correct the oil level - subject to separate repair order. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-0050ff, Major assemblies - check tightness and condition MODELS 454.0

AP00.20-P-1228SL

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 460 · Applies to: 453 · AR: AP00.20-P-1228SL, AP42.00-P-4290MCC

OVERVIEW for service sheet 04.12.2017 Model 453 (except 453.09/39/49) Modification notes 04.12.2017 Interval for "Replace spark plugs" changed Every 40,000 km (25,000 mi)/4 years Service A Service B Customer package For first time after 3 years, then every 2 years For the first time at 40,000 km (25,000 mi), thereafter at every Service B Every 40,000 km (25,000 mi)/4 years Every 60,000 km (37,500 mi) or 6 years have elapsed since last change P00.00-5751-11 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 A B Input condition not OK: Completed

Service reception The reception report for service on the vehicle is available in completely edited form AP00.20-P-0009S To be performed by the

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 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-1228sl, OVERVIEW for service sheet Model 453 (except 453.09/39/49)

Vehicle interior

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 461 · Applies to: 453 · AR: AP18.00-P-0101SS, AP40.10-P-4051EW, AP82.10-P-8252EW, AP82.10-P-8250EW, AP40.10-P-4054MCC

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 Check tire sealant AP40.10-P-4054MCC Enter tire sealant expiration date here:

---

Replace tire sealant, invoice as

additional operation. Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-1228sl, OVERVIEW for service sheet Model 453 (except 453.09/39/49)

AP00.20-P-1228SM

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 463 · Applies to: 453 · AR: AP00.20-P-1228SM, AP42.00-P-4290MCC

OVERVIEW for service sheet 04.12.2017 Model 453 (except 453.09/39/49) Modification notes 04.12.2017 Interval for "Replace spark plugs" changed Every 45,000 km (28,000 mi)/4 years Service A Service B Customer package For first time after 3 years, then every 2 years For the first time at 60,000 km (37,500 mi), thereafter at every Service B Every 45,000 km (28,000 mi)/4 years Every 90,000 km (56,000 mi) or 6 years have elapsed since last change P00.00-5751-11 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 A B Input condition not OK: Completed

Service reception The reception report for service on the vehicle is available in completely edited form AP00.20-P-0009S To be performed by the

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 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-1228sm, OVERVIEW for service sheet Model 453 (except 453.09/39/49)

Vehicle interior

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 464 · Applies to: 453 · AR: AP18.00-P-0101SS, AP40.10-P-4051EW, AP82.10-P-8252EW, AP82.10-P-8250EW, AP40.10-P-4054MCC

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 Check tire sealant AP40.10-P-4054MCC Enter tire sealant expiration date here:

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Replace tire sealant, invoice as

additional operation. Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-1228sm, OVERVIEW for service sheet Model 453 (except 453.09/39/49)

AP00.20-P-1228SN

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 466 · Applies to: 453 · AR: AP00.20-P-1228SN, AP42.00-P-4290MCC

OVERVIEW for service sheet 04.12.2017 Model 453 (except 453.09/39/49) Modification notes 04.12.2017 Interval for "Replace spark plugs" changed Every 80,000 km (50,000 mi)/4 years Service A Service B Customer package For first time after 3 years, then every 2 years For the first time at 80,000 km (50,000 mi), thereafter at every Service B Every 80,000 km (50,000 mi)/4 years Every 120,000 km (75,000 mi) or 6 years have elapsed since last change P00.00-5751-11 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 A B Input condition not OK: Completed

Service reception The reception report for service on the vehicle is available in completely edited form AP00.20-P-0009S To be performed by the

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 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-1228sn, OVERVIEW for service sheet Model 453 (except 453.09/39/49)

Vehicle interior

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 467 · Applies to: 453 · AR: AP18.00-P-0101SS, AP40.10-P-4051EW, AP82.10-P-8252EW, AP82.10-P-8250EW, AP40.10-P-4054MCC

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 Engine 281.910 AP09.10-P-0980S Replace air filter element Engine 281.920 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 Check tire sealant AP40.10-P-4054MCC Enter tire sealant expiration date here:

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Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-1228sn, OVERVIEW for service sheet Model 453 (except 453.09/39/49)

AP00.20-P-1228TAF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 469 · Applies to: 453 · AR: AP00.20-P-1228TAF, AP42.00-P-4290MCC

OVERVIEW for service sheet 04.12.2017 Model 453 (except 453.09/39/49) Modification notes 04.12.2017 Interval for "Replace spark plugs" changed Every 40,000 km/4 years Service A Service B Customer package Every 2 years At every Service B Every 40,000 km/4 years Every 60,000 km/6 years P00.00-5751-11 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 A B Input condition not OK: Completed

Service reception The completely processed pre-order is available for service on the vehicle To be performed by the

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 exterior Page 1 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-1228taf, OVERVIEW for service sheet Model 453 (except 453.09/39/49)

Check condition of vehicle exterior

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 470 · Applies to: 453 · AR: AP18.00-P-0101SS, AP40.10-P-4051EW

AP60.00-P-0050S Check condition of windshield AP67.10-P-6750A Check condition of wiper blades AP82.30-P-8253G Front flap Check battery charge level with Magic Eye and enter result in table If present Brake system: Check fluid level AP42.10-P-4210S Check main circuit coolant level AP20.30-P-2050S Check condition of front-end flap service area AP00.20-P-0091S Vehicle interior Replace activated charcoal particle filter Vehicles with air conditioning AP83.00-P-8384S Check warning and function indicator lamps in instrument cluster AP54.30-P-5451S Instrument cluster: Reset service indicator AP00.20-P-0043S 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 condition/tire tread depth and enter in table AP40.10-P-4052B Assess condition of brake pads and enter into table AP42.10-P-4252S Assess condition of brake disks on front axle and enter in table AP42.10-P-4258S Check tires for damage and crack formation and enter result in table AP40.10-P-4051EW Tires Customer package Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-1228taf, OVERVIEW for service sheet Model 453 (except 453.09/39/49)

AP00.20-P-1240SM

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 473 · Applies to: 453 · AR: AP00.20-P-1240SM

OVERVIEW for service sheet, USA 04.12.2017 Model 453 (except 453.09/39/49) Modification notes 04.12.2017 Interval for "Replace spark plugs" changed Every 30,000 mi/3 years Service A Service B Customer package For first time after 3 years, then every 2 years For first time after 60,000 mi, then at every Service B Every 30,000 mi/3 years Every 60,000 mi/6 years P00.00-5751-11 Customer Order number VIN/license plate number Current mileage Service code Workshop code Remaining distance Remaining time Oil type/viscosity Completion time/date Service consultation performed at vehicle Yes No Notes/explanations The following activities are hereby confirmed: - Completion of relevant service operations Signature A B Input condition not OK: Completed

Service reception The reception report for service on the vehicle is available in completely edited form AP00.20-P-0009S Page 1 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)

AR00.20-P-0002FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 476 · Applies to: 453 · AR: AR00.20-P-0002FF, AR54.10-P-0003FF, AR54.10-P-1129FF, AR54.10-P-1130FF, AP20.00-P-2010FF (+2 more)

Perform check of vehicles in stock every 270 days 24.3.05 MODELS 454 Perform work every 270 days

Print out, complete and archive this document

Rectify the defects/complaints that were found

in the process during disbursement or delivery inspection of the vehicle Completed Unlock vehicle via lock cylinder of the front left 1 door Open hood, clip on battery ground line AR54.10-P-0003FF 2 The STAR diagnosis tester does not have to be connected. Increase tire pressure to 3 bar 3 This helps to prevent flattening of the tires while the vehicle is standing. Check vehicle interior for leaks and let in some 4 Carry out visual inspection. air Check instrument panel and seat covers for 5 fading Check condition of battery AR54.10-P-1129FF 6 The STAR diagnosis tester does not have to be connected. Use battery tester 450 589 15 21 00. Enter test result: Battery OK.

AR54.10-P-1130FF Charge battery. Replace battery. Check coolant for corrosion or antifreeze, Engines 122.950, 134.910, 135.930 /950 AP20.00-P-2010FF 7 correct if necessary Engine 639.939 AP20.00-P-2010FG Check brake fluid for correct water content, AP42.00-P-4298SM 8 Use brake fluid tester 452 589 00 21 00. replace if necessary Check outside surfaces of vehicle for 9 aggressive contamination, e.g., bird droppings, clean if necessary Check engine compartment and wheelhouses 10 for damage (e.g., damage caused by martens, animal nests) Conduct a road test 11 Switch on air conditioning (special equipment) for at least 5 min. Apply brakes to free brake disks from corrosion. Open hood, close vehicle doors, and lock with 12 remote control key Disconnect ground cable from battery AR54.10-P-0003FF 13 Discharge of battery by quiescent current consumers (clock etc.) is prevented. Close engine hood 14 15 Stock maintenance 270 days performed by: Chassis number: Company: Name: Date: Signature: Remarks/defects found: Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar00.20-p-0002ff, Perform check of vehicles in stock every 270 days MODELS 454

AR00.20-P-0001FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 477 · Applies to: 453 · AR: AR00.20-P-0001FF, AR54.10-P-0003FF, AR54.10-P-1129FF, AR54.10-P-1130FF

Perform check of vehicles in stock every 90 days 24.3.05 MODELS 454 Perform work every 90 days

Print out, complete and archive this document

Rectify the defects/complaints that were found

in the process during disbursement or delivery inspection of the vehicle Completed Unlock vehicle via lock cylinder of the front left 1 door Open hood, clip on battery ground line AR54.10-P-0003FF 2 The STAR diagnosis tester does not have to be connected. Increase tire inflation pressure to 3 bar 3 This helps to prevent flattening of the tires while the vehicle is standing. Check vehicle interior for leaks 4 Carry out visual inspection. Check instrument panel and seat covers for 5 fading Check condition of battery AR54.10-P-1129FF 6 The STAR diagnosis tester does not have to be connected. Use battery tester 450 589 15 21 00. Enter test result: Battery OK.

AR54.10-P-1130FF Charge battery.

Replace battery.

Check outside surfaces of vehicle for 7 aggressive contamination, e.g., bird droppings, clean if necessary Check engine compartment and wheelhouses 8 for damage (damage caused by martens, animal nests) Close vehicle doors and lock using remote 9 control key Disconnect ground cable from battery AR54.10-P-0003FF 10 Discharge of battery by quiescent current consumers (clock etc.) is prevented. Close engine hood 11 12 Stock maintenance 90 days performed by: Chassis number: Company: Name: Date: Signature: Remarks/defects found: Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar00.20-p-0001ff, Perform check of vehicles in stock every 90 days MODELS 454

If the vehicle needs to be moved, pay

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 479 · Applies to: 453 · AR: AP18.00-P-1811MS, AP82.35-P-8249US, AP42.10-P-4256EW

attention to engine and transmission operation. If problems occur, Determine faults and conduct extended diagnosis subject to separate repair order. Check condition of wiper blades and wiping pattern. AP82.30-P-8253G If problems occur, Remedy complaint subject to separate repair order. Remove protective foil for maintenance indicator from wiper blade. Vehicle with maintenance indicator on wiper blade. AP82.30-P-8253G Vehicle exterior, body (cleaned, transport protection removed) Attach rod antenna. Remove rubber spacer disks from rear window. Lubricate lock on liftgate. Only on cabriolets. Multipurpose oil

A 000 989 84 01. Engine compartment Check engine oil level. Model 453 (except 453.091/391/491) AP18.00-P-1811MS Check all visible parts in the engine compartment for damage and leak tightness. AP00.20-P-0055S Front enclosure Check coolant level and antifreeze content of coolant in coolant expansion reservoir. Model 453 (except 453.091/391/491) AP20.30-P-2050S If problems occur, Adapt antifreeze content and fill up if necessary, subject to separate repair order. Check coolant level and antifreeze content of coolant in coolant expansion reservoir for high-voltage battery cooling circuit. Model 453.091/391/491 AP20.30-P-2053C If problems occur, Adapt antifreeze content and fill up if necessary, subject to separate repair order. Windscreen washer: Check fluid level. AP82.35-P-8249US Use summer/winter cleaner

depending on season. Renew brake fluid. AP42.00-P-4280S Tires, brakes Correct tire pressure and enter set tire pressure in table. AP40.15-P-4061C Assess condition of brake disks and enter evaluation in table. AP42.10-P-4256EW Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-1100c, Perform delivery and hand-over inspection Model 453

AP00.20-P-0042FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 486 · Applies to: 453 · AR: AP00.20-P-0042FF

Reset service indicator 1.12.03 MODELS 454.0 1 Trip odometer button A1p13 Multifunction display P00.20-2265-11 Resetting 1 Switch on ignition 2 Select the maintenance indicator with the trip odometer button (1) within the first 4 s 3 Switch off ignition within the display period of The maintenance indicator remains in the approx. 10 s multifunction display (A1p13) 4 Press trip odometer (1) and switch on the ignition with the button pressed 5 Keep pressing the trip odometer (1) for a During this period, the maintenance further 10 s indicator is not replaced by other displays in the multifunction display (A1p13). The oil reset is then performed. After this is completed, the multifunction display (A1p13) indicates the remaining distance for the next maintenance interval (startup distance). Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-0042ff, Reset service indicator MODELS 454.0

AP00.20-P-0001FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 487 · Applies to: 453 · AR: AP00.20-P-0001FF, AP42.00-P-4290FF

SERVICE SHEET for Active Service System (ASSYST) 20.4.07 MODEL 454.0 Model 454 Customer: Order number: Correctness of service scope confirmed by Completion of jobs confirmed by service foreman: mechanic's signature: Completion date Additional operations A B Service Service

Define additional operations in accordance with prescribed kilometer or time interval The service scope is shown in the maintenance interval display (WIA) of the instrument cluster: Service A - one key symbol Service B - two key symbols The maintenance interval display is adjusted at the plant or after the last reset so that the next service is due on: For gasoline engines: after 20,000 km or after one year, whichever occurs first. For diesel engines with mineral oil: after 20,000 km or after one year, whichever occurs first. For diesel engines with synthetic oil: after 25,000 km or after one year, whichever occurs first. Oil type/viscosity Customer interview conducted Yes (Document inspection points immediately in service No sheet) Notes/explanations: Modification notes 27.3.07 Discontinuity of platinum spark plugs in the additional operation: Replace spark plugs General service operations Service Not OK A B Brake testing on test stand AP42.00-P-4290FF Enter braking values in N: Page 1 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

Engine coolant: Check fill level and

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 490 · Applies to: 453 · AR: AP20.00-P-2010FF, AP20.00-P-2010FG, AP42.10-P-4210FF, AP42.00-P-4298SM, AP82.35-P-8210FF (+5 more)

AP20.00-P-2010FF on gasoline engines antifreeze protection and correct if necessary °C AP20.00-P-2010FG on diesel engines Brake fluid: Check fill level AP42.10-P-4210FF Brake fluid: Measure water content AP42.00-P-4298SM Document any change of brake fluid in the service booklet. Windshield washer system: Check fill level AP82.35-P-8210FF and correct if necessary Underside of vehicle Underfloor paneling removed

Check vehicle underside, to the extent that it can be seen, for damage and corrosion by means of visual inspection Check poly V-belt for AP13.22-P-1351FF wear and damage Engine and transmission: check for damage AP00.20-P-0050FF and leaks by means of visual inspection Cooling system: visually inspect for damage and leaks Brake lines and brake system: Check for fixing, damage and leaks by means of visual inspection Exhaust system: visually inspect for damage and leaks Fuel system: visually inspect for damage and AP47.00-P-4750FF leaks Check play of front axle joints, Check rubber boots for damage Check all rubber mounts at the front and rear axles for damage Check tie rod joints and drag link joints for AP46.00-P-4653FF play, check rubber boots for damage Wheels, brakes Check front and rear brake pads for lining AP42.10-P-4251FF On vehicles with code (30Y) thickness and brake disks for condition Disk brakes on rear axle Check lining thickness of front brake pads and AP42.10-P-4251FG On vehicles without code (30Y) condition of front brake disks Disk brakes on rear axle Check brake lining thickness of drum brake AP42.10-P-4253FF On vehicles without code (30Y) through inspection hole Disk brakes on rear axle If the lining thickness is approaching the wear limit, then the exact lining thickness should be established when the brake drum is removed. Check tires for damage and crack formation, AP40.10-P-4051FF Measure tread depth, enter in mm: FL FR RL RR Check tire inflation pressure and correct if Specified values of tire inflation pressure necessary See adhesive label on fuel filler flap. Page 4 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

Replace first aid bag, invoice as an

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 501 · Applies to: 453 · AR: AP18.00-P-1811MS, AP20.00-P-2010MCC, AP20.00-P-2010MEV, AP82.35-P-8249US, AP40.15-P-4061MCC (+1 more)

additional operation. Engine compartment Check all visible parts in engine compartment for damage and leaks Model 451, 453 Model 453 AP00.20-P-0055S Check engine oil level Engine 132, 281, 660 AP18.00-P-1811MS Check coolant level in coolant expansion reservoir 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 453 with engine 281 AP20.30-P-2050S Windshield washer system - Check fluid level AP82.35-P-8249US Underside of vehicle Check all major assemblies, systems and component parts for visible damage, soiling, corrosion damage, wear and leaks Engine,

Transmission, Steering, Exhaust system, Service brake and parking brake, Suspension, Fuel system, Front axle and rear axle, Springing and shock absorbers, Body, Underfloor paneling. Wheel-and-tire assemblies, brakes Check the tires and disk wheels as well as spare wheel Attention must be paid to the condition, wear and damage as well as the ease of movement of the wheel and tire assemblies. Correct tire pressure and enter set tire pressure in table Model 451 AP40.15-P-4061MCC Model 453 AP40.15-P-4061C Perform brake test and enter the result in the table AP42.00-P-4290MCC Conduct a road test Check starter, clutch, shift mechanism, transmission, steering and display instruments for proper operation. Attention must be paid to the engine output, handling characteristics and noise development. Miscellaneous Enter any other faults in table Brake values Left Right Front Rear Parking brake Tire condition Right front Left front Right rear Left rear Page 4 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-0084b, Used vehicle check Model 451, 453 jung@smart

Model 451 with engine 132, 660

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 505 · Applies to: 453 · AR: AP18.00-P-1811MS, AP40.15-P-4061SM, AP40.15-P-4061MCC, AP40.15-P-4061RR

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 Correct tire pressure and enter set tire pressure in table Model 450, 451, 452, 453, 454 Model 450.3/4 AP40.15-P-4061SM Model 451 AP40.15-P-4061MCC Model 452.3/4 AP40.15-P-4061RR Model 453 AP40.15-P-4061C Brake values Left Right Front Rear Parking brake Set tire pressure in bar or psi Front axle Rear axle bar/psi Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.20-p-0082b, Winter Inspection Model 450, 451, 452, 453, 454

BB00.40-P-0300ZZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 506 · Applies to: 453 · AR: BB00.40-P-0300ZZ, BB00.40-P-0310ZZ, BB00.40-P-0330ZZ, BB00.40-P-0340ZZ, BB00.40-P-0350ZZ (+1 more)

Directory of additional operating fluids 21.10.2016 Model all Coolant, anticorrosion agent/antifreeze BB00.40-P-0310ZZ Operating fluids for brakes BB00.40-P-0330ZZ Hydraulic fluids BB00.40-P-0340ZZ Further operating fluids BB00.40-P-0350ZZ Preservation of vehicles/engines BB00.40-P-0380ZZ Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, bb00.40-p-0300zz, Directory of additional operating fluids Model all

BB00.40-P-0000ZZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 507 · Applies to: 453 · AR: BB00.40-P-0000ZZ

General list 10.5.12 Sheet 022.0 Obligations Regarding Approval for Operating BB00.40-P-0022-00A Fluids Sample for information only Hazardous substances Sheet 023.0 BB00.40-P-0023-00A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, bb00.40-p-0000zz, General list Sheet 000

BB00.40-P-0100ZZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 508 · Applies to: 453 · AR: BB00.40-P-0100ZZ, BB00.40-P-0110ZZ, BB00.40-P-0120ZZ, BB00.40-P-0130ZZ, BB00.40-P-0140ZZ

List of fuels 10.5.12 General information on fuels Sheet 110 BB00.40-P-0110ZZ Fuels for gasoline engines Sheet 120 BB00.40-P-0120ZZ Fuels for road vehicle diesel engines Sheet 130 BB00.40-P-0130ZZ Fuels for industrial engines Sheet 140 BB00.40-P-0140ZZ Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, bb00.40-p-0100zz, List of fuels Sheet 100

BB00.40-P-0200ZZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 509 · Applies to: 453 · AR: BB00.40-P-0200ZZ, BB00.40-P-0210ZZ, BB00.40-P-0220ZZ, BB00.40-P-0230ZZ, BB00.40-P-0260ZZ

List of lubricants 10.5.12 General information on lubricants Sheet 210 BB00.40-P-0210ZZ Engine oils Sheet 220 BB00.40-P-0220ZZ Gear oils Sheet 230 BB00.40-P-0230ZZ Greases Sheet 260 BB00.40-P-0260ZZ Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, bb00.40-p-0200zz, List of lubricants Sheet 200

AR00.60-P-0100MCC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 521 · Applies to: 453 · AR: AR00.60-P-0100MCC

Secure vehicle on vehicle lift 17.9.08 MODEL 450, 451, 452, 454 P00.60-2121-09 Model 450, 451, 452 Illustrated on model 451 1 Rag 3 Lifting platform support arm 5 Hand brake lever 2 Tensioning strap Model 450, 451 shown on model 451 with code (X22) RHD beverage holder 6 Screw/bolt (with m odel 450 with code (I10) Beverage holder or with model 451 with code (X21) LHD beverage holder or with model 451 with code (X22) RHD beverage holder) 7 Beverage holder (with m odel 450 with code (I10) Beverage holder or with model 451 with code (X21) LHD beverage holder or with model 451 with code (X22) RHD beverage holder) P00.60-2128-01 Model 454 1 Rag 2 Tensioning strap 4 Center console P00.60-2126-06 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar00.60-p-0100mcc, Secure vehicle on vehicle lift MODEL 450, 451, 452, 454

AR00.60-P-0100SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 524 · Applies to: 453 · AR: AR00.60-P-0100SR

Secure vehicle on vehicle lift 21.06.2017 Model 453 Modification notes 27.04.2017 Securing method completely revised. Shown on front left side of vehicle 1 Tensioning strap 2 Front vehicle lift swivel arm 3 Carrier 4 Seat belt buckle 5 Rear vehicle lift swivel arm P00.60-2231-06 Model 453.3/4 except for code J59 (center armrest) 6 Cup holder P00.60-2232-11 Page 1 of 3 © Mercedes-Benz AG, 5/22/18, L/07/20, ar00.60-p-0100sr, Secure vehicle on vehicle lift Model 453

AP00.70-P-1001ZZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 527 · Applies to: 453 · AR: AP00.70-P-1001ZZ, AP42.00-P-4290BA, AP42.00-P-4290MCC, AR97.20-P-4000GQ, AR97.20-P-4000CW (+3 more)

Render new vehicles, which were immobilized operational 05.03.2020 Model 117, 118, 156, 166, 167, 172, 176, 177, 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 451, 453, 461, 463 Bring to operational readiness 1 Check refrigerant level of air conditioning Model 461 with code H02 (Air conditioning, manual) system. Model 463 up to model year 2019 with code H02 (Air conditioning, manual) Risk of death Danger when working on component Do not touch damaged or defective live AS00.00-Z-0035-01A

parts and systems with U >= 30 V alternating component parts and lines or non-insulated voltage (AC) or U >= 60 V direct voltage (DC) electrical connections and lines. 2 Check status of high-voltage battery on Model 242.890 additional instrument display. Topical note General information on vehicles with high- AH00.00-Z-0300-01A voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment If the charge level of the high-voltage battery is below 50 %, Charge high-voltage battery completely. 3 Perform brake test. Model 117, 118, 156, 166, 167, 172, 176, 177, 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 451, 453, 461, 463 Model 117, 118, 156, 166, 167, 172, 176, 177, AP42.00-P-4290BA 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293 Model 463 as of model year 2019 Model 451.3/4, 453 AP42.00-P-4290MCC Model 461 AP42.00-P-4290G Model 463 up to model year 2019 4 Remove transport film. Model 117, 118, 156, 166, 167, 172, 176, 177, 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 451, 453, 461, 463 Topical note Notes on paintwork, decorative and Model 117, 118, 156, 166, 167, 172, 176, 177, AH98.00-P-9019-01Z detachable components 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 461, 463 Notes on transportation sheeting Model 117, 118, 156, 166, 167, 172, 176, 177, AH97.20-P-9409-03A 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293 Model 166 AR97.20-P-4000GQ

Model 204, 212 AR97.20-P-4000A

with code 524 (Paint protection) Model 204 AR97.20-P-4000CW

except code 524 (Paint protection) Model 216, 221 AR97.20-P-4000SX

5 Was and dry off vehicle. 6 Remove any drips and rough residues from Model 117, 118, 156, 166, 167, 172, 176, 177, AP98.00-P-0635A paintwork, windows and trim pieces. 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 461, 463With high-gloss varnish paintwork Model 117, 118, 156, 166, 167, 172, 176, 177, AP98.00-P-0635RQ 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 453, 461, 463with matt paintwork Model 451 AP98.00-P-0635SM Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.70-p-1001zz, Render new vehicles, which were immobilized operational Model 117, 118, 156, 166, 167, 172, 176, 177, 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 451, 453, 461, 463

AP00.70-P-1000SM

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 529 · Applies to: 453 · AR: AP00.70-P-1000SM, AR00.20-P-0001SM, AR00.20-P-0001CR, AR00.20-P-0001RR, AR00.20-P-0001FF (+5 more)

Safety precautions for new vehicles that are being put in storage 27.6.07 MODEL 450.3 /4, 452.3 /4, 454.0 New vehicles in the context of this description

are vehicles for which no inspection has been carried out to date. For other vehicles, the instructions in the Specifications for Operating Fluids apply In areas in which extremely high corrosive Export countries: In these case proceed

attacks can be expected from experience, the as per the Specifications for Operating Fluids. measures given here are not always sufficient even for new vehicles Print out, fill in and store this document in

an archive The test points listed below should be carried

If the vehicle is put into storage over a out when a vehicle is put into storage longer period, additional measures should be carried out regularly: Every 90 days, see: Perform check of vehicles in stock every 90

days Model 450 except 450.418 AR00.20-P-0001SM Model 450.418 AR00.20-P-0001CR Model 452 AR00.20-P-0001RR Model 454 AR00.20-P-0001FF Every 270 days, see: Perform check of vehicles in stock every 270

days Model 450 except 450.418 AR00.20-P-0002SM Model 450.418 AR00.20-P-0002CR Model 452 AR00.20-P-0002RR Model 454 AR00.20-P-0002FF The defects/complaints found in the process should be eliminated when the vehicle is put into storage or at a predelivery inspection. Put vehicle into storage completed In order to protect the fuel tank from condensate, we recommend filling the tank completely Brake the vehicle until the service brakes are This prevents the brake pad from hot so that adhering moisture on the brake becoming stuck to the brake disks. disks and brake pads evaporates Secure the vehicle by engaging a gear or by a wedge, parking brake in release position Move all the seats into the normal position (set seat backrest to upright position) Open the door on the passenger-side and Model 450 lock the vehicle with the transmitter key Open hood, close the vehicle doors and lock Model 452 with the transmitter key Open engine hood, close the vehicle doors Model 454 and lock with the transmitter key Disconnect battery ground line This in turn prevents any discharging of the battery through quiescent current consumers (time switch etc.). STAR DIAGNOSIS need not be connected. Disconnect/connect battery ground line Model 450 AR54.10-P-0003SM

Model 452 AR54.10-P-0003RR Model 454 AR54.10-P-0003FF Close door on passenger-side Model 450 Close front hood Model 452 Close engine hood Model 454 Putting the vehicle into storage carried out by: Chassis number: Parked at: Company: Name: Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.70-p-1000sm, Safety precautions for new vehicles that are being put in storage MODEL 450.3 /4, 452.3 /4, 454.0

AP00.70-P-1000ZZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 531 · Applies to: 453 · AR: AP00.70-P-1000ZZ, AR54.10-P-1129MCC, AR54.10-P-1129SR, AP40.15-P-4061MCC, AP98.00-P-0641SM

Safety precautions for new vehicles that are being put in storage 05.03.2020 Model 117, 118, 156, 166, 167, 172, 176, 177, 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 451, 453, 461, 463 Perform safety precautions 1 Check condition of battery. Model 117, 118, 156, 166, 167, 172, 176, 177, 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 451, 453, 461, 463 Model 117, 118, 156, 166, 167, 172, 176, 177, AP54.10-P-5449U 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 463 Model 451.3/4 AR54.10-P-1129MCC

Model 453 AR54.10-P-1129SR

Risk of death Danger when working on component Do not touch damaged or defective live AS00.00-Z-0035-01A

parts and systems with U >= 30 V alternating component parts and lines or non-insulated voltage (AC) or U >= 60 V direct voltage (DC) electrical connections and lines. 2 Check status of high-voltage battery on Model 242.890 additional instrument display. Topical note General information on vehicles with high- AH00.00-Z-0300-01A voltage on-board electrical system and/or lithium-ion battery and/or gaseous-fuel drive system as well as personal protective equipment If the charge level of the high-voltage battery is below 50 %, Charge high-voltage battery completely. 3 Apply preservation agent to brake disks. AP42.10-P-4258-03A Zinc dust paint spray can *BR00.45-Z-1055-07A 4 Correct tire inflation pressure. Model 117, 118, 156, 166, 167, 172, 176, 177, 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 451, 453, 461, 463 Model 117, 118, 156, 166, 167, 172, 176, 177, AP40.15-P-4061A 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293 Model 463 as of model year 2019 Model 451 AP40.15-P-4061MCC Model 453 AP40.15-P-4061C Model 461 AP40.15-P-4060G Model 463 up to model year 2019 5 Fill the vehicle with fuel. In order to prevent corrosion.

6 Secure vehicle.

Secure vehicle by engaging a gear or the park pawl and using chocks. Otherwise damage may occur. 7 Release parking brake. 8 Check paintwork; apply gloss preserver if Model 117, 118, 156, 166, 167, 172, 176, 177, necessary. 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 451, 453, 461, 463 Topical note Notes on paintwork, decorative and Model 117, 118, 156, 166, 167, 172, 176, 177, AH98.00-P-9019-01Z detachable components 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 461, 463 Model 117, 118, 156, 166, 167, 172, 176, 177, AP98.00-P-0641A 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 461, 463With high-gloss varnish paintwork Model 451 AP98.00-P-0641SM Repair materials Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap00.70-p-1000zz, Safety precautions for new vehicles that are being put in storage Model 117, 118, 156, 166, 167, 172, 176, 177, 190, 197.3/4, 204, 205, 207, 212, 213, 216, 217, 218, 221, 222, 223, 231, 238, 242, 246, 247, 253, 257, 290, 292, 293, 451, 453, 461, 463

AR01.00-P-1201SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 560 · Applies to: 453 · AR: AR01.00-P-1201SR, AR15.12-P-1010SR, AR01.00-P-1300SR

Check compression pressure 19.08.2014 ENGINE 281 1 Compression recorder 2 Connector P01.00-3531-06 Risk of accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. Remove

1 Warm up engine to normal operating Only check when engine is at normal

temperature and then switch off the ignition operating temperature. 2 Remove spark plugs AR15.12-P-1010SR Check

3 Actuate the starter and allow the engine to turn for about 3 s 4 Insert compression recorder (1) with *001589762100 Compression tester appropriate connector (2) into spark plug bore 5 Actuate starter and crank engine until no Helper required.

further pressure rise is monitored on compression recorder (1). 6 Carry out test procedure at remaining Repeat operation steps 4 and 5.

cylinders in the same way 7 Compare measurements for the individual For deviation of a cylinder to the remaining cylinders with each other cylinders: Check cylinder leakage of the respective cylinder. AR01.00-P-1300SR Install

8 Install spark plugs AR15.12-P-1010SR 9 Read out fault memory; clear if necessary AD00.00-P-2000-06SR

001 589 76 21 00 Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar01.00-p-1201sr, Check compression pressure ENGINE 281

AR01.00-P-1300SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 562 · Applies to: 453 · AR: AR01.00-P-1300SR

Check cylinders for leaks 02.05.2019 Engine 281 in model 453 Modification notes 25.04.2019 Remove/install cover above poly-V-belt, added. Step 9 Shown with CODE I01 (AAC) 7 Cover 8 Bolts P13.22-A005-06 1 Crankshaft belt pulley 2 Center bolt P01.00-3533-06 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.00-p-1300sr, Check cylinders for leaks Engine 281 in model 453

P01.00-3532-09

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 563 · Applies to: 453 · AR: AR15.12-P-1010SR

3 Adapter 5 Pressure loss tester 6 Filler neck cap 4 Dead center locator 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 accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. Check

1 Warm up engine to normal operating Only check cylinder leakage when the

temperature and switch it off.
engine is at normal operating temperature. 2 Remove maintenance flap.
Risk of injury Do not open cooling system unless coolant Warning to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. 3 Turn cap on cooling system expansion reservoir counterclockwise by half a revolution, relieve overpressure, then unscrew cap.
4 Remove spark plugs. AR15.12-P-1010SR 5 Unscrew filler neck cap (6). 6 Screw adapter (3) into spark plug bore of 451589009100 Adapter cylinder to be checked. 7 Attach dead center locator (4) to adapter (3). 450589172100 Pressure loss tester 8 Lift vehicle with lifting platform. 9 Unscrew screws (8) and remove cover (7). 10 Turn engine in direction of engine rotation at Turn engine until the ball in the inspection

the center bolt (2) of the crankshaft belt pulley glass on the top dead center locator (4) falls (1) and use top dead center locator (4) to set suddenly. piston on cylinder to be checked to top dead center. 11 Lower vehicle with vehicle lift. 12 Apply parking brake. 13.1 Engage gear. Engine 281 in model 453 with transmission 700.12 13.2 Bring transmission into park position. Engine 281 in model 453 with transmission 700.41 Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.00-p-1300sr, Check cylinders for leaks Engine 281 in model 453

Disconnect top dead center locator (4) from

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 564 · Applies to: 453 · AR: AR15.12-P-1010SR

14 Disconnect top dead center locator (4) from adapter (3). 15 Connect compressed-air hose to pressure loss Use a calibrated

pressure loss tester tester (5). (5). 450589172100 Pressure loss tester 16 Connect pressure loss tester (5) to adapter (3). 17 Apply compressed air to the cylinder to be checked and read off pressure loss at pressure loss tester (5). Determine loss of pressure at cylinder AH01.00-N-1300-02A Cylinder leakage: permissible loss total BE01.00-P-1001-02Z indication Cylinder leaktightness: Permissible losses at BE01.00-P-1002-02Z valves and cylinder head gasket Cylinder leaktightness: Permissible losses at BE01.00-P-1003-02Z pistons and piston rings If increased pressure loss is detected: Determine cause. 18 Put transmission into neutral position. 19 Release parking brake. 20 Check other cylinders in the same way. If required. 21 Disconnect pressure loss tester (5) from adapter (3). 22 Remove adapter (3) from the spark plug bore of the most recently checked cylinder. 23 Lift vehicle with lifting platform. 24 Install cover (7) with screws (8). 25 Lower vehicle with vehicle lift. 26 Install filler neck cap (6). 27 Install spark plugs. AR15.12-P-1010SR 28 Install cap on cooling system expansion reservoir. 29 Install maintenance flap. Cylinder leakage Number Designation Engine all (4xWD, CAR, smart) 25 BE01.00-P-1001-02Z Cylinder leakage: permissible loss total indication % Cylinder leakage Number Designation Engine all (4xWD, CAR, smart) 10 BE01.00-P-1002-02Z Cylinder leaktightness: Permissible losses at valves and cylinder head % gasket Cylinder leakage Number Designation Engine all (4xWD, CAR, smart) 20 BE01.00-P-1003-02Z Cylinder leaktightness: Permissible losses at pistons and piston rings % 450 589 17 21 00 451 589 00 91 00 Pressure loss tester Adapter Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.00-p-1300sr, Check cylinders for leaks Engine 281 in model 453

AR01.00-P-0200SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 567 · Applies to: 453 · AR: AR01.00-P-0200SR, AR15.12-P-1010SR

Inspect cylinders with a light probe 24.03.2020 Engine 281 in model 453 Shown with CODE I01 (AAC) 7 Cover 8 Bolts P13.22-A005-06 Remove/install

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

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. 1 Lift vehicle using the vehicle lift until the rear wheels can be turned freely. 2 Remove spark plugs. AR15.12-P-1010SR 3 Remove screws (8) and remove cover (7). 4 Feed a suitable hose through the spark plug Installation: Lead the led in hose by hand

threaded hole into the cylinder to be checked and in doing so feel the state of the piston in and turn engine in the direction of engine the cylinder. rotation at the center bolt of the crankshaft belt pulley until the piston stands at the bottom dead center of the cylinder. 5 Connect endoscope to inspection light and feed endoscope through the spark plug threaded bore into cylinder to be checked. 000 588 01 21 00 Endoscope WS01.00-P-0097B

Check

6 Check cylinder barrel, piston crown, and valves. General information on checking valves, valve AH05.30-P-1000-02SZ seats and valve guides General information on inspecting cylinder AH01.00-P-0300-01A walls 7 Check other cylinders in the same way. 8 Install in the reverse order. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.00-p-0200sr, Inspect cylinders with a light probe Engine 281 in model 453

AR01.00-P-0200FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 568 · Applies to: 453 · AR: AR01.00-P-0200FF, AP15.10-P-1580FF, AP15.10-P-1580FB, AR01.30-P-5800FB, AR01.30-P-5800FF

Inspecting cylinders with a light probe 16.10.03 ENGINES 122.9, 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Cylinder inspection equipment

2 Flexible inspection light

P01.00-2423-05 Removing/installing

1 Remove spark plugs Replace spark plugs Engines 134.9, 135.9 AP15.10-P-1580FF

Engine 122.9 AP15.10-P-1580FB 2 Withdraw ignition key The possibility of inadvertant operation of

the starter is excluded. 3 Position piston of first cylinder to be inspected Turn the engine using a suitable tool at at bottom dead center the belt pulley on the crankshaft if necessary. 4 Connect up cylinder inspection equipment (1) The specified flexible inspection lights (2) and lead flexibles inspection light (2) into the can be used as desired. spark plug bore WH58.30-Z-1006-05A WH58.30-Z-1007-05A *WH58.30-Z-1014-05A Checking

5 Inspect cylinder walls Normal condition: matt gray surface, with honing pattern. In cases of doubt: Remove cylinder head Engine 122.9 AR01.30-P-5800FB Engines 134.910, 135.9 AR01.30-P-5800FF General information on inspecting cylinder AH01.00-P-0300-01A

walls 6 Check all other cylinders in the same way Continue to turn the engine using a suitable tool at the belt pulley on the crankshaft until the piston on the cylinder to be tested is at bottom dead center. 7 Install in reverse order Commercially available tools Number Designation WH58.30-Z-1006-05A Flexible endoscope, package contents 1 (complete unit), Firma Richard Wolf GmbH D-75438 Knittlingen Firma Karl Storz GmbH D-78532 Tuttlingen WH58.30-Z-1007-05A Flexible endoscope package contents 2 (for workshops which already have an approved endoscope from the Wolf or Storz company), Firma Richard Wolf GmbH D-75438 Knittlingen Firma Karl Storz GmbH D-78532 Tuttlingen WH58.30-Z-1014-05A Cylinder inspection equipment Page 1 of 1 © Mercedes-Benz AG, 5/20/18, L/07/20, ar01.00-p-0200ff, Inspecting cylinders with a light probe ENGINES 122.9, 134.9, 135.9 in MODEL 454.0

AR01.00-P-0200FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 569 · Applies to: 453 · AR: AR01.00-P-0200FG, AR07.16-P-1000FF, AR01.30-P-5800FG

Inspecting cylinders with light probe 21.11.05 ENGINE 639.9 in MODEL 454.0 1 Flexible inspection light

2 Cylinder inspection equipment

P01.00-2782-06 Remove/install

1 Withdraw ignition key The starter will not get operated

accidentally. 2 Remove fuel injectors AR07.16-P-1000FF 3 Position piston of the first cylinder to be If required, rotate engine at the belt pulley inspected to the bottom dead center of the crankshaft. *454589110900

4 Connect cylinder illumination unit (2) and The specified flexible endoscopes (1) can insert flexible endoscope (1) into the be used alternatively. corresponding injector bore (arrows) WH58.30-Z-1006-05A Flexible inspection light WH58.30-Z-1007-05A Flexible inspection light *WH58.30-Z-1014-05A Cylinder inspection light Checking

5 Inspect cylinder walls Normal state: Matt gray surface with honing pattern. In cases of doubt: Remove cylinder head AR01.30-P-5800FG General information on inspecting cylinder AH01.00-P-0300-01A

walls 6 Inspect all remaining cylinders in the same Continue turning the engine at the belt way pulley of the crankshaft adequately until the piston of the cylinder to be inspected is at the bottom dead center. *454589110900

7 Install in the reverse order 454 589 11 09 00 Wrench socket Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.00-p-0200fg, Inspecting cylinders with light probe ENGINE 639.9 in MODEL 454.0

AR01.00-P-3050SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 571 · Applies to: 453 · AR: AR01.00-P-3050SR

Release and position rear drive module 30.4.15 Engine 281 in model 453 P01.00-3539-09 Shown on engine 281.920 with transmission 700.12 1 Rear muffler 4 Bracket 9 Vacuum line 2 Elastomer bearing 7 Hydraulic line (with transmission 10 Screw 700.12) 3 Ground cable 8 Bracket 11 Positive line P01.00-3538-09 Shown on engine 281.910 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.00-p-3050sr, Release and position rear drive module Engine 281 in model 453

Coolant hoses

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 572 · Applies to: 453 · AR: AR00.60-P-0100SR, AR35.15-P-0250SR, AR35.15-P-0204SR, AR22.10-P-4330SR, AR26.60-P-6626SR (+1 more)

5 Coolant hoses 14 Air intake hose 22 Engine mount 6 Bracket 15 Electrical line Y58 Fuel tank vent valve 12 Fuel line 16 Nut 13 Cable tie 17 Engine mount P01.00-3540-07 Shown on engine 281.920 18 Flange 20 Piston 19 Nut 21 Knurled knob 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. Lower, position 1 Remove covering over engine 2 Secure vehicle on vehicle lift AR00.60-P-0100SR 3 Remove underfloor paneling 4 Remove rear axle crossmember AR35.15-P-0250SR 5 Remove control arm AR35.15-P-0204SR 6 Remove front engine mount on transmission AR22.10-P-4330SR housing, unfasten of the body side and swivel downwards 7 Unhook rear muffler (1) from the right elastomer bearing (2) 8 Remove bracket (4) with ground line (3) 9 Unclip coolant hoses (5) from bracket (6) 10 Unclip hydraulic line (7) for clutch operation Engine 281 in model 453 with transmission from bracket (8) and unfasten from the body 700.12 11 Unclip vacuum lines (9) from the brackets on the body 12 Remove screw/bolt (10) and detach positive line (11) from the body 13 Unclip fuel line (12) from the brackets on the body 14 Remove cable tie (13) from engine wiring harness 15 Remove air intake hose (14) 16.1 Remove shift cables from transmission Engine 281 in model 453 with transmission 700.12 AR26.60-P-6626SR 16.2 Remove cable for selector lever lock from Engine 281 in model 453 with transmission transmission 700.41 AR27.60-P-0002SR 17 Unhook fuel tank bleed valve (Y58) at the body 18 Unclip electrical line (15) for fuel tank bleed valve (Y58) on air filter housing 19 Unfasten nuts (16) for engine mount (17, 22)

Do not unscrew nuts (16) for engine mount (17, 22) completely. The engine may fall down otherwise. *BA22.10-P-1004-01H Nut, engine mount to bearing pin 20 Attach engine support fixture AR01.10-P-2400-06SR 000 588 03 62 00 Lifting platform WS01.00-P-0091A

Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.00-p-3050sr, Release and position rear drive module Engine 281 in model 453

Adaptation

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 573 · Applies to: 453 · AR: AR22.10-P-1101SR, AR22.10-P-1102SR

453589016200 Adaptation 21 Remove engine mounts (17) AR22.10-P-1101SR 22 Remove engine mounts (22) AR22.10-P-1102SR 23 Place flange (18) for drainage pin on the 453589006200 Lowering bolts threaded pins of the engine mount flange and tighten nuts (19) finger-tight 24 Screw piston (20) of the drainage pin onto the engine support bearing pin 25 Tighten piston (20) of the drainage pin at the knurled knob (21) finger-tight 26 Raise vehicle with the vehicle lift in stages

until the piston (20) of the drainage pin has When lifting onto hose, watch out for lines and moved completely into the flange (18) and the detachable parts. engine hangs free They can be damaged otherwise. Helper required.

27 Remove engine support fixture AR01.10-P-2400-06SR 000 588 03 62 00 Lifting platform WS01.00-P-0091A

*453589016200 Adaptation 28 Position in reverse order Engine mounts, engine supports Number Designation Engine 281 in model 453 BA22.10-P-1004-01H Nut, engine mount to bearing pin Nm 62 453 589 00 62 00 453 589 01 62 00 Lowering bolts Adaptation Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.00-p-3050sr, Release and position rear drive module Engine 281 in model 453

AR01.00-P-2411FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 574 · Applies to: 453 · AR: AR01.00-P-2411FG, AR83.25-P-1402FF, AR54.00-P-0002FF, AR07.08-P-7006FF, AR07.09-P-0001FF (+1 more)

Removing/installing the engine wiring harness 30.11.04 ENGINE 639.939 in MODEL 454.0 P01.00-2670-08 Shown on transmission 717.475 1 Engine wiring harness Removing/installing

Risk of death caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A Danger! toppling off the lifting platform. hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. 1 Remove water collector AR83.25-P-1402FF 2 Remove battery tray AR54.00-P-0002FF 3 Remove control unit for Electronic Diesel AR07.08-P-7006FF System (EDS) 4 Remove vacuum reservoir AR07.09-P-0001FF Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by ignition of AS47.00-Z-0001-01A flammable products, risk of poisoning Only pour fuels into suitable and appropriately

caused by inhaling fuel vapors or swallowing marked containers. fuel as well as risk of injury to skin and eyes Wear protective clothing when handling fuel. exposed to fuel. 5 Disconnect engine wiring harness (1) AR01.00-P-2410-02FH 6 Remove engine support on the right AR22.10-P-4340FG 7 Remove engine wiring harness (1) 8 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.00-p-2411fg, Removing/installing the engine wiring harness ENGINE 639.939 in MODEL 454.0

AN01.00-P-0006FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 575 · Applies to: 453 · AR: AN01.00-P-0006FF, AR05.30-P-3030FF

Retrofit performance kit BRABUS 24.2.04 ENGINE 135.950 in MODEL 454.0 except CODE (E50) Trailer hitch with CODE (F04) Sport exhaust system, Brabus (DFO) 1 Sticker 2 Engine cover 3 Sticker 4 Sticker 5 Bracket N3/10 Motor electronics control unit P01.00-2653-06 Removing/installing

Retrofitting of this performance kit causes the

engine output to increase from 80 kW (109 HP) to 90 kW (122 HP) 1 Replace camshafts and valve springs Installation:

The camshafts and valve spring from the parts kit hardware performance kit SB3 must be used. Removing/installing valve springs (cylinder AR05.30-P-3030FF

head installed) 2 Install in reverse order 3 Glue sticker (1) onto the engine cover (2) The surface to be glued must cleaned and free of grease. 4 Glue sticker (3) onto the motor electronics The surface to be glued must cleaned and control unit (N3/10) free of grease. 5 Glue sticker (4) onto the bracket (5) for the The surface to be glued must cleaned and motor electronics control unit (N3/10) free of grease. 6 Program the BRABUS software (SB3) Programming of the software (SB3) is only possible after releasing using a TAN (transaction number). The order form for releasing is obtainable from the Market Performance Center. Connect up STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A 7 Put the expert's report in the vehicle Receive the expert's report in the package contents or print out expert's report new. 8.1 Enter special equipment in the vehicle data Only for workshops with a dealer system DMS card and in the vehicle's online data card Autoline 8.0 Code (13Z) performance kit 3 Brabus. 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, 5/20/18, L/07/20, an01.00-p-0006ff, Retrofit performance kit BRABUS ENGINE 135.950 in MODEL 454.0 except CODE (E50) Trailer hitch with CODE (F04) Sport exhaust system, Brabus (DFO)

BE01.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 577 · Applies to: 453 · AR: BE01.00-Z-9999CZ

Test and adjustment values: Smart: Complete engine, crankcase ventilation, 18.09.2019 cylinder head , crankcase MODEL all Compression pressure Engine 122, 132.910/930, 134, 135.930/950, BE01.00-P-1000-01G 281, 639, 660.940/950/951 Compression pressure ENGINE 160.910/920/921/922 BE01.00-P-1000-01H Cylinder leaktightness ENGINE all, 000, 102, 104, 112, 115, 161, BE01.00-P-1000-02Z 166, 200, 271, 272, 274, 602, 607, 608, 611, 612, 615, 616, 617, 622, 632, 642, 646, 647, 651, 654, 661, 662, 668, 699 ... Check values for cylinder head ENGINE 122, 132, 134, 135, 281, 639 ... BE01.30-P-1000-02F Cylinder head/cylinder head bolts ENGINE 122.950, 134.910/911, 135.930/950, BE01.30-P-1000-04F 639.939 in MODEL 454.0 Test specifications for cylinder bore ENGINE 122, 134, 135, 160, 639 ... BE01.40-P-1000-01L Test specifications for cylinder bore ENGINE 132.9 in MODEL 451.3/4 ENGINE BE01.40-P-1000-01P 281 Inspection data of crankcase ENGINE 122, 132, 134, 135, 281, 639 ... BE01.40-P-1000-02I Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be01.00-z-9999cz, Test and adjustment values: Smart: Complete engine, crankcase ventilation, cylinder head , crankcase MODEL all

AR01.00-P-1200FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 578 · Applies to: 453 · AR: AR01.00-P-1200FF, AP15.10-P-1580FF, AP15.10-P-1580FB

Testing compression pressure 21.11.05 ENGINE 122.9, 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Connectors of fuel injection valves 2 Compression tester set

P01.00-2481-06 Only vehicles with engine 122 X47 Camshaft rpm sensor connector P01.00-2788-04 Remove/install

Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 1 Warm up engine to operating temperature of Test compression pressure only when approximately 80 °C engine is at normal operating temperature. 2 Remove spark plugs Replace spark plugs Model 454.0 with engine 134.9, 135.9 AP15.10-P-1580FF

Model 454.0 with engine 122.9 AP15.10-P-1580FB 3.1 Detach connectors of fuel injection valves (1) Model 454.0 with engine 134.9, 135.9 3.2 Disconnect camshaft rpm sensor connector Model 454.0 with engine 122.9 (X47) 4 Crank engine with starter Crank engine several times to eliminate combustion residues in the cylinder. Checking 5 Insert compression tester set (2) into the Repeat test at all cylinders. spark plug bore of the first cylinder, crank Press the accelerator pedal. To check the engine with starter and read off measured compression pressure, crank the engine by at value least eight revolutions. *450589052100

6 Compare all measured values with the Compression pressure new value BE01.00-P-1001-01G permissible values Compression pressure wear limit or limit value BE01.00-P-1002-01G Compression pressure permissible difference *BE01.00-P-1003-01G between individual cylinders Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.00-p-1200ff, Testing compression pressure ENGINE 122.9, 134.9, 135.9 in MODEL 454.0

If the values are below the limits for wear

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 579 · Applies to: 453 · AR: AR01.00-P-1300FF

or if the permissible difference between individual cylinders is exceeded, carry out the pressure loss test. Refer to: Inspect cylinders for leaks AR01.00-P-1300FF 7 Install in the reverse order 8 Read fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Test data of compression pressure Number Designation Engine Engine Engine Engine 122 134 135.930 135.950 BE01.00-P-1001-01G Compression pressure new value bar 12.1 13.2 14,3 15.5 8,3 9 10 11 BE01.00-P-1002-01G Compression pressure wear limit or limit value bar 0,98 0,98 0,98 0,98 BE01.00-P-1003-01G Compression pressure permissible difference between bar individual cylinders 450 589 05 21 00 Compression tester set Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.00-p-1200ff, Testing compression pressure ENGINE 122.9, 134.9, 135.9 in MODEL 454.0

AR01.10-P-2401FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 581 · Applies to: 453 · AR: AR01.10-P-2401FF, AR88.40-P-3000FF, AR88.00-P-2792FF, AR54.00-P-0002FF, AR43.10-P-0355FF (+2 more)

Remove, install engine with transmission 11.5.06 ENGINE 134.9, 135.9 in MODEL 454.0 P01.10-2522-09 Shown on engine 135.9 with transmission 717.471 1 Transmission 5 Fuel pipe 9 Bolt 2 Shift cables (for transmission 6 Fuel distributor 10 Nuts 717.470/471) 7 Brake booster vacuum line 11 Coolant hoses 3 Line 8 Transmission mount 12 Coolant hose 4 Clamp 13 Coolant hose Remove/install

1 Remove engine hood AR88.40-P-3000FF 2 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 3 Remove battery tray AR54.00-P-0002FF 4.1 Pry ball heads for shift cables (2) off Only with transmission 717.470/471 transmission (1) and loosen shift cables (2) out of the brackets on transmission (1) 5 Remove lead (3) Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by fuel igniting, AS47.00-Z-0001-01A risk of poisoning Only pour fuels into suitable and appropriately caused by inhaling and swallowing fuel and risk of injury marked containers. to eyes and skin caused by contact with fuel. Wear protective clothing when handling fuel. 6 Spread clamp (4), pull fuel line (5) off fuel Catch fuel running out with suitable distributor (6) and seal openings using vessel. suitable plugs 7 Remove vacuum line for brake booster (7) Do not pull vacuum line of brake booster (7) out of brake booster. Vehicles with code (LHD) Left-hand drive AR43.10-P-0355FF vehicle Vehicles with code (RHS) Right-hand drive AR43.10-P-0355FI vehicle Risk of injury to skin and eyes caused by Do not open cooling system unless coolant AS20.00-Z-0001-01A Danger!

scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. 8 Turn cooling system cap on radiator counterclockwise through half a revolution, release overpressure, then unscrew cap on cooling system expansion reservoir. 9.1 Detach electrical wiring harness on shift Only for transmission 717.474 AR26.60-P-0040-01FF actuator 10.1 Remove poly-V-belt Only for vehicles with code (I01) Air AR13.22-P-1202FF conditioning Plus or code (I77) Manual AC Page 1 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.10-p-2401ff, Remove, install engine with transmission ENGINE 134.9, 135.9 in MODEL 454.0

AR01.10-P-2401FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 585 · Applies to: 453 · AR: AR01.10-P-2401FG

Remove, install engine with transmission 20.3.06 ENGINE 639.9 in MODEL 454.0 P01.10-2626-09 Shown on transmission 717.475 1 Coolant hose 7 Charge air hose 12 Bracket 2 Hose clamp 8 Coolant hose 13 Vacuum line 3 Coolant hose 9 Coolant hose 14 Coolant hose 4 Hose clamp 10 Expansion reservoir 15 Coolant pipe 5 Charge air hose 11 Brake booster vacuum line 16 Bolts 6 Hose clamp P01.10-2625-07 Shown on transmission 717.475 17 Nuts 20 Bolt 23 Engine 18 Nut 21 Nuts 24 Transmission mount 19 Engine support 22 Transmission Page 1 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.10-p-2401fg, Remove, install engine with transmission ENGINE 639.9 in MODEL 454.0

AR01.10-P-2401SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 589 · Applies to: 453 · AR: AR01.10-P-2401SR

Remove/install engine with transmission 14.03.2018 Engine 281 in model 453 Modification notes 12.07.2017 Operation steps revised. Operation step 1 to operation step 77. P01.10-3243-09 Shown on ENGINE 281.920 1 Engine wiring harness 6 Vacuum lines 10 Nuts 2 Fuel line 7 Intake manifold 19 Cable tie 3 Fuel distributor 8 Electrical line 4 Air intake hose 9 Air cleaner housing P01.10-3245-08 Shown on engine 281.910 with transmission 700.41 Page 1 of 6 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.10-p-2401sr, Remove/install engine with transmission Engine 281 in model 453

Install front engine mount (12) and tighten

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 593 · Applies to: 453 · AR: AR22.10-P-4330SR, AR25.20-P-1000SR, AR26.60-P-6626SR, AR27.60-P-0002SR, AR13.22-P-1202SR (+5 more)

49 Install front engine mount (12) and tighten AR22.10-P-4330SR associated screws 50 Attach ground line (11) to the transmission BA27.10-P-1001-06A Engine 281 in model 453 with housing transmission 700.41Bolt, ground line to transmission BA26.00-P-1009-01A Engine 281 in model 453 with transmission 700.12Bolt, ground line to transmission 51 Install hydraulic line at clutch slave cylinder Engine 281 in model 453 with transmission and bleed clutch operation 700.12 AR25.20-P-1000SR 52.1 Attach shift cables to the transmission Engine 281 in model 453 with transmission 700.12 AR26.60-P-6626SR 52.2 Attach cable for selector lever lock to the Engine 281 in model 453 with transmission transmission 700.41 AR27.60-P-0002SR 53 Clip in electric line (8) at air filter housing (9) and connect at bleed valve of fuel tank 54.1 Attach vacuum lines (6) to intake manifold (7) Engine 281.920 in model 453 54.2 Attach vacuum lines (6) to charge air pipe Engine 281.910 in model 453 55 Attach coolant hoses (25) Engine 281.910 in model 453 Replace clamps.

*003589033700 Hose clamp pliers 56 Install coolant hoses (5) Replace clamps.

003589033700 Hose clamp pliers 57 Remove protective covers and install air intake 001589039100 Set of protective covers hose (4) 58 Remove stop plugs and install fuel line (2) at *129589009100 Record plug fuel distributor (3) 59 Install poly-V belt AR13.22-P-1202SR 60 Install rear axle shafts (18) Engine 281 in model 453 Engine 281 in model 453 with transmission AR35.30-P-0620SR 700.12 Engine 281 in model 453 with transmission AR35.30-P-0620SRA 700.41 61 Install control arms AR35.15-P-0204SR 62 Install rear axle crossmember AR35.15-P-0250SR 63 Install rear muffler (17) AR49.10-P-4823SR 64 Clip engine wiring harness (1) into body and guide to installation location of ME-SFI [ME] control unit (N3/10) 65 Install cable tie (19) at engine wiring harness Install cable tie (19).

(1) 66 Connect all electrical connectors at ME-SFI AR07.08-P-7008SR [ME] control unit (N3/10) 67 Install ground line (24) and tighten nut (23) Engine 281 in model 453 with transmission 700.41 BA54.10-P-1004-01I Nut, battery ground line to body 68 Install ground line (22) and tighten nut (21) BA54.10-P-1004-01I Nut, battery ground line to body 69 Connect electrical connection (20) 70 Install charge current line AR15.18-P-0001-01SR 71 Install fuel tank AR47.10-P-4100SR 72 Fill coolant and bleed cooling system AR20.00-P-1142SR Only install covering over engine after the

leak test. 73 Lower vehicle using vehicle lift and remove AR00.60-P-0100SR vehicle lift safety device 74 Install fan unit AR20.40-P-5614SR Only install covering over engine after the

leak test. 75 Connect ground lead to battery AR54.10-P-0003SR Check

Risk of burn injuries, suffocation and Wear protective clothing and safety glasses. AS49.00-Z-0001-01A Warning

poisoning when working on the exhaust Use the extraction system. Move people out of system and the components connected to it. the hazard area. Risk of suffocation and risk of poisoning caused by inhalation of gaseous and solid components of the exhaust. Risk of poisoning caused by skin contact with solid components of the exhaust. Page 5 of 6 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.10-p-2401sr, Remove/install engine with transmission Engine 281 in model 453

AR01.10-P-4200SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 595 · Applies to: 453 · AR: AR01.10-P-4200SR, AR15.40-P-5032SR, AR13.25-P-3200SR, AR13.21-P-3350SR

Removing and installing generator bracket 21.07.2014 ENGINE 281 in MODEL 453 P01.10-3242-09 1 Alternator carrier 3 Guide pulley G2 Alternator 2 Screw/bolt 4 Tensioning device Remove

1 Remove alternator (G2) AR15.40-P-5032SR 2 Remove tensioning device (4) AR13.25-P-3200SR 3 Remove guide pulley (3) from alternator carrier When replacing the alternator carrier (1). (1) AR13.21-P-3350SR 4 Remove screw/bolts (2) and remove the Pay attention to different screw/bolt

alternator carrier (1) from cylinder head lengths (2). Install

5 Lay alternator carrier (1) on the cylinder head Pay attention to different screw/bolt

and in the screw/bolts (2) up to the end stop lengths (2). 6 Fully tighten screw/bolts (2) 7 Attach guide pulley (3) at the alternator carrier When replacing the alternator carrier (1). (1) AR13.21-P-3350SR 8 Install clamping device (4) AR13.25-P-3200SR 9 Install alternator (G2) AR15.40-P-5032SR Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.10-p-4200sr, Removing and installing generator bracket ENGINE 281 in MODEL 453

AR01.20-P-5014FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 601 · Applies to: 453 · AR: AR01.20-P-5014FG, AR01.20-P-9750FF, AR07.03-P-1010FG, AR07.16-P-1000FF

Remove, install cylinder head cover 7.1.09 ENGINE 639.9 in MODEL 454.0 4 Bracket (with Code (K13) Diesel particulate filter) B19/9x1 Temperature sensor connector upstream diesel particulate filter (with Code (K13) Diesel particulate filter) B19/11x1 Temperature sensor connector upstream turbocharger (with Code (K13) Diesel particulate filter) P01.20-2208-04 P01.20-2119-07 1 Bracket 2 Hose 3 Cylinder head cover Remove/install

1.1 Loosen wiring harnesses from bracket (4) On vehicles with Code (K13) Diesel particulate filter 2.1 Disconnect temperature sensor connector On vehicles with Code (K13) Diesel upstream diesel particulate filter (B19/9x1) particulate filter and temperature sensor connector upstream turbocharger (B19/11x1) and place wiring harnesses to one side 3 Remove oil separator AR01.20-P-9750FF 4 Remove rail AR07.03-P-1010FG 5 Remove injectors AR07.16-P-1000FF 6 Detach bracket (1) at cylinder head cover (3) 7 Detach hose (2) at cylinder head cover (3) 8 Remove bolts on cylinder head cover (3) The bolts in the cylinder head cover (3) are of varying lengths. AR01.20-P-5014-03FG Installation: Observe tightening pattern of

cylinder head cover (3). *BA01.20-P-1001-01O

*BA01.20-P-1002-01O

9 Remove cylinder head cover (3) Installation:

Clean sealing surfaces and install new seals. 10 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 11 Conduct engine test run and check engine for leaks in the area of the cylinder head cover (3) Crankcase ventilation, cylinder head cover Number Designation Engine 639.939 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.20-p-5014fg, Remove, install cylinder head cover ENGINE 639.9 in MODEL 454.0

AR01.20-P-5014FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 603 · Applies to: 453 · AR: AR01.20-P-5014FF, AR15.12-P-2003FF

Remove/install cylinder head cover 10.12.03 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Cylinder head cover 2 Wiring harness 3 Tubing 4 Bolt 5 Tubing P01.20-2080-06 Remove/Install

1 Remove ignition coils AR15.12-P-2003FF 2 Detach wiring harness (2) from cylinder head cover (1) 3 Remove hoses (3, 5) from the cylinder head cover (1) 4 Remove bolts (4) The cylinder head cover (1) is secured with 10 bolts (4). AR01.20-P-5014-03FF Installation: Pay attention to tightening

diagram of cylinder head cover (1). *BA01.20-P-1001-01K

5 Remove cylinder head cover (1) Inspect condition of rubber profile gasket of cylinder head cover (1), replace if necessary. Installation: Clean the sealing surfaces. 6 Install in the reverse order Cylinder head cover

Number Designation Engine Engine 134.910 134.911 BA01.20-P-1001-01K Bolt of cylinder head cover to cylinder head Nm 8 8 Cylinder head cover

Number Designation Engine Engine 135.930 135.950 BA01.20-P-1001-01K Bolt of cylinder head cover to cylinder head Nm 8 8 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.20-p-5014ff, Remove/install cylinder head cover ENGINE 134.9, 135.9 in MODEL 454.0

AR01.20-P-5014SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 604 · Applies to: 453 · AR: AR01.20-P-5014SR

Remove/install cylinder head cover 20.08.2019 Engine 281 in model 453 Modification notes 20.08.2019 Note added. Operation step 14 P01.20-2366-09 Shown on ENGINE 281.920 1 Cylinder head cover 7 Bolts T1/1 Cylinder 1 ignition coil 3 Hose 8 Heat shield T1/2 Cylinder 2 ignition coil 5 Vent housing 9 Heat shield T1/3 Cylinder 3 ignition coil 6 Vent hose 13 Engine wiring harness Shown on ENGINE 281.920 1 Cylinder head cover 2 Bolts 4 Bolts 5 Vent housing 10 Catalytic converter 11 Bracket 12 Bracket (with engine 281.920) P01.20-2367-06 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.20-p-5014sr, Remove/install cylinder head cover Engine 281 in model 453

Remove/install

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 605 · Applies to: 453 · AR: AR15.12-P-2003SR, AR49.10-P-5500SRA, AR49.10-P-6905SR

1 Remove cover over engine. Installation: Only install covering over

engine after the leak test. 2 Remove hose (3). 3 Remove vent hose (6) from the vent housing (5). 4 Remove vent hose (6) from the working area and fix in place. 5 Unscrew screw/bolts (4). 6 Remove vent housing (5) upward. Installation: Replace seal.

7 Unscrew screws (7). 8 Remove ignition coil for cylinder 1 (T1/1), AR15.12-P-2003SR ignition coil for cylinder 2 (T1/2), and ignition coil for cylinder 3 (T1/3). 9 Disconnect engine wiring harness (13) in the AR01.00-P-2420-01SR area of the cylinder head cover (1) and remove from the working area. 10.1 Remove catalytic converter (10). Engine 281.910 in model 453 AR49.10-P-5500SRA 10.2 Remove heat shields (8, 9) from the catalytic Engine 281.920 in model 453 converter (10) and place to one side. AR49.10-P-6905SR 11 Remove bracket (11). 12 Remove bracket (12). Engine 281.920 in model 453 13 Unscrew bolts (2). Tightening procedure AR01.20-P-5014-03SR Installation: Observe tightening procedure

for cylinder head cover (1). *BA01.20-P-1002-01I Bolt, cylinder head cover to cylinder head 14 Release cylinder head cover (1) from the cylinder head and timing case cover and remove.
General information on checking camshafts AH05.20-P-1000-09SZ and bearing points of camshafts Notes on application of flange sealants to seal AH00.00-P-0500-01MNE major assemblies Installation: Replace seal on cylinder

head cover (1). Apply sealing compound in the area of the joint edge of the cylinder head and timing case cover. Sealing compound *BR00.45-Z-1053-01A Clean

15 Remove remaining sealing compound in the area of the joint edge of the cylinder head and timing case cover. 16 Install in the reverse order. Crankcase ventilation, cylinder head cover Number Designation Engine 281 BA01.20-P-1002-01I Bolt, cylinder head cover to cylinder head Nm 10 Repair materials Number Designation Order number BR00.45-Z-1053-01A Sealing compound Q0000282V000000000 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.20-p-5014sr, Remove/install cylinder head cover Engine 281 in model 453

AR01.20-P-5015FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 606 · Applies to: 453 · AR: AR01.20-P-5015FF

Remove/install cylinder head cover trim panel 18.5.04 ENGINE 639.939 in MODEL 454.0 1 Trim panel of cylinder head cover 2 Bolts P01.20-2118-04 Remove/Install

1 Open engine hood See Operating Instructions 2 Remove bolts (2) 3 Remove cylinder head cover trim panel (1) Installation:

Ensure that the cylinder head cover trim panel (1) is correctly seated. 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.20-p-5015ff, Remove/install cylinder head cover trim panel ENGINE 639.939 in MODEL 454.0

AR01.20-P-9750FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 607 · Applies to: 453 · AR: AR01.20-P-9750FF, AR01.20-P-5015FF, AR07.09-P-0001FF

Remove/install oil separator 10.5.04 ENGINE 639.939 in MODEL 454.0 1 Trim panel 2 Hose 3 Oil separator 4 Bolts 5 Cylinder head cover P01.20-2117-04 Remove/Install

1 Remove trim panel of cylinder head cover AR01.20-P-5015FF 2 Remove pressure reservoir AR07.09-P-0001FF 3 Loosen clamps (arrowed) and take off trim panel (1) 4 Detach hose (2) from oil separator (3) 5 Remove bolts (4) *BA01.20-P-1003-01O

6 Loosen oil separator (3) from cylinder head Installation:

Clean the sealing surfaces cover (5) and remove and install new gasket. 7 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off when engine is running. Risk of injury Wear closed and snug-fitting work clothes.

caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 8 Conduct an engine test run and check the oil separator (3) for leaks Crankcase ventilation, cylinder head cover Number Designation Engine 639.939 BA01.20-P-1003-01O Torx bolt of oil separator to cylinder head Nm 12 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.20-p-9750ff, Remove/install oil separator ENGINE 639.939 in MODEL 454.0

AR01.20-P-9750SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 608 · Applies to: 453 · AR: AR01.20-P-9750SR, AR20.00-P-1142SR, AR15.30-P-7100SR

Remove/install oil separator 21.07.2014 ENGINE 281.910 in MODEL 453 P01.20-2374-09 1 Oil separator 3 Vent hose 5 Screw/bolts 2 Coolant line 4 Charge air pipe M1 Starter Remove/install

1 Drain coolant AR20.00-P-1142SR 2 Remove starter (M1) AR15.30-P-7100SR 3 Remove coolant line (2) on crankcase and *BA20.10-P-1012-01J Bolt, coolant line to crankcase place to one side 4 Remove bleed hose (3) on charge air pipe (4) Installation: Replace seal.

5 Remove screw/bolts (5) 6 Take off oil separator (1) together with bleed Installation: Replace seal from oil

hose (3) from crankcase separator (1). 7 Install in the reverse order Coolant pump, coolant thermostat Number Designation ENGINE 281 BA20.10-P-1012-01J Bolt, coolant line to crankcase Nm 10 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.20-p-9750sr, Remove/install oil separator ENGINE 281.910 in MODEL 453

AR01.20-P-9691SB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 609 · Applies to: 453 · AR: AR01.20-P-9691SB

Remove/install oil separator on cylinder head cover 15.07.2016 Engine 281 in model 453 P01.20-2421-08 Shown on engine 281.910 1 Oil separator 4 Screw/bolts 2 Crankcase ventilation system 5 Electrical wiring harness 3 Screw/bolt Remove/install

1 Remove covering over engine Installation: Only install covering over

engine after the leak test. 2 Remove screw/bolt (3) Model 453.06/36/46 3 Unfasten hose for crankcase ventilation system (2) on oil separator (1) 4 Unclip electrical wiring harness (5) on oil separator (1) 5 Unscrew screw/bolts (4) 6 Remove oil separator (1) from cylinder head Installation: Replace seal from oil

cover separator (1). 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.20-p-9691sb, Remove/install oil separator on cylinder head cover Engine 281 in model 453

AR01.20-P-9765FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 610 · Applies to: 453 · AR: AR01.20-P-9765FG, AR07.09-P-0001FF, AP20.00-P-2010FG

Removing/installing the heating element for the crankcase ventilation system 7.10.04 ENGINE 639.939 in MODEL 454.0 P01.20-2138-07 1 Expansion reservoir 5 Intake air hose 8 Clip 3 Cover 6 Coolant hose 9 Oil separator 4 Heating element for the crankcase 7 Coolant hose ventilation system Removing/installing

Risk of injury to skin and eyes suffering Do not open cooling system unless coolant AS20.00-Z-0001-01A Danger!

scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage bottles. Wear protective gloves, protective clothing and eye protection. 1 Open engine hood 2 Unscrew screw cap on expansion reservoir Turn in an anti-clockwise direction, (1) release pressure, and then unscrew cooling system cap. 3 Remove vacuum reservoir AR07.09-P-0001FF 4 Loosen clamps (arrows) and remove cover (3) 5 Remove heating element for crankcase ventilation system (4) on intake air hose (5) 6 Clamp off coolant hose (6) using suitable hose clamp pliers 7 Remove clamps (8) and take coolant hoses Collect coolant which flows out in a (6, 7) off heating element for crankcase suitable vessel. ventilation system (4) Installation:

Replace clamps (8). 8 Remove heating element for crankcase ventilation system (4) on oil separator (9) 9 Install in reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 10 Conduct engine test run and check cooling Until the cooling fan is switched on. system in the area of the heating element of the crankcase ventilation system (4) for leaks 11 Check coolant level, adjust to correct level if necessary. Engine cooling system - inspect fluid level, AP20.00-P-2010FG

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.20-p-9765fg, Removing/installing the heating element for the crankcase ventilation system ENGINE 639.939 in MODEL 454.0

AR01.30-P-5800FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 611 · Applies to: 453 · AR: AR01.30-P-5800FF

Remove/install cylinder head 2.11.11 ENGINES 134.9, 135.9 in MODEL 454.0 Shown on engine 134.9 1 Cylinder head 2 Coolant hose 3 Coolant hose 4 Coolant pipe P01.30-2234-12 Shown on engine 134.9 14 Chain tensioner 15 Screw/bolt 16 Tensioning rail 17 Screw/bolt 18 Slide rail 19 Timing chain P05.10-2288-11 Page 1 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.30-p-5800ff, Remove/install cylinder head ENGINES 134.9, 135.9 in MODEL 454.0

Shown on engine 135.9

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 612 · Applies to: 453 · AR: AR01.10-P-2401FF, AR15.30-P-7100FG, AR05.20-P-6010FF, AR01.40-P-8000FF, AR05.20-P-6992FF (+2 more)

1 Cylinder head 5 Cylinder crankcase 6 Cylinder head gasket 7 Cylinder head bolt 8 Washer 9 Screw/bolt 10 Bracket 11 Intake manifold 12 Screw/bolt 13 Lifting eye P01.30-2227-06 Removing

1 Remove engine with transmission AR01.10-P-2401FF 2 Disconnect transmission from timing case See: Remove/install starter AR15.30-P-7100FG 3 Install removed engine on assembly stand AR01.10-P-2400-07FF *454589006200

*454589026200

Engine assembly stand Workshop crane/engine crane 4 Turn engine to ignition TDC for cylinder 1 See: Check basic position of camshafts AR05.20-P-6010FF 5 Remove timing case cover AR01.40-P-8000FF 6 Remove camshafts AR05.20-P-6992FF Also remove camshaft sprocket on exhaust camshaft. 7 Take off timing chain (19) 8 Remove valve tappet AR05.00-P-2310FF 9 Remove bolt (15) and tensioning rail (16) 10 Remove screw/bolt (17) and slide rail (18) 11 Remove coolant hoses (2, 3) from cylinder head (1) and from coolant pipe (4) 12 Unscrew bolt (9) from bracket (10) Bracket (10) remains on cylinder head (1). 13 Remove screw/bolt (12) and detach suspension eyelet (13) from cylinder head (1) 14 Remove adjustable camshaft timing solenoid AR05.20-P-7295FF 15 Gradually unscrew cylinder head bolts (7) and In order to avoid stresses in cylinder head remove with washers (8) (1) and loosen cylinder head bolts (7) in the reverse order of tightening instructions. See: Tightening specifications for cylinder head AR01.30-P-5800-07FF bolts 16 Remove cylinder head (1) from crankcase (5) 17 Take cylinder head gasket (6) off crankcase (5) Checking

18 Clean sealing surfaces on the cylinder head (1) and crankcase (5) and check for visible damage 19 Clean separating surface on cylinder head (1) AR01.30-P-5800-12FF An uneven sealing surface of cylinder and check for damage and flatness head (1) can lead to leaks in the area of cylinder head gasket (6). *BE01.30-P-1001-02F

Page 2 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.30-p-5800ff, Remove/install cylinder head ENGINES 134.9, 135.9 in MODEL 454.0

Clean separating surface on crankcase (5)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 613 · Applies to: 453 · AR: AR05.20-P-7295FF, AR05.00-P-2310FF, AR05.20-P-6992FF, AR05.20-P-6020FG, AR01.40-P-8000FF (+2 more)

20 Clean separating surface on crankcase (5) AR01.40-P-9133-01FF An uneven sealing surface of crankcase and check for damage and flatness (5) can lead to leaks in the area of cylinder head gasket (6). *BE01.40-P-1001-02I

21 Check cylinder head bolts (7) AR01.30-P-5800-03FF Replace overlong cylinder head bolts (7). *BE01.30-P-1001-04F Install

22 Check tapped holes for cylinder head bolts (7) in crankcase (5) for contamination; clean if necessary 23 Place cylinder head gasket (6) on crankcase Replace cylinder head gasket (6). (5) Pay attention to installation position of cylinder head gasket (6). Place cylinder head gasket (6) into the guide pins (arrows). 24 Place cylinder head (1) on crankcase (5) When replacing the cylinder head (1), the intake manifold (11) must be modified. When positioning the cylinder head (1), the guide pins (arrows) on crankcase (5) must engage with guide bores of the cylinder head (1). 25 Insert cylinder head bolts (7) with washers (8) AR01.30-P-5800-07FF Tighten cylinder head bolts (7) according into the cylinder head (1) and tighten in stagesto the sequence of the tightening instructions. *BA01.30-P-1001-01N

26 Install solenoid for camshaft control AR05.20-P-7295FF 27 Attach lifting eye (13) to cylinder head (1) and tighten screw/bolt (12) 28 Tighten bracket (10) with bolt (9) The bracket (10) must lie flat on crankcase (5) when screwing in bolt (9). If the bracket (10) is not flat on the crankcase (5), loosen bracket (10) and reposition. 29 Attach coolant hoses (2, 3) to cylinder head Make sure that coolant hoses (2, 3) are (1) and to coolant pipe (4) seated correctly. 30 Insert valve tappet in cylinder head (1) See: Remove/install valve tappets AR05.00-P-2310FF 31 Install camshafts AR05.20-P-6992FF Do not install exhaust camshaft camshaft sprocket. 32 Position slide rail (18) and tighten screw/bolt *BA05.10-P-1001-01I

(17) 33 Position tensioning rail (16) and tighten bolt *BA05.10-P-1002-01I

(15) 34 Install timing chain (19) with exhaust camshaft See: camshaft sprocket Set basic position of camshafts AR05.20-P-6020FG 35 Install timing case cover AR01.40-P-8000FF 36 Remove engine from assembly stand AR01.10-P-2400-07FF *BA26.10-P-1001-01D

*454589006200

*454589026200

Engine assembly stand for cars gotis://A_01_15.0 Boom crane gotis://H_00.12_03.0 37 Attach starter to transmission See: Remove/install starter AR15.30-P-7100FG 38 Install engine with transmission AR01.10-P-2401FF Check values for cylinder head Number Designation Engine Engine 134.910/911 135.930/950 BE01.30-P-1001-02F Permissible variation of flatness of lower over the entire length mm 0.03 to 0.2 0.03 to 0.2 separating surface Cylinder head/cylinder head bolts Page 3 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.30-p-5800ff, Remove/install cylinder head ENGINES 134.9, 135.9 in MODEL 454.0

AR01.30-P-5800FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 616 · Applies to: 453 · AR: AR01.30-P-5800FG

Remove/install cylinder head 10.11.11 ENGINES 639.9 in MODEL 454.0 P01.30-2252-07 Shown on vehicle with code (I01) AC Plus 1 Screw/bolts 2 Coolant pipe A9 Refrigerant compressor (with code A9x1 Refrigerant compressor connector (I01) AC Plus or with Code (I77) (with code (I01) AC Plus or with 3 Engine wiring harness Manual AC) Code (I77) Manual AC) 4 Catalytic converter (without code (K13) Diesel particulate filter) P01.30-2253-08 Shown on vehicle with code (I01) AC Plus 5 Screw/bolts 9 Intake camshaft 12 Bracket 6 Exhaust manifold shield 10 Exhaust camshaft 13 Turbocharger 8 Timing chain 11 Screw/bolts 14 Oil return line Shown with engine removed 15 Screw/bolts 16 Mixing chamber 17 Screw/bolts 18 Screw/bolt 19 Coolant hose 20 Exhaust gas recirculation cooler 21 Connection fitting P01.30-2254-05 Page 1 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.30-p-5800fg, Remove/install cylinder head ENGINES 639.9 in MODEL 454.0

Pull out vacuum line to vacuum reservoir (26)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 618 · Applies to: 453 · AR: AR05.20-P-6040FG, AR05.20-P-6292FG, AR05.20-P-6292FH, AR20.00-P-1010FG

12 Pull out vacuum line to vacuum reservoir (26) of turbocharger (13) 13.1 Remove refrigerant compressor connector Only on vehicles with code (I01) Air (A9x1) at the refrigerant compressor (A9) conditioning Plus or Code (I77) Manual AC 14 Remove screws/bolts (17) *BA20.10-P-1003-01R

15 Unscrew screw/bolt (18) at bracket of exhaust *BA14.20-P-1002-01H

gas recirculation cooler (20) 16 Unscrew screw/bolts (15) at mixing chamber *BA14.20-P-1001-01H

(16) 17 Pull out connection fittings (21) out of exhaust Installation: Replace gasket at

gas recirculation cooler (20) connection fitting (21). 18 Disconnect coolant hose (19) at charge air Installation:

Ensure that the coolant hose manifold (19) is correctly seated at the charge air distribution pipe. 19 Unscrew screw/bolts (1) at coolant pipe (2) 20 Disconnect engine wiring harness at engine AR01.00-P-2420-01FG (3) 21 Remove camshaft sprocket AR05.20-P-6040FG Secure timing chain (8) in appropriate position using a cable tie to prevent timing chain (8) from falling. 22 Remove inlet camshaft (9) AR05.20-P-6292FG 23 Remove exhaust camshaft (10) AR05.20-P-6292FH 24 Position engine mount bracket (24) and Use removed nuts. secure to engine with two Screw/bolts 25 Lower engine using vehicle jack Use suitable wooden or rubber supports, otherwise the oil pan can be damaged. Ensure that the jack is securely positioned to prevent it from slipping. 26 Unscrew cylinder head bolts (25) and screw/ In order to avoid stresses in the cylinder bolts (22, 27) head (23), loosen cylinder head bolts (25) and Screw/bolts (22, 27) in the reverse order of the tightening instructions. Replace cylinder head bolts (25). Installation:

Tighten cylinder head bolts (25) and Screw/bolts (22, 27) according to the sequence of the tightening pattern. Tightening specifications for cylinder head AR01.30-P-5800-07FG bolts *BA01.30-P-1001-01R

*BA01.30-P-1002-01R

*BA01.30-P-1009-01R

27 Remove cable tie from timing chain (8), raise Carefully place cylinder head (23) onto a cylinder head (23) and guide timing chain (8) suitable support, otherwise the slide rail of the from the bottom out of the cylinder head (23) timing chain (8) can be damaged. Aid of 2 helpers required. Do not allow timing chain (8) to fall out. Installation: Align cylinder head (23)

using the guide sleeves (arrows) in the crankcase (29). 28 Remove the cylinder head gasket (28) and Installation: Replace cylinder head

prevent the timing chain (8) from falling out gasket (28). Align cylinder head gasket (28) using guide sleeves (arrows) in the crankcase (29). 29 Check tapped holes for cylinder head bolts (25) in crankcase (29) for contamination; clean if necessary 30.1 Reinstall detachable body components of When replacing the cylinder head (23). cylinder head (23) Checking

31 Clean sealing surfaces on the cylinder head (23) and crankcase (29) and check for visible damage 32 Inspect flatness of cylinder head (23) AR01.30-P-5800-12FF An uneven sealing surface of cylinder head (23) can lead to leaks in the area of cylinder head gasket (28). BE01.30-P-1001-02F Straightedge 33 Inspect crankcase (29) for flatness AR01.40-P-9133-01FF An uneven sealing surface of crankcase (29) can lead to leaks in the area of cylinder head gasket (28). BE01.40-P-1001-02I Straightedge 34 Install in the reverse order 35 Inspect cooling system for leaks AR20.00-P-1010FG Page 3 of 5 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.30-p-5800fg, Remove/install cylinder head ENGINES 639.9 in MODEL 454.0

AR01.30-P-5800SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 621 · Applies to: 453 · AR: AR01.30-P-5800SR

Remove/install cylinder head 26.08.2019 Engine 281 in model 453 Modification notes 26.08.2019 Note added. Operation step 11 Shown on engine 281.910 3 Connection fitting 8 Coolant hose 9 Screw P01.30-2472-11 P01.30-2456-09 1 Cylinder head 3 Connection fitting 7 Alternator carrier 2 Cylinder head bolt 6 Screw Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.30-p-5800sr, Remove/install cylinder head Engine 281 in model 453

Cylinder head seal

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 622 · Applies to: 453 · AR: AR05.20-P-6992SR, AR09.40-P-6021SR, AR09.41-P-1311SR, AR09.41-P-1310SR, AR09.20-P-1310SR (+1 more)

4 Cylinder head seal 5 Threaded hole P01.30-2452-06 Remove

1 Remove camshafts. AR05.20-P-6992SR 2 Remove oil return feed line from the Engine 281.910 in model 453 AR09.40-P-6021SR crankcase. 3 Remove charge air pipe. Engine 281.910 in model 453 AR09.41-P-1311SR 4.1 Remove charge-air distributor. Engine 281.910 in model 453 AR09.41-P-1310SR 4.2 Remove the intake manifold. Engine 281.920 in model 453 AR09.20-P-1310SR 5 Remove coolant hose (8) from connection *003589033700 Hose clamp pliers fitting (3). 6 Remove screw (9). 7 Remove clamping device. AR13.25-P-3200SR 8 Remove screw (6) from the alternator carrier (7). 9 Loosen cylinder head bolts (2) in reverse order AR01.30-P-5800-01SR of tightening procedure. 10 Remove cylinder head bolts (2). 11 Remove cylinder head (1) from crankcase. General information on checking valves, valve AH05.30-P-1000-02SZ seats and valve guides Aid of helper required.

12 Remove cylinder head gasket (4) from crankcase. Clean

13 Clean threaded holes (5) of the cylinder head bolts (2) in the crankcase. 14 Clean sealing surfaces on cylinder head (1) and on crankcase. Check

15 Check cylinder head (1) for visible damage Permissible deviation in flatness of bottom *BE01.30-P-1001-02F and flatness. contact surface If there are problems, Replace cylinder head(1). Install

16 Place cylinder head gasket (4) on the The marking "TOP" on the cylinder head

crankcase and align. gasket (4) must point upwards. Install new cylinder head gasket (4).

17 Place cylinder head (1) on the crankcase. Aid of helper required.

18 Screw in cylinder head bolts (2) and screw (6) Replace cylinder head bolts (2) and wet on

of the alternator carrier (7) up to end stop. the threads and contact surfaces with engine oil. Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.30-p-5800sr, Remove/install cylinder head Engine 281 in model 453

Tighten cylinder head bolts (2) according to

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 623 · Applies to: 453 · AR: AR13.25-P-3200SR, AR09.41-P-1310SR, AR09.20-P-1310SR, AR09.41-P-1311SR, AR09.40-P-6021SR (+1 more)

19 Tighten cylinder head bolts (2) according to AR01.30-P-5800-01SR the tightening procedure. *BA01.30-P-1001-01K Screw/bolt, cylinder head to crankcase 20 Tighten screw (6) on the alternator carrier (7). 21 Install clamping device. AR13.25-P-3200SR 22 Tighten screw (9). 23 Attach coolant hose (8) to the connection Replace clamp.

fitting (3). *003589033700 Hose clamp pliers 24.1 Install charge-air distributor. Engine 281.910 in model 453 AR09.41-P-1310SR 24.2 Install intake manifold. Engine 281.920 in model 453 AR09.20-P-1310SR 25 Install charge air pipe. Engine 281.910 in model 453 AR09.41-P-1311SR 26 Attach oil return feed line to the crankcase. Engine 281.910 in model 453 AR09.40-P-6021SR 27 Install camshafts. AR05.20-P-6992SR Check

Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 28 Perform engine test run and check engine in the area of the cylinder head (1) for leak tightness. Check values for cylinder head Number Designation Engine 281 BE01.30-P-1001-02F Permissible deviation in flatness of over the entire length mm - bottom contact surface across the diagonals mm 0,03...0,1 Cylinder head Number Designation Engine 281 BA01.30-P-1001-01K Screw/bolt, cylinder head to crankcase Stage 1 Nm 25 ° Stage 2 270 ° Stage 3 - ° Stage 4 - 003 589 03 37 00 Hose clamp pliers Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.30-p-5800sr, Remove/install cylinder head Engine 281 in model 453

AR01.30-P-5700FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 624 · Applies to: 453 · AR: AR01.30-P-5700FG, AR01.20-P-5014FG

Remove/install front cover on cylinder head 29.1.09 ENGINES 639.939 in MODEL 454.0 P43.10-2047-07 6 Bracket 8 Nut 10 Nuts 7 Filler neck 9 Bolts P01.30-2250-08 Shown with the engine removed 1 Front cover 3 Screw 5 Sealing ring 2 Bolts 4 Vacuum pump Remove/install

1 Remove cylinder head cover AR01.20-P-5014FG 2 Push down brake pedal several times To reduce any vacuum. 3 Unlock brake booster vacuum line on vacuum pump (4) and detach upwards 4 Remove filler neck (7) with bracket Installation:

Replace the sealing ring of the filler neck (7). 5 Remove bolts (9) 6 Support engine in the area of the oil pan using Use a suitable support of wood or rubber a suitable jack to prevent damage to the oil pan. Ensure that the jack is securely positioned to prevent it from slipping. 7 Unscrew nut (8) *BA22.10-P-1003-01Q

8 Unscrew nuts (10) *BA22.10-P-1006-01Q

9 Remove bracket (6) 10 Unscrew bolts (2) at front cover (1) *BA01.30-P-1007-01R

11 Detach front cover (1) out of guides on the Installation: Clean sealing surfaces on

cylinder head and remove together with front cover (1) and cylinder head. Vacuum pump (4) from cylinder head Replace sealing ring (5). Sealing compound BR00.45-Z-1053-01A 12.1 Remove bolts (3) and vacuum pump (4) Only when replacing the front cover (1). BA43.05-P-1001-01G

13 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.30-p-5700fg, Remove/install front cover on cylinder head ENGINES 639.939 in MODEL 454.0

AR01.30-P-5702FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 626 · Applies to: 453 · AR: AR01.30-P-5702FG, AR20.00-P-1142FG, AR01.20-P-5014FG, AR09.10-P-1150FG, AR07.02-P-1020FF (+1 more)

Remove/install rear cover on cylinder head 29.1.09 ENGINES 639.939 in MODEL 454.0 P01.30-2251-09 1 High-pressure pump 5 Water drain 9 Screw 2 Air intake hose 6 Coolant hose 10 Bracket 3 Bracket 7 Clip 11 Bolts 4 Bolts 8 Rear cover 12 Sealing ring Remove/install

1 Drain coolant AR20.00-P-1142FG 2 Remove cylinder head cover AR01.20-P-5014FG 3 Remove air filter housing AR09.10-P-1150FG 4 Remove high-pressure pump (1) AR07.02-P-1020FF 5 Unscrew bolts (4) of bracket (3) 6 Expose water drain (5) upward 7 Remove air intake hose (2) with bracket (3) 8 Loosen clamp (7) and remove coolant hose (6) 9 Unscrew bolt (9) on bracket (10) from rear cover (8) 10 Unscrew bolts (11) from rear cover (8) *BA01.30-P-1008-01R

11 Loosen rear cover (8) from guides in cylinder Installation: Install

new sealing ring (12). head and remove Clean sealing surfaces on rear cover (8) and cylinder head and coat with sealant. Sealing compound *BR00.45-Z-1053-01A 12 Install in the reverse order 13 Inspecting cooling system for leaks AR20.00-P-1010FG Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not touch hot or rotating parts. engine as it is running 14 Conduct engine test run and check cylinder head in the area of the rear cover (8) for leaks 15 Check engine oil level by means of oil dipstick Engine oil level must lie between the markings 'Min' and 'Max'; otherwise, engine damage may occur. Cylinder head Number Designation Engine 639.939 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.30-p-5702fg, Remove/install rear cover on cylinder head ENGINES 639.939 in MODEL 454.0

AR01.40-P-9202FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 628 · Applies to: 453 · AR: AR01.40-P-9202FF, AR01.10-P-2401FB, AR01.10-P-2401FF, AR01.10-P-2401FG

Measure cylinder bores 19.7.06 ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0 1 Measuring point 2 Measuring point 3 Measuring point A Longitudinal direction B Transverse direction a Upper reversal point of 1st piston ring b Bottom dead center of piston c Lower reversal point from oil scraper ring P01.40-0228-06 Figure item, etc. Work instructions 1, 2, 3 Measuring points on cylinder liner Measure cleaned cylinder liners with an inside caliper at measuring points (1, 2, 3) in the direction of travel (A) and transverse direction (B). Engine 122.9 BE01.40-P-1001-01L Engine 134.9, 135.9, 639.9 BE01.40-P-1002-01L *WH58.30-Z-1011-12A

If there is excessively high wear or a damaged running surface the engine must be replaced. Refer to: Remove, install engine with transmission Engine 122.9 AR01.10-P-2401FB Engines 134.9, 135.9 AR01.10-P-2401FF Engine 639.9 AR01.10-P-2401FG Check values for cylinder bore Number Designation Engine 122.9 BE01.40-P-1001-01L Cylinder dia. Marking A mm 75.500 to 75.530 Marking B mm 76.000 to 76.030 Marking C mm 76.500 to 76.530 Check values for cylinder bore Number Designation Engines 134.9, 135.9 BE01.40-P-1002-01L Cylinder liner dia. Standard dimension mm 75 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.40-p-9202ff, Measure cylinder bores ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0

AR01.40-P-9202SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 630 · Applies to: 453 · AR: AR01.40-P-9202SR, AR03.10-P-7021SR

Measure cylinder bores 19.08.2014 ENGINE 281 in MODEL 453 1 Measuring point 2 Measuring point 3 Measuring point A Longitudinal direction B Transverse direction a Upper reversal point of 1st piston ring b Bottom dead center of piston P01.40-2345-03 Remove

1 Remove pistons
AR03.10-P-7021SR 2 Clean cylinder bores for the crankcase
Check

3 Measure cylinder bore at the measuring Dia. of cylinder bore *BE01.40-P-1001-01P points (1, 2, 3) in a longitudinal direction (A) and transverse direction (B)
For an excessively high wear: Replace crankcase. Install

4 Install pistons
AR03.10-P-7021SR Check values for cylinder bore Number Designation ENGINE 281 BE01.40-P-1001-01P Dia. of cylinder bore Standard size mm 72,200...72,215 Out-of-roundness (in mm 0,015 new condition) Wear limit in mm 0,01 longitudinal and transverse direction Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar01.40-p-9202sr, Measure cylinder bores ENGINE 281 in MODEL 453

AR01.40-P-8410SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 631 · Applies to: 453 · AR: AR01.40-P-8410SR, AR01.40-P-8000SR, AR18.40-P-3510SR, AR03.30-P-8002SR, AR18.10-P-6020SR

Remove, install cylinder crankcase lower section 06.03.2020 Engine 281 in model 453 P01.40-2331-09 Shown on engine 281.910 1 Crankcase lower section 4 Guide tube 7 Electrical wiring harness 2 Engine oil heat exchanger 5 Bolts 8 Screw 3 Coolant hoses 6 Electrical connector 9 Charge current line Remove

1 Remove timing case cover AR01.40-P-8000SR 2 Remove guide tube (4) AR18.40-P-3510SR 3 Remove flywheel AR03.30-P-8002SR 4 Remove oil pump AR18.10-P-6020SR 5 Disconnect electrical connector (6) 6 Unclip electrical wiring harness (7) from crankcase lower part (1) 7 Unscrew bolt (8) 8 Unclip charge current line (9) from crankcase lower part (1) and remove from working area 9 Remove coolant hose (3) on engine oil heat Engine 281.910 in model 453 exchanger (2) *003589033700 Hose clamp pliers 10 Remove all screw/bolts (5) Tightening procedure AR03.20-P-4351-05SR The position of the screw/bolts (5) can be

taken from the tightening procedure. 11 Unfasten crankcase lower part (1) from crankcase upper part and take off 12 Remove rear radial shaft sealing ring from crankshaft Clean

13 Remove the rest of the sealant on crankcase lower part (1) and on crankcase upper part 14 Clean sealing surfaces on crankcase lower Assembly cleaner *BR00.45-Z-1028-04A part (1) and on crankcase upper part Install

15 Apply sealant to sealing surfaces on crankcase lower part (1) and on crankcase upper part Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar01.40-p-8410sr, Remove, install cylinder crankcase lower section Engine 281 in model 453

Information on application of sealant to

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 632 · Applies to: 453 · AR: AR03.20-P-3063SR, AR18.10-P-6020SR, AR03.30-P-8002SR, AR18.40-P-3510SR, AR01.40-P-8000SR

AH01.40-P-1000-03TJ crankcase bottom section Sealant, Loctite 5970, 50 ml *BR00.45-Z-1013-01A 16 Place crankcase lower part (1) with screw/ Pay attention to different lengths of

bolts (5) evenly on the crankcase upper part. screws. 17 Fully tighten screws/bolts(5) Tightening procedure AR03.20-P-4351-05SR Observe tightening procedure for screw/

bolts (5). *BA01.40-P-1011-01M Screw/bolt, lower crankcase section to upper crankcase section 18 Install rear radial shaft sealing ring AR03.20-P-3063SR Replace rear radial shaft sealing ring.

19 Attach coolant hoses (3) to engine oil heat Replace clamps.

exchanger (2) *003589033700 Hose clamp pliers 20 Clip in charge current line (9) onto crankcase lower part (1) 21 Tighten screw (8) 22 Clip in electrical wiring harness (7) on crankcase lower part (1) 23 Connect electrical connection(6) 24 Install oil pump AR18.10-P-6020SR 25 Install flywheel AR03.30-P-8002SR 26 Install guide tube (4) AR18.40-P-3510SR 27 Install timing case cover AR01.40-P-8000SR Cylinder crankcase, timing case cover, end cover Number Designation Engine 281 BA01.40-P-1011-01M Screw/bolt, lower crankcase section to upper crankcase section Nm 25 003 589 03 37 00 Hose clamp pliers Repair materials Number Designation Order number BR00.45-Z-1013-01A Sealant, Loctite 5970, 50 ml A 003 989 98 20 10 BR00.45-Z-1028-04A Assembly cleaner A 000 986 56 01 Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar01.40-p-8410sr, Remove, install cylinder crankcase lower section Engine 281 in model 453

AR01.40-P-8920FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 633 · Applies to: 453 · AR: AR01.40-P-8920FF, AR03.30-P-8002FF

Remove/install end cover together with shaft seal 8.1.07 ENGINE 134.9, 135.9 in MODEL 454.0 1 Bolts 2 End cover 3 Radial shaft seal P01.40-2138-11 Remove/install

1 Remove flywheel AR03.30-P-8002FF 2 Remove bolts (1) *BA01.40-P-1008-01O

3 Loosen end cover (2) from crankcase and Installation:

Clean sealing surfaces. remove Apply Sealant and apply engine oil to radial shaft sealing ring (3). Position sleeve on crankshaft and end cover (2) on crankcase. *454589021400

Sealant *BR00.45-Z-1053-01A Notes on application of sealant to end cover AH01.40-P-1000-06FF

with radial shaft seal 4 Install in the reverse order Timing case cover

Number Designation Engine Engine 134.911 134.910 BA01.40-P-1008-01O Bolt connecting end cover of radial shaft Nm 8 8 sealing ring to the crankcase Timing case cover

Number Designation Engine Engine 135.930 135.950 BA01.40-P-1008-01O Bolt connecting end cover of the radial shaft Nm 8 8 sealing ring to the crankcase Page 1 of 2 © Mercedes-Benz AG, 5/20/18, L/07/20, ar01.40-p-8920ff, Remove/install end cover together with shaft seal ENGINE 134.9, 135.9 in MODEL 454.0

AR01.40-P-8920FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 635 · Applies to: 453 · AR: AR01.40-P-8920FG, AR03.30-P-8002FG, AR01.45-P-7500FH

Remove/install end cover together with shaft seal 19.1.09 ENGINE 639.939 in MODEL 454.0 1 Oil pan 2 Bolts 3 End cover with radial shaft seal 4 Crankcase P01.40-2173-03 Remove/install

1 Remove flywheel AR03.30-P-8002FG 2 Remove oil pan (1) AR01.45-P-7500FH 3 Remove bolts (2) and remove end cover with Installation: Replace end cover with

radial shaft sealing ring (3) from crankcase (4) radial shaft sealing ring (3), clean sealing surface on crankcase (4) and coat radial shaft sealing ring with engine oil. *BA01.40-P-1001-01V

4 Install in the reverse order Crankcase, timing case cover, end cover Number Designation Engine 639.9 BA01.40-P-1001-01V Bolt connecting end cover of radial shaft sealing Nm 8 ring to the crankcase Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.40-p-8920fg, Remove/install end cover together with shaft seal ENGINE 639.939 in MODEL 454.0

AR01.40-P-8000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 636 · Applies to: 453 · AR: AR01.40-P-8000FF, AR20.10-P-1271FF

Remove/install timing case cover 16.3.04 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Timing case cover 2 Oil strainer 3 Bolts 4 Bolts P01.40-2148-06 Shown on engine 135.9 5 Main lifter

6 Support fixture

P01.40-2147-11 P01.40-2146-07 Shown on engine 135.9 1 Timing case cover 8 Bracket 10 Engine mount 7 Filler neck 9 Engine bracket Remove/Install

Replace self-locking nuts and bolts. Installation 1 Remove coolant pump AR20.10-P-1271FF Page 1 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.40-p-8000ff, Remove/install timing case cover ENGINE 134.9, 135.9 in MODEL 454.0

Remove belt pulley

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 637 · Applies to: 453 · AR: AR03.30-P-1700FF, AR01.45-P-7500FF, AR01.20-P-5014FF, AR18.40-P-3510FF

2 Remove belt pulley AR03.30-P-1700FF 3 Remove oil pan AR01.45-P-7500FF 4 Detach oil strainer (2) Installation:

Replace sealing ring of oil strainer (2). *BA01.40-P-1009-01O

*BA01.40-P-1010-01O

5 Unscrew bolts (3, 4) on timing case cover (1) Only unscrew those bolts (3, 4) on the timing case cover (1) that are accessible from below. *BA01.40-P-1002-01O

*BA01.40-P-1003-01O

*BA01.40-P-1005-01O

6 Mount support fixture (6) AR01.10-P-2400-06FF The main lifters (5) of the companies Mazzola and AS Hydraulic are selectively usable. *454589006200

WH58.30-Z-1011-07A Main lifter Co. Mazzola WH58.30-Z-1011-07A Main lifter Fa. AS Hydraulic 7 Lower main lifter (5) and remove from under The main lifters (5) of the companies the vehicle Mazzola and AS Hydraulic are selectively usable. *454589006200

WH58.30-Z-1011-07A Main lifter Co. Mazzola WH58.30-Z-1011-07A Main lifter Fa. AS Hydraulic 8 Lower vehicle 9 Support the support fixture (6) from *454589006200

underneath using a suitable jack and lift until the engine mount (10) starts lifting slightly 10.1 Remove filler neck (7) of washer fluid Engine 135.9 reservoir 11.1 Detach bracket (8) of filler neck (7) Engine 135.9 12 Detach engine bracket (9) from engine mount *BA22.10-P-1003-01Q

(10) and from timing case cover (1) *BA22.10-P-1004-01Q

*BA22.10-P-1005-01Q

*454589040900

13.1 Remove engine mounts (10) Engine 135.9 *BA22.10-P-1001-01Q

14 Remove cylinder head cover AR01.20-P-5014FF 15 Remove the dipstick guide tube AR18.40-P-3510FF 16 Unscrew the remaining bolts (3, 4) on the *BA01.40-P-1002-01O

timing case cover (1) *BA01.40-P-1003-01O

*BA01.40-P-1004-01O

*BA01.40-P-1005-01O

17 Loosen timing case cover (1) and remove Installation:

Clean sealing surfaces of upward timing case cover (1) and of crankcase. Replace sealing ring for oil hole in timing case cover (1). Coat sealing surface of timing case cover (1) with sealing compound Sealing compound *BR00.45-Z-1053-01A Notes on application of sealant to timing case AH01.40-P-1000-01FF

cover 18 Install in the reverse order Timing case cover

Number Designation Engine Engine 134.911 134.910 BA01.40-P-1002-01O Torx bolt of timing case to crankcase M6 Nm 9 9 BA01.40-P-1003-01O Torx bolt of timing case to crankcase M10 Nm 39 39 Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.40-p-8000ff, Remove/install timing case cover ENGINE 134.9, 135.9 in MODEL 454.0

AR01.40-P-8000FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 640 · Applies to: 453 · AR: AR01.40-P-8000FG, AR01.10-P-2401FG, AR15.40-P-5032FG, AR01.30-P-5700FG, AR03.30-P-1700FG (+2 more)

Remove/install timing case cover 29.1.09 ENGINES 639.939 in MODEL 454.0 1 Timing case cover 2 Engine support 3 Bolts 4 Belt pulley 5 Bolts 6 Camshaft sprocket 7 Oil pan 8 Bolts P01.40-2169-06 1 Timing case cover 9 Slide rail P01.40-2172-01 Remove/install

1 Remove engine with transmission AR01.10-P-2401FG 2 Remove alternator AR15.40-P-5032FG 3 Remove front cover at cylinder head AR01.30-P-5700FG 4 Remove belt pulley (4) AR03.30-P-1700FG 5 Unscrew bolts (3) and remove engine support *BA22.10-P-1007-01Q

(2) 6 Remove bolts (5) on cylinder head from timing *BA01.30-P-1002-01R

case cover (1) 7 Remove oil pan (7) AR01.45-P-7500FH 8 Remove bolts (8) on timing case cover (1) out *BA01.30-P-1003-01R

of crankcase 9 Remove timing case cover (1) Carefully loosen timing case cover (1) using a rubber hammer. Installation: Observe fitted sleeves (2

each) on cylinder crankcase.Clean sealing surfaces, coat sealing surface with sealing compound. Observe application of sealant. Insert slide rail (9) into the bearing pin in the timing case cover (1). Carefully pull cylinder head gasket downwards and coat on both sides with sealing compound. Sealing compound *BR00.45-Z-1053-01A Check crankshaft radial sealing ring; replace if necessary. See Replace front crankshaft radial sealing ring AR03.20-P-3000FG Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.40-p-8000fg, Remove/install timing case cover ENGINES 639.939 in MODEL 454.0

AR01.40-P-8000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 642 · Applies to: 453 · AR: AR01.40-P-8000SR, AR01.10-P-2401SR, AR01.20-P-5014SR, AR05.20-P-7215SR, AR03.20-P-3000SR (+1 more)

Remove/install timing case cover 8.5.15 Engine 281 in model 453 1 Timing case cover 2 Oil duct cover 3 Belt pulley 4 Screw 5 Bolts 6 Electrical wiring harness P01.40-2339-06 1 Timing case cover 7 Sealing ring P01.40-2340-01 Remove/install

1 Remove engine with transmission AR01.10-P-2401SR 2 Remove screw/bolts, starter to transmission BA15.30-P-1001-01E Bolt, starter to transmission 3 Remove screw/bolts, transmission to engine BA26.00-P-1001-01A Engine 281 in model 453 with transmission 700.12Bolt, transmission to engine BA27.10-P-1002-06A Engine 281 in model 453 with transmission 700.41Bolt, transmission to engine 4 Unscrew nuts, transmission to engine and BA26.00-P-1002-01A Engine 281 in model 453 with remove transmission from engine transmission 700.12Nut, transmission to engine *BA27.10-P-1003-06A Engine 281 in model 453 with transmission 700.41Nut, transmission to engine 5 Fix engine onto an engine repair stand 000 588 00 31 00 Assembly stand WS01.00-N-3028B

6 Remove cylinder head cover AR01.20-P-5014SR 7 Oil duct cover (2) for camshaft positioner AR05.20-P-7215SR 8 Remove front radial shaft sealing ring AR03.20-P-3000SR Installation: Replace front radial shaft

sealing ring. 9 Remove belt pulley (3) for coolant pump AR20.10-P-1275SR Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.40-p-8000sr, Remove/install timing case cover Engine 281 in model 453

AR01.45-P-7500FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 645 · Applies to: 453 · AR: AR01.45-P-7500FH, AP18.00-P-0101FG, AR49.10-P-7170FF, AR49.10-P-5500FG, AR49.10-P-5501FF

Remove, install oil pan 20.3.06 ENGINE 639.9 in MODEL 454.0 Shown on vehicles with Code (I01) AC Plus 1 Bolt 2 Bolt 3 Oil pan P01.45-2165-11 Remove, install

1 Drain engine oil Installation:

Install new filter. Engine oil and filter change AP18.00-P-0101FG

2 Remove exhaust flex pipe AR49.10-P-7170FF 3.1 Remove catalytic converter On vehicles without Code (K13) Diesel AR49.10-P-5500FG particulate filter 3.2 Remove catalytic converter diesel particulate On vehicles with Code (K13) Diesel AR49.10-P-5501FF filter unit particulate filter 4.1 Unscrew bolt (1) For vehicles with Code (I01) Air conditioning Plus or Code (I77) Manual AC *BA83.55-P-1004-01L

5 Unscrew bolt (2) *BA15.30-P-1001-01I

6 Remove bolts for oil pan (3) Installation:

Tighten bolts on oil pan (3) evenly. *BA01.45-P-1001-01P

*BA01.45-P-1005-01P

7 Remove oil pan (3) Installation:

Clean sealing surfaces and install new gasket. 8 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 9 Perform engine test run and check engine in area of the oil pan (3) for leaks Oil pan

Number Designation Engine 636.939 BA01.45-P-1001-01P Torx bolt connecting oil pan to crankcase Stage 1 Nm 5 Stage 2 Nm 10 BA01.45-P-1005-01P Torx bolt connecting oil pan to transmission Nm 23 housing Starter

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.45-p-7500fh, Remove, install oil pan ENGINE 639.9 in MODEL 454.0

AR01.45-P-7500FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 647 · Applies to: 453 · AR: AR01.45-P-7500FF, AP18.00-P-0101FF

Remove/install oil pan 15.9.03 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Oil pan 2 Bolt 3 Transmission cover 4 Bolt P01.45-2222-11 Remove/install

1 Drain engine oil Installation:

Replace engine oil and oil filter. Engine oil and filter change AP18.00-P-0101FF

2 Unscrew bolts (2) of transmission cover (3) 3 Remove transmission cover (3) 4 Unscrew bolts (4) at circumference of oil pan *BA01.45-P-1001-01L

(1) from the crankcase 5 Carefully detach oil pan (1) from crankcase Installation: Clean sealing surfaces, coat

using a rubber mallet and remove sealing surface of crankcase with sealing compound. Sealing compound *BR00.45-Z-1053-01A Notes on application of sealant to oil pan AH01.45-P-0001-01FF

6 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns during Do not grasp hot or rotating parts. starting procedure or when working near engine 7 Perform engine test run and check engine around oil pan (1) for leaks Oil pan

Number Designation Engine Engine 134.910 134.911 BA01.45-P-1001-01L Torx bolt, oil pan to crankcase Nm 8 8 Oil pan

Number Designation Engine Engine 135.930 135.950 BA01.45-P-1001-01L Torx bolt, oil pan to crankcase Nm 8 8 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.45-p-7500ff, Remove/install oil pan ENGINE 134.9, 135.9 in MODEL 454.0

AR01.45-P-7500SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 649 · Applies to: 453 · AR: AR01.45-P-7500SR, AP18.00-P-0101SS

Remove/install oil pan 18.02.2020 Engine 281 in model 453 1 Screw 2 Screw 3 Screw 4 Screw 5 Screw 6 Screw 7 Screw 8 Screw 9 Screw 10 Screw 11 Screw 12 Oil pan P01.45-2425-06 Topical note Notes on self-locking nuts and bolts AH00.00-N-0001-01A Remove

1 Drain engine oil Engine 281.920 in model 453 AP18.00-P-0101SS

Engine 281.910 in model 453 AP18.00-P-0101S

2 Commercially available devices/tools Remove screw/bolts (1 to 11) on the oil pan

(12)
Cordless drill/driver or rechargeable drill 3 Detach oil pan (12) from crankcase using a *122589002800 Blade knife and remove Clean

4 Clean sealing surface on oil pan (12) When reusing the oil pan (12). Loctite 7063 (400 ml) cleaning spray BR00.45-Z-1046-04A 5 Clean sealing surface on crankcase Loctite 7063 (400 ml) cleaning spray BR00.45-Z-1046-04A Install

6 Apply sealant to oil pan (12) Notes on sealant path for oil pan AH01.45-P-0001-01FB Sealing compound BR00.45-Z-1053-01A 7 Place oil pan (12) with screw/bolts (1 to 11) evenly on the crankcase. 8 Tighten screw/bolts (1 to 11) in ascending BA01.45-P-1001-01J Bolt, oil pan to crankcase/timing case sequence cover 9 Pour in engine oil Engine 281.920 in model 453 AP18.00-P-0101SS

Engine 281.910 in model 453 AP18.00-P-0101S

Check

Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 10 Perform engine test run and check engine in area of the oil pan (12) for leaktightness Oil pan Number Designation Engine 281 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar01.45-p-7500sr, Remove/install oil pan Engine 281 in model 453

BE03.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 658 · Applies to: 453 · AR: BE03.00-Z-9999CZ

Test and adjustment values: Smart: Crank assembly 18.09.2019 MODEL all Test specifications for connecting rod bolts ENGINE 639.939 BE03.10-P-1000-03H Check values for piston rings ENGINE 639.939 BE03.10-P-1000-05G Check values for piston rings ENGINE 122.9, 132.910/930, 134.910/911, BE03.10-P-1000-05H 135.930/950 ENGINE 281 Check values for connecting rod bearing shellsEngine 281 BE03.10-P-1000-06A Check values for crankshaft bearing cap bolts ENGINE 132.9 BE03.20-P-1000-01G Test specifications for crankshaft ENGINE 122.9 in MODEL 454.0 BE03.20-P-1000-02G Check values for crankshaft main bearing Engine 281 BE03.20-P-1000-03S shells Test specifications for crankshaft bearing ENGINE 122.9, 134.9, 135.9 in MODEL 454.0 BE03.20-P-1000-04G clearance Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be03.00-z-9999cz, Test and adjustment values: Smart: Crank assembly MODEL all

AR03.10-P-7021FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 660 · Applies to: 453 · AR: AR03.10-P-7021FG, AR01.10-P-2401FG, AR01.30-P-5800FG, AR01.45-P-7500FH, AR18.10-P-6020FG

Piston removal and installation 8.9.04 ENGINE 639.939 in MODEL 454.0 P03.10-2092-09 1 Pistons 5 Piston pin 8 Connecting rod bearing shell 2 Conrod 6 Bolt 9 Oil baffle 3 Connecting rod bearing cap 7 Anti-twist lock 10 Bolts 4 Circlip Removing

1 Remove engine with transmission AR01.10-P-2401FG 2 Remove cylinder head AR01.30-P-5800FG 3 Remove oil pan AR01.45-P-7500FH 4 Remove oil pump AR18.10-P-6020FG 5 Unscrew bolts (10) and remove the oil baffle (9) 6 Unscrew bolts (6) and remove connecting rod Mark the connecting rod (2) and the bearing cap (3) with connecting rod bearing connecting rod bearing cap (3) to each other shell (8) (arrow A) pointing towards the each other. The conrod (2) and the conrod bearing cap (3) are cracked (broken). 7 Remove the connecting rod (2) together with In case of used pistons (1), the markings piston (1) by lifting upward may no longer be visible due to carbonization. For this reason, remove the carbon deposits from the pistons (1). If the marking on the pistons (1) is no longer visible, the pistons (1) must be marked again. Assignment of pistons to cylinder bore AH03.10-P-0001-02FG

8 Remove the circlip (4) of the piston pin (5) Check condition of circlip (4), replace if necessary. 9 Press out the piston pin (5) and detach the piston (1) from the connecting rod (2) 10 Clean cylinder bores, connecting rod journals, connecting rod bearing shells (8) and piston (1) Installing

11 Lubricate piston pin (5) and the connecting rod (2) using engine oil 12 Insert the connecting rod (2) in the piston (1), Assemble piston (1) and connecting rod press the piston pin (5) into the piston (1) and (2) together in such a way that the marking on into the connecting rod (2) by hand the piston (1) points in the direction of the timing case cover. The marking (arrow A) on the connecting rod (2) points to the inlet side. Mark connecting rod (2) to the installation location. Assignment of pistons to cylinder bore AH03.10-P-0001-02FG

Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.10-p-7021fg, Piston removal and installation ENGINE 639.939 in MODEL 454.0

Insert the circlip (4) of the piston pin (5) into

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 661 · Applies to: 453 · AR: AR18.10-P-6020FG, AR01.45-P-7500FH, AR01.30-P-5800FG, AR01.10-P-2401FG

13 Insert the circlip (4) of the piston pin (5) into Ensure the correct seating of the circlip (4) the groove on the piston (1) in the groove. 14 Lubricate cleaned cylinder bores, conrod bearing journals, conrod bearing shells (8) and piston (1) using engine oil 15 Place the tensioning strap above the piston Piston ring gaps must be offset 120°. (1) and stretch the piston rings *450589001400

16 Assign the piston (1) to the cylinder bore and Turn crankshaft in such a way that the install connecting rod (2) does not touch the crankshaft when inserting the piston (1). Assignment of pistons to cylinder bore AH03.10-P-0001-02FG

17 Check the shank length of bolts (6). AR03.10-P-6111-01FG BE03.10-P-1001-03H 18 Mount connecting rod bearing shells (8) and The anti-twist locks (7) on the connecting bottom connecting rod bearing cap (3) rod bearing shells (8) must be located in the grooves (8) of the connecting rod (2) and of the connecting rod bearing cap (3). Pay attention to identification (arrow A) of the connecting rod (2) with respect to the connecting rod bearing cap (3). The connecting rods have been cracked (broken) during production. The connecting rods (2) must be installed in the same position and in the same direction. 19 Tighten bolts (6) BA03.10-P-1001-01O

20 Rotate the crankshaft and check the crank mechanism for unobstructed movement 21 Tighten oil baffle (9) with bolts (10) *BA18.10-P-1003-01L

22 Install oil pump AR18.10-P-6020FG 23 Installing oil pan AR01.45-P-7500FH 24 Install cylinder head AR01.30-P-5800FG 25 Install engine with transmission AR01.10-P-2401FG Inspection data of conrod bolts Number Designation Engine 639.939 8 1 Connecting rod Thread diameter M BE03.10-P-1001-03H bolt Shank length when new mm 46.8...47.3 max. mm 48 Connecting rod

Number Designation Engine 639.939 in model 454.0 BA03.10-P-1001-01O Bolt for conrod cap on conrod 1st stage Nm 5 2nd stage Nm 25 3rd stage ° Reused screw 90 ° New screw 180 Oil pump Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.10-p-7021fg, Piston removal and installation ENGINE 639.939 in MODEL 454.0

AR03.10-P-7021SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 663 · Applies to: 453 · AR: AR03.10-P-7021SR

Remove/install piston 20.04.2020 Engine 281 in model 453 P03.10-2151-09 1 Bolts 6 Crankshaft 11 Piston ring (taper-faced ring) 2 Connecting rod 7 Piston 12 Piston ring (oil scraper ring) 3 Connecting rod bearing cap 8 Tensioning strap 13 Retaining ring 4 Connecting rod bearing shell 9 Cylinder bore 14 Piston pin 5 Connecting rod bearing shell 10 Piston ring (plain compression ring) 7 Piston A Valve recess P03.10-2150-06 Risk of injury Wear protective gloves, protective clothing Caution to skin and eyes due to AS18.00-Z-0001-01A

handling of engine oil. Risk of poisoning and safety glasses.

caused by swallowing engine oil Do not fill engine oil into beverage containers. Page 1 of 5 © Mercedes-Benz AG, 5/22/18, L/07/20, ar03.10-p-7021sr, Remove/install piston Engine 281 in model 453

Risk of injury

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 664 · Applies to: 453 · AR: AR01.30-P-5800SR, AR01.40-P-8410SR

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

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note Notes on avoiding damage through AH00.00-P-5000-01A contamination and foreign objects Remove

1 Remove cylinder head. AR01.30-P-5800SR 2 Remove crankcase lower section. AR01.40-P-8410SR 3 Mark connecting rods (2) relative to respective

cylinder. Do not interchange connecting rods (2). Engine damage can occur otherwise. 4 Apply markings to pistons (7) and cylinder Only where pistons (7) are reused. bores (9).

Do not interchange pistons (7). Engine damage can occur otherwise. 5 Mark connecting rods (2) and respective

connecting rod bearing caps (3) relative to Connecting rods (2) and connecting rod each other. bearing caps (3) are cracked (broken). Do not interchange. Otherwise the dimensional accuracy will no longer be obtained otherwise and can lead to engine damage. 6 Remove bolts (1). 7 Remove connecting rod bearing caps (3) and connecting rod bearing shells (5) from crankshaft (6). 8 Mark installation position of connecting rod Only where connecting rod bearing shells (5) bearing shells (5) in connecting rod bearing are reused. caps (3).

Do not interchange connecting rod bearing shells (5) and connecting rod bearing caps (3). Engine damage can occur otherwise. 9 Remove connecting rod bearing shells (5) from the respective connecting rod bearing caps (3). 10 Remove pistons (7) with the connecting rods (2) and connecting rod bearing shells (4) from the cylinder bores (9). 11 Mark installation position of connecting rod Only where connecting rod bearing shells (4) bearing shells (4) relative to connecting rods are reused. (2).

Do not interchange connecting rod bearing shells (4) and connecting rods (2). Engine damage can occur otherwise. 12 Remove the connecting rod bearing shells (4). 13 Clamp connecting rods (2) with the pistons (7) Use protective jaws. into a vise. 14 Remove retaining rings (13). 15 Mark piston pins (14) and connecting rods (2) Only where pistons (7) are reused. relative to pistons (7).

Do not interchange piston pins (14), connecting rods (2) and pistons (7). Engine damage can occur otherwise. 16 Press piston pins (14) out of pistons (7). 17 Remove pistons (7) from connecting rods (2). 18 Remove connecting rods (2) from the vise. Clean

19 Carefully remove combustion residues from

the top-land zone of the cylinder bores (9) and There must not be any combustion residues clean cylinder bores (9) with compressed air. remaining in cylinder bores (9). Otherwise, the piston rings (10, 11, 12) will be damaged. Assembly cleaner *BR00.45-Z-1028-04A 20 Clean all power unit components.

The power unit components must be absolutely free of soiling. Engine damage can occur otherwise. Check

21 Check pistons (7) and piston rings (10, 11, 12) Where pistons (7) and piston rings (10, 11, 12) for wear and damage. are reused. Page 2 of 5 © Mercedes-Benz AG, 5/22/18, L/07/20, ar03.10-p-7021sr, Remove/install piston Engine 281 in model 453

Notes on the assessment of pistons and piston

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 665 · Applies to: 453 · AR: AR03.10-P-7311SR, AR03.20-P-4351SR, AR01.40-P-8410SR, AR01.40-P-9202SR

AH03.10-P-0001-04MM rings If there is a problem, replace respective pistons (7) and piston rings (10, 11, 12). Remove/install piston rings AR03.10-P-7311SR 22 Check side clearance of the piston rings (10, Only when reusing the pistons (7) with already 11). used piston rings (10, 11). AR03.10-P-7311-01SR Commercially available devices/tools

Feeler gage Piston ring vertical clearance *BE03.10-P-1001-05H If there is a problem, replace respective pistons (7) and piston rings (10, 11, 12). Remove/install piston rings AR03.10-P-7311SR 23 Check end gap of piston rings (10, 11, 12). Only where piston rings (10, 11, 12) are reused. Remove/install piston rings AR03.10-P-7311SR AR03.10-P-7311-02SR Commercially available devices/tools

Feeler gage End gap for upper and lower ring of oil scraper BE03.10-P-1004-05H ring Piston ring end gap BE03.10-P-1002-05H If there is a problem, replace respective pistons (7) and piston rings (10, 11, 12). Remove/install piston rings AR03.10-P-7311SR 24 Check connecting rod bearing shells (4, 5) and connecting rod journals for wear and damage. Notes on assessing wear on connecting rod AH03.10-P-0001-03MM bearings and connecting rod journals If there is a problem, Replace connecting rod bearing shells (4, 5) and/or crankshaft (6). Remove/install crankshaft AR03.20-P-4351SR 25 Check remaining power unit components for If there is a problem, damage and wear. Replace corresponding power unit components. 26 Check cylinder barrels for wear and damage. General information on inspecting cylinder AH01.00-P-0300-01A walls If there is a problem, Replace crankcase. Remove, install cylinder crankcase lower AR01.40-P-8410SR section 27 Measure cylinder bores (9). Only if honing pattern in cylinder bores (9) is visible and/or not destroyed. AR01.40-P-9202SR Install

28 Assign pistons (7) based on markings applied Only where pistons (7) are reused. during removal to corresponding cylinder bore (9).

Note the applied markings during removal. Engine damage can occur otherwise. 29 Clamp connecting rods (2) in vise. Use protective jaws. 30 Insert first new retaining ring (13) into piston Replace retaining rings (13).

boss. 31 Wet piston pins (14) and connecting rod small ends with engine oil. Page 3 of 5 © Mercedes-Benz AG, 5/22/18, L/07/20, ar03.10-p-7021sr, Remove/install piston Engine 281 in model 453

Topical note

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 667 · Applies to: 453 · AR: AR01.40-P-8410SR, AR01.30-P-5800SR

Notes on threaded connections fastened using AH00.00-P-0020-01A a tightening angle-based tightening process Specified engine oils (service) - Overview BB00.40-P-0223-02A

*BA03.10-P-1001-01K Bolt, connecting rod bearing cap to connecting rod 45 Crank crankshaft (6) by hand and check for If there is a problem, unobstructed movement of crank assembly. Check assignment and for correct seating of connecting rod bearing shells (4, 5) and connecting rod bearing caps (3). 46 Install crankcase lower section. AR01.40-P-8410SR 47 Install cylinder head. AR01.30-P-5800SR Check values for piston rings Number Designation Engine 281 BE03.10-P-1001-05H Piston ring vertical clearance Groove 1 mm 0,04...0,09 Groove 2 mm 0,03...0,07 max. mm - Check values for piston rings Number Designation Engine 281 BE03.10-P-1002-05H Piston ring end gap Groove 1 mm 0,15...0,30 Groove 2 mm 0,40...0,60 max. mm - Check values for piston rings Number Designation Engine 281 BE03.10-P-1004-05H End gap for upper and lower ring of oil Groove 3 mm 0,20...0,90 scraper ring max. mm - Connecting rod Number Designation Engine 281 BA03.10-P-1001-01K Bolt, connecting rod bearing cap to Stage 1 Nm 25 connecting rod ° Stage 2 110 450 589 00 14 00 Tensioning strap Repair materials Number Designation Order number BR00.45-Z-1028-04A Assembly cleaner A 000 986 56 01 Page 5 of 5 © Mercedes-Benz AG, 5/22/18, L/07/20, ar03.10-p-7021sr, Remove/install piston Engine 281 in model 453

AR03.10-P-7311FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 668 · Applies to: 453 · AR: AR03.10-P-7311FF, AR03.10-P-7021FF

Remove/install piston rings 13.4.06 ENGINE 134.9, 135.9 in MODEL 454.0 1 Pistons 2 Plain compression ring 3 Taper-faced ring 4 Oil scraper ring 5 Pliers P03.10-2084-04 Removing

1 Remove piston (1) AR03.10-P-7021FF 2 Remove plain compression ring (2 and taper- *450589143700

faced ring (3) from piston (1) using the pliers (5) 3 Remove three-piece oil ring (4) by hand from piston (1) 4 Measure side clearance of plain compression AR03.10-P-7311-01FF Replace plain compression ring (2), taper- ring (2) and taper-faced ring (3) faced ring (3) and oil scraper ring (4) together with piston (1) if necessary. BE03.10-P-1001-05H 5 Measure the end gap of the plain AR03.10-P-7311-02FF Replace plain compression ring (2), taper- compression ring (2) and the taper-faced ring faced ring (3) and oil scraper ring (4) set by (3) set if necessary. BE03.10-P-1002-05H 6 Clean piston (1) and check for damage Replace piston (1) if necessary. Install

7 Attach three-piece oil ring (4) by hand to piston (1) 8 Attach plain compression ring (2 and taper- Observe installation position faced ring (3) to piston (1) using the pliers (5) Markings on the plain compression ring (2) and taper-faced ring (3) must point towards the piston crown. First attach taper-faced ring (3) then plain compression ring (2). *450589143700

9 Install piston (1) AR03.10-P-7021FF Check values for piston rings Number Designation Engines 134.910/911, 135.930/950 BE03.10-P-1001-05H Piston ring vertical Groove 1 mm 0.03...0.07 clearance Groove 2 mm 0.02...0.06 max. mm 0.1 BE03.10-P-1002-05H Piston ring end gap Groove 1 mm 0.15 - 0.30 Groove 2 mm 0.30 - 0.50 max. mm 0.8 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.10-p-7311ff, Remove/install piston rings ENGINE 134.9, 135.9 in MODEL 454.0

AR03.10-P-7311SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 670 · Applies to: 453 · AR: AR03.10-P-7311SR, AR03.10-P-7021SR

Remove/install piston rings 19.08.2014 ENGINE 281 in MODEL 453 1 Piston 2 Plain compression ring 3 Taper-faced ring 4 Oil scraper ring 5 Pliers P03.10-2084-04 2 Plain compression ring 3 Taper-faced ring P03.10-2136-11 Remove

1 Remove piston (1) AR03.10-P-7021SR 2 Remove plain compression ring (2 and taper- 450589143700 Pliers faced ring (3) from piston (1) using the pliers (5)
3 Remove three-piece oil ring (4) by hand from piston (1)
4 Clean piston (1) and check for damage
If there are problems: Replace piston (1) together with the plain compression ring (2), taper-faced ring (3) and oil scraper ring (4). 5 Measure side clearance of the plain AR03.10-P-7311-01SR compression ring (2) and the taper-faced ring (3)
Piston ring vertical clearance BE03.10-P-1001-05H If there are problems: Replace piston (1) together with the plain compression ring (2), taper-faced ring (3) and oil scraper ring (4). 6 Measure end gap of the plain compression AR03.10-P-7311-02SR ring (2) of the taper-faced ring (3) and the upper and lower rings of the oil scraper ring (4)

Piston ring end gap BE03.10-P-1002-05H End gap for upper and lower ring of oil scraper BE03.10-P-1004-05H ring If there are problems: Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.10-p-7311sr, Remove/install piston rings ENGINE 281 in MODEL 453

Possibly also replace plain compression ring

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 671 · Applies to: 453 · AR: AR03.10-P-7021SR

(2), taper-faced ring (3) and oil scraper ring (4). Install

7 Attach three-piece oil ring (4) by hand to the piston (1)
8 Attach taper-faced ring (3) with the pliers (5) Observe installation position. The marking

to piston (1) (arrow) on the taper-faced ring (3) must point to piston crown. *450589143700 Pliers 9 Attach plain compression ring (2) with the Observe installation position. The marking

pliers (5) at piston (1)
(arrow) on the plain compression ring (2) must point to piston crown. *450589143700 Pliers 10 Turn plain compression ring (2), taper-faced ring (3) and oil scraper ring (4) in its grooves in such a way that the openings are offset respectively at an angle of about 120 degrees together 11 Install piston (1)
AR03.10-P-7021SR Check values for piston rings Number Designation ENGINE 281 BE03.10-P-1001-05H Piston ring vertical clearance Groove 1 mm 0,04...0,09 Groove 2 mm 0,03...0,07 max. mm - Check values for piston rings Number Designation ENGINE 281 BE03.10-P-1002-05H Piston ring end gap Groove 1 mm 0,15...0,30 Groove 2 mm 0,40...0,60 max. mm - Check values for piston rings Number Designation ENGINE 281 BE03.10-P-1004-05H End gap for upper and lower ring of oil scraper Groove 3 mm 0,20...0,90 ring max. mm - 450 589 14 37 00 Pliers Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.10-p-7311sr, Remove/install piston rings ENGINE 281 in MODEL 453

AR03.10-P-7021FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 672 · Applies to: 453 · AR: AR03.10-P-7021FF, AR01.30-P-5800FF

Removing and installing a piston 20.9.04 ENGINES 134.9, 135.9 in MODEL 454.0 P03.10-2085-09 Shown on engine 134.9 1 Bolts 5 Crankshaft 9 Plain compression ring 2 Conrod 6 Pistons 10 Taper-faced ring 3 Connecting rod bearing cap 11 Do not remove oil scraper ring 7 Clamping strap

4 Conrod bearing shells 8 Cylinder bores Removing

1 Remove cylinder head Engines 134.910, 135.930/950 AR01.30-P-5800FF 2 Turn engine at assembly stand until the connecting rod bearing cap (3) is accessible 3 Mark connecting rod (2) and connecting rod The connecting rods (2) and connecting bearing cap (3) relative to each other rod bearing caps (3) are cracked and must not be mixed up with each other. 4 Remove bolts (1) and connecting rod bearing cap (3) 5 Remove connecting rod bearing shell (4) from crankshaft (5) 6 Remove piston (6) with connecting rod (2) In case of used pistons (6), the markings from cylinder bore (8) may no longer be visible due to carbonization. For this reason, remove the carbon deposits from the pistons (6). The pistons (6) must be marked again if the markings on the pistons (6) are no longer visible. Installing

7 Clean and lubricate cylinder bores (8), connecting rod journal, connecting rod bearing shells (4) and piston (6) 8 Position plain compression ring (9), taper- AR03.10-P-7311-03FF faced ring (10) and three-piece oil ring (11) on piston (6) 9 Lay tensioning strap (7) on piston (6) and Do not turn piston ring end gap any more. tighten *450589001400

10 Lay connecting rod bearing shells (4) in connecting rod (2) and connecting rod bearing cap (3) and center 11 Assign piston (6) to cylinder bores (8) Turn the crankshaft (5) if needed so that the connecting rod (2) does not touch the connecting rod journal when inserting the piston (6). Assignment of pistons to cylinder bore AH03.10-P-0001-02FF

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.10-p-7021ff, Removing and installing a piston ENGINES 134.9, 135.9 in MODEL 454.0

Turn engine at assembly stand through 90°

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 673 · Applies to: 453 · AR: AR01.30-P-5800FF

12 Turn engine at assembly stand through 90° Ensure that the connecting rod bearing shell (4) on the crankshaft (5) does not fall out. 13 Insert connecting rod (2) with piston (6) into Turn the crankshaft (5) if needed so that the corresponding cylinder bore (8) the connecting rod (2) does not touch the connecting rod journal when inserting the piston (6). *450589001400

14 Fit connecting rod bearing cap (3) Observe marking of connecting rod (2) relative to connecting rod bearing cap (3). 15 Lubricate bolts (1) and screw in Replace bolts (1). *BA03.10-P-1001-01N

16 Turn engine at assembly stand through 90° 17 Check crankshaft (5) for unobstructed movement by turning 19 Install cylinder head Engines 134.910, 135.930/950 AR01.30-P-5800FF Connecting rod

Number Designation Engines 134.910/911, 135930/950 BA03.10-P-1001-01N Bolt for conrod cap on conrod Stage 1 Nm 15 ° Stage 2 92 450 589 00 14 00 Retaining strap Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.10-p-7021ff, Removing and installing a piston ENGINES 134.9, 135.9 in MODEL 454.0

AR03.10-P-7311FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 674 · Applies to: 453 · AR: AR03.10-P-7311FG, AR03.10-P-7021FG

Removing/installing from piston rings 8.9.04 ENGINE 639.939 in MODEL 454.0 1 Plain compression ring 2 Taper-faced hook scraper ring 3 Oil scraper ring 4 Coil spring 5 Pistons 6 Pliers P03.10-2090-06 Removing

1 Remove piston (5) AR03.10-P-7021FG 2 Insert the plain compression ring (1), the *450589143700

taper-faced hook scraper ring (2) and the oil scraper rings (3) into the piston (5) using pliers (6) 3 Remove spring expander (4) by hand 4 Measure plain compression ring (1), taper- BE03.10-P-1003-05G faced hook scraper ring (2) and oil scraper ring (3) using a suitable measuring instrument 5 Measure end gap of plain compression ring AR03.10-P-7311-02FF In case of wear: Replace plain (1), the taper-faced hook scraper ring (2) and compression ring (1), taper-faced hook the oil scraper ring (3) using a suitable feeler scraper ring (2) and oil scraper ring (3). gauge BE03.10-P-1002-05G 6 Clean piston (5) and check for damage Installing

7 Insert spring expander (4) by hand in the groove on the piston (5) 8 Insert oil scraper ring (3) using pliers (6) into Note the installation position. The marking the lowest groove on the piston (5) 'Top' must point to the piston crown. Insert spring expander (4) in oil scraper ring (3) offset by 180° (arrow A) to the joint. *450589143700

9 Insert plain compression ring (1) and taper- Note the installation position. The marking faced hook scraper ring (2) using pliers (6) 'Top' must point to the piston crown. into the appropriate groove on the piston (5) Insert the joints on the plain compression ring (1), the taper-faced hook scraper ring (2) and the oil scraper ring (3) offset by 120° *450589143700

10 Measure side clearance of plain compression AR03.10-P-7311-01FG ring (1), the taper-faced hook scraper ring (2) and the oil scraper ring (3) using a suitable feeler gauge *BE03.10-P-1001-05G 11 Install piston (5) AR03.10-P-7021FG Inspection data of piston rings Number Designation Engine 639.939 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.10-p-7311fg, Removing/installing from piston rings ENGINE 639.939 in MODEL 454.0

AR03.20-P-3637FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 676 · Applies to: 453 · AR: AR03.20-P-3637FG, AR03.20-P-3638FG

Checking the basic position of the balancing shaft 15.12.08 ENGINE 639.939 in MODEL 454.0 1 Screw plug 2 Belt pulley P03.20-2202-06 Removing

Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A toppling off the lifting platform. hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. 1 Raise vehicle with lifting platform 2 Position the piston of cylinder 1 to ignition The belt pulley (2) is accessible over the TDC by rotating at the belt pulley (2) to top service flap in the right fender liner. dead center The TDC marking on the belt pulley (2) must be aligned with the positioning edge on the timing case cover (arrow A). 3 Unscrew screw plug (1) on timing case cover Checking

4 Insert a 4.5 mm diameter drift over the Adjust the basic position of the balance opening (arrow B) into the bore on the shaft if the 4.5 mm diameter drift does not fit correctional weight for the balance shaft into the bore on the correctional weight for the balance shaft. See: Set the basic position of balance shaft AR03.20-P-3638FG Installing

5 Tighten screw plug (1) Install new gasket. *BA01.30-P-1005-01R

6 Lower vehicle with lifting platform Cylinder head Number Designation Engine 639.939 BA01.30-P-1005-01R Screw plug, small to timing case cover Nm 12 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-3637fg, Checking the basic position of the balancing shaft ENGINE 639.939 in MODEL 454.0

AR03.20-P-1000FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 677 · Applies to: 453 · AR: AR03.20-P-1000FG, AR01.10-P-2401FG, AR05.10-P-8484FG, AR18.10-P-6020FG, AR03.20-P-3638FG (+2 more)

Remove/install balancing shaft 1.10.04 ENGINE 639.939 in MODEL 454.0 P03.20-2200-09 1 Balance shaft with housing 4 Oil pump chain 6 Bolts 2 Chain tensioner of oil pump chain 5 Oil pump chain slide rail 7 Bolts 3 Belt pulley Remove/install

1 Remove engine with transmission AR01.10-P-2401FG 2 Remove slide rail from timing case cover AR05.10-P-8484FG When removing the slide rail, the TDC marking on the belt pulley (3) is adjusted to the guide edge at the timing case cover (arrow A). Do not turn the crankshaft any further. 3 Press oil pump chain tensioner (2) onto stop and secure with a drift with a diameter of 3.5 mm over the bore hole (arrow B) 4 Remove oil pump AR18.10-P-6020FG 5 Remove oil pump chain slide rail (5) 6 Remove oil pump chain (4) Do not turn crankshaft. Installation: When placing the oil pump

chain (4), pay attention to the basic setting of the balance shaft with housing (1). See: Set the basic position of the balance shaft AR03.20-P-3638FG 7 Remove oil-water heat exchanger See: On vehicles with Code (LHD) Left-hand drive AR18.30-P-6840FG vehicle On vehicles with Code (RHD) Right-hand AR18.30-P-6840FF drive vehicle 8 Unscrew bolts (6, 7) and remove balance Installation:

Clean sealing surfaces and shaft with housing (1) replace all three sealing rings. Pay attention to the various lengths of the bolts (6, 7). *BA03.20-P-1001-02F

9 Install in reverse order Balance shaft Number Designation Engine 639.939 in model 454.0 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-1000fg, Remove/install balancing shaft ENGINE 639.939 in MODEL 454.0

AR03.20-P-4351FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 679 · Applies to: 453 · AR: AR03.20-P-4351FF, AR03.10-P-7021FF, AR01.40-P-8920FF, AR03.20-P-1010FF

Remove/install crankshaft 30.01.2019 Engine 134.9, 135.9 in model 454.0 Shown on engine 135.9 1 Cylinder crankcase 2 Thrust plate 3 Cylinder crankcase bearing shell 4 Crankshaft 5 Crankshaft bearing cap bearing shell 6 Crankshaft bearing cap 7 Screw P03.20-2192-12 Remove

1 Remove pistons AR03.10-P-7021FF 2 Remove end cover together with radial shaft AR01.40-P-8920FF sealing ring 3 Remove drive gear for balance shaft For engine 134.9 AR03.20-P-1010FF 4 Remove screws (7) Tightening procedure for crankshaft bearing caps AR03.20-P-4351-02FF Release bolts (7) in reverse order to

tightening procedure. See: 5 Remove crankshaft bearing cap (6) with Crankshaft bearing caps (6) are numbered

crankshaft bearing cap bearing shell (5) consecutively, starting at first crankshaft bearing cap (6) at front at timing case. 6 Remove crankshaft (4) from cylinder crankcase (1) 7 Remove thrust plates (2) and cylinder crankcase bearing shells (3) from cylinder crankcase (1) Install

8 Insert cylinder crankcase bearing shells (3) Assign crankshaft bearing shells into cylinder crankcase (1) and crankshaft bearing cap bearing shells (5) into crankshaft bearing caps (6) and oil with engine oil AR03.20-P-4360-01FF Take into account correct assignment of

cylinder crankcase bearing shells (3) and crankshaft bearing cap bearing shells (5). See: 9 Oil thrust plates (2) with engine oil and insert into cylinder crankcase (1) 10 Oil crankshaft bearing journals of crankshaft (4) with engine oil and insert crankshaft (4) into cylinder crankcase (1) 11 Attach crankshaft bearing caps (6) to crankshaft bearing journals of crankshaft (4) Interference fit of crankshaft bearing cap AH03.20-P-4351-02MM Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-4351ff, Remove/install crankshaft Engine 134.9, 135.9 in model 454.0

Crankshaft bearing caps (6) are numbered

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 680 · Applies to: 453 · AR: AR01.40-P-8920FF, AR03.20-P-1010FF, AR03.10-P-7021FF

consecutively, starting at first crankshaft bearing cap (6) at front at timing case. Do not interchange crankshaft bearing caps (6). 12 Screw in bolts (7) AR03.20-P-4351-02FF See:

*BA03.20-P-1001-01G Bolt for crankshaft bearing cap Tightening procedure Crankshaft bearing cap 13 Install end cover together with radial shaft AR01.40-P-8920FF sealing ring 14 Check crankshaft (4) via turning for unobstructed movement 15 Install drive gear for balance shaft For engine 134.9 AR03.20-P-1010FF 16 Install pistons AR03.10-P-7021FF Crankshaft bearing cap Number Designation ENGINE 134.910/911, 135.930/950 BA03.20-P-1001-01G Bolt for crankshaft bearing cap Stage 1 Nm 35 ° Stage 2 62 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-4351ff, Remove/install crankshaft Engine 134.9, 135.9 in model 454.0

AR03.20-P-4351FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 681 · Applies to: 453 · AR: AR03.20-P-4351FG, AR01.10-P-2401FG, AR05.10-P-4600FG, AR01.40-P-8920FG, AR03.10-P-7021FG

Remove/install crankshaft 30.01.2019 Engine 639.9 in model 454.0 1 Crankshaft 2 main bearing shells of the cylinder crankcase 3 Thrust plate in crankcase 4 Main bearing shells of the bearing cap 5 thrust plates of the bearing cap 6 Crankshaft bearing cap 7 Screw P03.20-2199-12 Remove

1 Remove engine with transmission AR01.10-P-2401FG 2 Remove crankshaft gear AR05.10-P-4600FG 3 Remove end cover together with radial shaft AR01.40-P-8920FG sealing ring 4 Remove connecting rod with piston AR03.10-P-7021FG Do not disconnect connecting rod and

piston. 5 Loosen and unscrew the screws (7), starting Use commercially available double-

from the outside hexagon socket wrench socket, size 14. 6 Remove the crankshaft bearing cap (6) with The crankshaft bearing caps (6) are

the main bearing shells of the bearing cap (4) numbered consecutively, beginning at the first and the thrust plates of the bearing cap (5) crankshaft bearing cap (6) at the front on the timing case cover. Assign the main bearing shells of the bearing cap (4) and the thrust plates of the bearing cap (5) to the correct crankshaft bearing cap (6). 7 Take crankshaft (1) out of cylinder crankcase 8 Remove the main bearing shells of the Assign the main bearing shells of the

cylinder crankcase (2) and thrust plates of the cylinder crankcase (2) and the thrust plates of cylinder crankcase (3) from the cylinder the cylinder crankcase (3) to the correct crankcase crankshaft bearing. Install

9 Assign the main bearing shells of the bearing AR03.20-P-4360-01AL cap (4) and thrust plates of the bearing cap (5) to the crankshaft bearing caps (6) and insert them. Assign the main bearing shells of the cylinder crankcase (2) and thrust plates of the cylinder crankcase (3) to the cylinder crankcase and insert them Bearing diagram for crankshaft AH03.20-P-4351-01FG Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-4351fg, Remove/install crankshaft Engine 639.9 in model 454.0

Lubricate the main bearing shells of the

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 682 · Applies to: 453 · AR: AR03.10-P-7021FG, AR01.40-P-8920FG, AR05.10-P-4600FG, AR01.10-P-2401FG

cylinder crankcase (2) and the main bearing shells of the bearing cap (4) with engine oil. The oil grooves in the thrust plates of the cylinder crankcase (3) and the thrust plates of the bearing cap (5) must point to the thrust collars of the crankshaft (1). The thrust plates of the bearing cap (5) are protected from angular movement in the crankshaft bearing cap (6) by a retaining lug. 10 Insert crankshaft (1) into the cylinder crankcase 11 Place the crankshaft bearing cap (6) with the main bearing shells of the bearing cap (4) and the thrust plates of the bearing cap (5) in position, and tighten with screws (7) Interference fit of crankshaft bearing cap AH03.20-P-4351-02MM The crankshaft bearing caps (6) are

numbered consecutively, beginning at the first crankshaft bearing cap (6) at the front on the timing case cover. Note the fit of the crankshaft bearing caps (6). Lubricate the screws (7) of the crankshaft bearing caps (6) on the thread and the screw head contact surface with engine oil. Tighten the screws (7) from the inside to the outside. Turn crankshaft (1) in direction of engine rotation and check for ease of movement. Use commercially available double-hexagon socket wrench socket, size 14. *BA03.20-P-1001-01I Screw/bolt, crankshaft bearing cap to cylinder crankcase 12 Install connecting rod with piston AR03.10-P-7021FG 13 Install end cover together with radial shaft AR01.40-P-8920FG sealing ring 14 Install crankshaft gear AR05.10-P-4600FG 15 Install engine with transmission AR01.10-P-2401FG Crankshaft Number Designation ENGINE 639.939 BA03.20-P-1001-01I Screw/bolt, crankshaft bearing cap to cylinder Stage 1 Nm 55 crankcase ° Stage 2 90 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-4351fg, Remove/install crankshaft Engine 639.9 in model 454.0

AR03.20-P-4351SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 683 · Applies to: 453 · AR: AR03.20-P-4351SR

Remove/install crankshaft 06.03.2020 Engine 281 in model 453 Modification notes 14.03.2019 Allocate new bearing shells. Operation step 15 1 Crankshaft 2 Crankshaft bearing cap 3 Flywheel 4 Radial shaft sealing ring P03.20-2388-06 P03.20-2395-09 2 Crankshaft bearing cap 6 Bearing shell 8 Bearing shell 5 Crankcase 7 Thrust plate Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-4351sr, Remove/install crankshaft Engine 281 in model 453

Risk of injury

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 684 · Applies to: 453 · AR: AR03.10-P-7021SR, AR03.20-P-3063SR

Wear protective gloves, protective clothing Caution to skin and eyes due to AS18.00-Z-0001-01A

handling of engine oil. Risk of poisoning and safety glasses.

caused by swallowing engine oil Do not fill engine oil into beverage containers. Risk of injury Always wear protective gloves when working Caution caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note Notes on avoiding damage through AH00.00-P-5000-01A contamination and foreign objects Remove

1 Remove pistons with connecting rod. AR03.10-P-7021SR The connecting rods remain on the

pistons. 2 Remove rear radial shaft sealing ring (4). AR03.20-P-3063SR 3 Mark crankshaft bearing caps (2) relative to

crankcase (5). Do not mix up crankshaft bearing caps (2). Engine damage can occur otherwise. 4 Loosen screws of the crankshaft bearing cap AR03.20-P-4351-02SR (2) in reverse order of the tightening procedure and remove. 5 Remove crankshaft bearing caps (2). Carefully pry out crankshaft bearing

caps (2). 6 Mark bearing shells (8) relative to the Only when reusing the bearing shells (8). respective crankshaft bearing caps (2). 7 Remove bearing shells (8) from the respective crankshaft bearing caps (2). 8 Remove crankshaft (1) from the crankcase (5).

9 Mark bearing shells (6) relative to the Only when reusing the bearing shells (6). crankcase (5). 10 Mark thrust plates (7) relative to the crankcase Only when reusing the thrust plates (7). (5). 11 Remove bearing shells (6) and thrust plates (7) from the crankcase (5). Clean

12 Clean all parts of the crank assembly.

The parts of the crank assembly must be absolutely free of soiling. Engine damage will occur otherwise. Assembly cleaner *BR00.45-Z-1028-04A Check

13 Check bearing shells (6, 8), thrust plates (7), and the crankshaft bearing journals for wear and damage. Information on assessing wear of main AH03.20-P-1000-02MM bearings and main bearing journals If there is a problem, Replace corresponding bearing shells (6, 8), thrust plates (7), or crankshaft (1). 14 Check remaining power unit components for If there is a problem, wear and damage. Replace corresponding power unit components. Install

15 Allocate new bearing shells (6, 8). Only when installing new bearing shells (6, 8). AR03.20-P-4360-01SR 16 Wet bearing shells (6) and thrust plates (7) with engine oil. Specified engine oils (service) - Overview BB00.40-P-0223-02A

17.1 Insert new bearing shells (6) and new thrust Only when installing new bearing shells (6) plates (7) in the crankcase (5). and thrust plates (7). The grooves (arrows) for the thrust plates (7) are attached single-sidedly and must be visible after insertion. 17.2 Insert previously marked bearing shells (6) Only when reusing the bearing shells (6) and and previously marked thrust plates (7) at the thrust plates (7). respectively marked location in the crankcase (5). Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-4351sr, Remove/install crankshaft Engine 281 in model 453

The grooves (arrows) for the thrust plates

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 685 · Applies to: 453 · AR: AR03.20-P-3063SR, AR03.10-P-7021SR

(7) are attached single-sidedly and must be visible after insertion. 18 Wet crankshaft bearing journals and connecting rod journals with engine oil. Specified engine oils (service) - Overview BB00.40-P-0223-02A

19 Position crankshaft (1) in the crankcase (5) and position. 20 Wet bearing shells (8) with engine oil. Specified engine oils (service) - Overview BB00.40-P-0223-02A

21.1 Insert new bearing shells (8) in the crankshaft Only when installing new bearing shells (8). bearing caps (2). 21.2 Insert previously marked bearing shells (8) in Only when reusing the bearing shells (8). the respectively marked crankshaft bearing caps (2). 22 Install crankshaft bearing caps (2) at the

respective marked location in the crankcase Install crankshaft bearing caps (2) at the same (5). location and in the same direction as before. Engine damage can occur otherwise. 23 Wet bolt heads of the screws of the crankshaft bearing caps (2) with engine oil. Specified engine oils (service) - Overview BB00.40-P-0223-02A

24 Screw in screws of the crankshaft bearing Tightening procedure for crankshaft bearing AR03.20-P-4351-02SR caps (2). caps Topical note Notes on threaded connections fastened using AH00.00-P-0020-01A a tightening angle-based tightening process

Observe tightening procedure. Engine damage can occur otherwise. *BA03.20-P-1001-01G Bolt for crankshaft bearing cap 25 Install rear radial shaft sealing ring (4). AR03.20-P-3063SR 26 Install pistons with connecting rod. AR03.10-P-7021SR Crankshaft bearing cap Number Designation Engine 281 BA03.20-P-1001-01G Bolt for crankshaft bearing cap Stage 1 Nm 32 ° Stage 2 62 Repair materials Number Designation Order number BR00.45-Z-1028-04A Assembly cleaner A 000 986 56 01 Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-4351sr, Remove/install crankshaft Engine 281 in model 453

AR03.20-P-1010FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 686 · Applies to: 453 · AR: AR03.20-P-1010FG, AR01.10-P-2401FG, AR05.10-P-8484FG, AR18.10-P-6020FG, AR03.20-P-3638FG

Removing and installing drive wheel for balance shaft 21.11.05 ENGINE 639.9 in MODEL 454.0 P03.20-2203-09 1 Drive gear 4 Bolt 6 Oil pump chain 2 Chain tensioner of oil pump chain 5 Balance weight 7 Counterholder 3 Belt pulley Remove/install

1 Remove engine with transmission AR01.10-P-2401FG 2 Remove sliding rail from timing case cover AR05.10-P-8484FG When removing the slide rail the TDC marking is set on the belt pulley (3) to the positioning edge on the timing case cover (arrow A). The crankshaft must not turned anymore. 3 Place belt pulley (3) on crankshaft and secure Do not tighten bolt on belt pulley (3). with bolt 4 Counterhold belt pulley (3) using *BA03.20-P-1003-02F

counterholder (7) and loosen bolt (4) on drive wheel (1) *454589014000

5 Take off belt pulley (3) 6 Push oil pump chain (2) chain tensioner to the stop and secure with a 3.5 mm dia. drift over the bore (arrow B) 7 Remove oil pump AR18.10-P-6020FG 8 Remove oil pump chain (6) Do not turn crankshaft. Installation: Observe basic position of the

balance shaft when laying on oil pump chain (6). Refer to: Set the basic position of the balance shaft AR03.20-P-3638FG 9 Unscrew bolt (4) Installation: Only attach bolt (4) to fix

correctional weight (5). 10 Remove correctional weight (5) and drive wheel (1) 11 Install in the reverse order Balancing shaft

Number Designation Engine 639.939 in model 454.0 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-1010fg, Removing and installing drive wheel for balance shaft ENGINE 639.9 in MODEL 454.0

AR03.20-P-3000FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 688 · Applies to: 453 · AR: AR03.20-P-3000FG, AR03.30-P-1700FG

Replace front crankshaft radial sealing ring 17.1.06 ENGINE 639.9 in MODEL 454.0 Illustrated on removed engine 1 Crankshaft radial sealing ring 2 Timing case cover P03.20-2195-12 Remove

1 Remove belt pulley AR03.30-P-1700FG 2 Press out the crankshaft radial sealing ring (1) Do not damage the crankshaft or

with a suitable tool. mounting hole for the crankshaft radial sealing ring (1) otherwise the leaktightness of the new crankshaft radial sealing ring (1) cannot be guaranteed. Install

3 Clean the sealing surface on the timing case The sealing surface on the timing case cover (2) cover (2) must be free of grease and dry. 4 Fit the crankshaft radial sealing ring (1) in the Replace crankshaft radial sealing ring (1) timing case cover (2) with a drift The timing case cover (2) and the crankshaft radial sealing ring (1) must be flush. *454589041500

5 Install the belt pulley AR03.30-P-1700FG 454 589 04 15 00 Drift punch Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-3000fg, Replace front crankshaft radial sealing ring ENGINE 639.9 in MODEL 454.0

AR03.20-P-3000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 689 · Applies to: 453 · AR: AR03.20-P-3000SR, AR03.30-P-1700SR

Replace front crankshaft radial sealing ring 21.07.2014 ENGINE 281 in MODEL 453 1 Radial shaft sealing ring 4 Timing case cover P03.20-2390-05 P03.20-2389-09 1 Radial shaft sealing ring 3 Screw/bolt 2 Insertion device 4 Timing case cover Remove

1 Remove crankshaft belt pulley AR03.30-P-1700SR 2 Lever radial shaft sealing ring (1) out of

timing case cover (4) using a suitable tool
Ensure that the sealing surface of the timing case cover (4) is not damaged. A damaged sealing surface can lead to leaks. Clean

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-3000sr, Replace front crankshaft radial sealing ring ENGINE 281 in MODEL 453

Clean sealing surface on timing case cover

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 690 · Applies to: 453 · AR: AR03.30-P-1700SR

3 Clean sealing surface on timing case cover

(4)
The sealing surface on the timing case cover (4) must be free of grease and dry. Leaks can occur on the radial shaft sealing ring (1) otherwise. Install

4 Lay new radial shaft sealing ring (1) on the The radial shaft sealing ring (1) must be

insertion device (2) installed dry. 200589024300 Insertion tool 5 Place radial shaft sealing ring (1) with an 200589024300 Insertion tool insertion device (2) on timing case cover (4) 6 Screw in screw/bolt (3) for crankshaft belt 200589024300 Insertion tool pulley until the insertion device (2) lies on timing case cover (4) 7 Remove insertion device (2) from timing case 200589024300 Insertion tool cover (4) 8 Install crankshaft belt pulley AR03.30-P-1700SR 200 589 02 43 00 Insertion tool Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-3000sr, Replace front crankshaft radial sealing ring ENGINE 281 in MODEL 453

AR03.20-P-3063SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 691 · Applies to: 453 · AR: AR03.20-P-3063SR, AR03.30-P-8002SR

Replacing rear crankshaft radial seal 12.1.16 Engine 281 in model 453 Modification notes 14.7.15 Methods adapted according to the new special tool. P03.20-2426-08 1 Radial shaft sealing ring 3 Centering device 5 Screw/bolt 2 Screw/bolts 4 Installation tool Remove

1 Remove flywheel AR03.30-P-8002SR 2 Lever radial shaft sealing ring (1) out of

crankcase using a suitable tool Ensure that the sealing surface of the crankcase is not damaged. A damaged sealing surface can lead to leaks. Clean

3 Clean sealing surfaces on crankcase and crankshaft Install

4 Coat sealing lip and outer sealing surface of radial shaft sealing ring (1) with engine oil 5 Insert the centering device (3) in the new

radial shaft sealing ring (1) as shown Insert the centering device (3) from the outer side of the radial shaft sealing ring (1). The sealing lip of the radial shaft sealing ring (1) can get damaged otherwise. *281589004300 Press-in tool 6 Attach centering device (3) with a new radial Use three screw/bolts (2) of the flywheel.

shaft sealing ring (1) to the crankshaft 7 Attach installation tool (4) with screw/bolt (5) *281589004300 Press-in tool and shim to the centering device (3) 8 Screw in screw/bolt (5) until the installation tool (4) lies on the centering device (3) 9 Remove installation tool (4) and centering device (3) from the crankshaft 10 Install flywheel AR03.30-P-8002SR Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-3063sr, Replacing rear crankshaft radial seal Engine 281 in model 453

AR03.20-P-3000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 693 · Applies to: 453 · AR: AR03.20-P-3000FF, AR03.30-P-1700FF

Replacing the front crankshaft radial sealing ring 12.12.03 ENGINES 134.9, 135.9 in MODEL 454.0 Illustrated on a removed engine 135.9 1 Crankshaft radial seal 2 Timing case cover P03.20-2160-11 Removing

1 Remove belt pulley AR03.30-P-1700FF 2 Press out the crankshaft radial sealing ring (1) To ensure that the new crankshaft radial

with a suitable tool. sealing ring (1) remains tight, do not damage the crankshaft and the mounting bore for the crankshaft radial sealing ring (1); use clean a rag as base. Installing

3 Clean the sealing surface on the timing case The sealing surface on the timing case cover (2) cover (2) must be free of grease and dry. 4 Fit the crankshaft radial sealing ring (1) in the The crankshaft radial sealing ring (1) must timing case cover (2) with a suitable tool be flush with the timing case cover (2). 5 Install the belt pulley AR03.30-P-1700FF Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-3000ff, Replacing the front crankshaft radial sealing ring ENGINES 134.9, 135.9 in MODEL 454.0

AR03.20-P-3638FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 694 · Applies to: 453 · AR: AR03.20-P-3638FG, AR01.10-P-2401FG, AR05.10-P-8484FG, AR18.10-P-6020FG, AR01.45-P-7500FH

Set the basic position of the balance shaft 1.10.04 ENGINE 639.939 in MODEL 454.0 P03.20-2201-09 1 Balance shaft 3 Belt pulley 4 Oil pump chain 2 Chain tensioner of oil pump chain Removing

1 Remove engine with transmission AR01.10-P-2401FG 2 Remove sliding rail from timing case cover AR05.10-P-8484FG When removing the slide rail, the TDC marking on the belt pulley (3) is adjusted with respect to the positioning edge of the timing case cover (arrow A). The crankshaft must not be twisted any more. 3 Press the chain tensioner of the oil pump chain (2) all the way to the stop and secure with a drift having Ø 3.5 mm through the bore (arrow B) 4 Remove oil pump AR18.10-P-6020FG Adjusting 5 Lift oil pump chain (4) on drive gear for balance shaft (1) and turn balance shaft (1) until the bore holes (arrows C) are aligned 6 Fix balance shaft (1) through plugging in a drift with a diameter of 4.5 mm into its basic position (arrows C) 7 Check top dead center position of 1st cylinder Achieve this by fixing the timing case cover with two screws and putting the belt pulley (3) in place. Remove after checking timing case cover and belt pulley (3). 8 Install oil pump AR18.10-P-6020FG Do not fit oil pan. 9 Pull drift out of the chain tensioner for oil pump chain (2) 10 Pull drift out of the balance shaft (1) Check basic position of balance shaft (1) again. Installing

11 Installing oil pan AR01.45-P-7500FH 12 Install slide rail in timing case cover AR05.10-P-8484FG 13 Install engine with transmission AR01.10-P-2401FG Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.20-p-3638fg, Set the basic position of the balance shaft ENGINE 639.939 in MODEL 454.0

AR03.30-P-8002SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 695 · Applies to: 453 · AR: AR03.30-P-8002SR, AR25.10-P-0050SR, AR27.10-P-0502SR, AR03.30-P-5000SR

Remove/install a flywheel 21.07.2014 ENGINE 281 in MODEL 453 Shown on engine 281 with a removed transmission 700.41 1 Flywheel 2 Screw/bolts P03.30-2195-06 Remove/install

1.1 Remove clutch ENGINE 281 in MODEL 453 with TRANSMISSION 700.12 AR25.10-P-0050SR 1.2 Remove dual clutch transmission ENGINE 281 in MODEL 453 with TRANSMISSION 700.41 AR27.10-P-0502SR 2 Attach retaining lock for flywheel (1) AR03.30-P-5000SR 3 Loosen screw/bolts (2) Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Installation: Tighten screw/bolts (2)

evenly diagonally. *BA03.30-P-1002-01P Bolt, flywheel to crankshaft 4 Remove retaining lock for flywheel (1) AR03.30-P-5000SR 5 Installation: Do not tighten screw/bolts (2) Remove screw/bolts (2)

yet. Replace screw/bolts (2). 6 Remove flywheel (1) from crankshaft Installation: The bore in the flywheel (1)

must coincide with the guide pin on the crankshaft. 7 Install in the reverse order Flywheel, drive plate, vibration damper, starter ring gear Number Designation ENGINE 281 BA03.30-P-1002-01P Bolt, flywheel to crankshaft Stage 1 Nm 30 ° Stage 2 50 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.30-p-8002sr, Remove/install a flywheel ENGINE 281 in MODEL 453

AR03.30-P-1700FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 696 · Applies to: 453 · AR: AR03.30-P-1700FG, AR13.22-P-1202FG

Remove/install belt pulley 10.4.07 ENGINE 639.939 in MODEL 454.0 Illustrated on removed engine 1 Bolt 2 Belt pulley P03.30-2096-12 Remove/install

1 Remove poly-V belt AR13.22-P-1202FG 2 Hold belt pulley (2) with counterholder and *BA03.30-P-1001-01K

remove bolt (1) *454589014000

*454589110900

3 Remove belt pulley (2) Installation: Turn to ensure that groove in

the belt pulley (2) is aligned with roll pin in the crankshaft. 4 Install in the reverse order Flywheel, driven plate, vibration damper, starter ring gear

Number Designation Engine 639.939 BA03.30-P-1001-01K Bolt, belt pulley/vibration damper to Stage 1 Nm 200 crankshaft ° Stage 2 90 454 589 01 40 00 454 589 11 09 00 Wrench socket Counterholder Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.30-p-1700fg, Remove/install belt pulley ENGINE 639.939 in MODEL 454.0

AR03.30-P-1700SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 697 · Applies to: 453 · AR: AR03.30-P-1700SR, AR13.22-P-1202SR, AR03.20-P-3000SR

Remove/install belt pulley 21.07.2014 ENGINE 281 in MODEL 453 P03.30-2191-09 1 Crankshaft belt pulley 2 Screw/bolt 3 Retaining lock Remove/install

1 Remove poly-V belt AR13.22-P-1202SR 2 Attach retaining lock (3) AR03.30-P-1600-06SR BA01.40-P-1009-01M Screw/bolt, timing case cover to crankcase/cylinder head 3 Remove screw/bolt (2)
BA03.30-P-1001-01P Bolt, belt pulley/vibration damper (without decoupling element) to crankshaft 4 Unfasten crankshaft belt pulley (1) to Installation: The groove (arrow) in the

crankshaft and take off
crankshaft belt pulley (1) must be coincide with the guide spring on the crankshaft. Check

5 Check thrust surface of the radial shaft If there are problems: sealing ring at the crankshaft belt pulley (1) Replace crankshaft belt pulley (1). 6 Check radial shaft sealing ring for leakage If there are problems: Replace radial shaft sealing ring. AR03.20-P-3000SR 7 Install in the reverse order Cylinder crankcase, timing case cover, end cover Number Designation ENGINE 281 BA01.40-P-1009-01M Screw/bolt, timing case cover to crankcase/ Stage 1 (M8 bolts) Nm 8 cylinder head Stage 2 (M10 bolts) Nm 55 Stage 3 (M8 bolts) Nm 25 Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar03.30-p-1700sr, Remove/install belt pulley ENGINE 281 in MODEL 453

AR03.30-P-5000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 699 · Applies to: 453 · AR: AR03.30-P-5000SR, AR26.10-P-0020SR, AR27.10-P-0502SR

Remove/install retaining lock for crankshaft/ring gear 21.07.2014 ENGINE 281 in MODEL 453 Shown on TRANSMISSION 700.12 1 Crankcase upper section 2 Crankcase lower section 3 Screw/bolt 4 Screw/bolt 5 Hole 6 Hole 7 Retaining lock 8 Starter ring gear P03.30-2194-05 Remove

1.1 Remove manual transmission ENGINE 281 in MODEL 453 with TRANSMISSION 700.12 AR26.10-P-0020SR 1.2 Remove dual clutch transmission ENGINE 281 in MODEL 453 with TRANSMISSION 700.41 AR27.10-P-0502SR Install

2 Lay retaining lock (7) on crankcase upper *102589014000 Retaining lock section (1) and crankcase lower section (2) and engage on starter ring gear (8) 3 Tighten down retaining lock (7) onto bore (5) Tighten screw/bolts (3, 4) finger-tight.

using screw/bolt (3) and onto bore (6) using screw/bolt (4) Remove

4 Unscrew screw/bolt (4) 5 Remove screw/bolt (3) and remove retaining lock (7) Install

6.1 Install manual transmission ENGINE 281 in MODEL 453 with TRANSMISSION 700.12 AR26.10-P-0020SR 6.2 Install DKG ENGINE 281 in MODEL 453 with TRANSMISSION 700.41 AR27.10-P-0502SR 102 589 01 40 00 Retaining lock Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.30-p-5000sr, Remove/install retaining lock for crankshaft/ring gear ENGINE 281 in MODEL 453

AR03.30-P-1700FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 700 · Applies to: 453 · AR: AR03.30-P-1700FF, AR13.22-P-1202FF

Removing/installing the belt pulley 12.12.03 ENGINES 134.9, 135.9 in MODEL 454.0 Illustrated on removed engine 135.9 1 Bolt 2 Belt pulley P03.20-2159-11 Removing/installing

1 Remove poly-V-belt AR13.22-P-1202FF 2 Unscrew bolt (1) *BA03.30-P-1002-01L

*454589034000

3 Remove belt pulley (2) Installation: Turn the belt pulley (2) to

ensure that the groove on the belt pulley (2) coincides with the roll pin on the crankshaft. 4 Install in reverse order Flywheel, driven plate, vibration damper, starter ring gear

Number Designation Engines 134.910/911, 135930/950 BA03.30-P-1002-01L Central bolt for belt pulley on crankshaft 1st stage Nm 50 ° 2nd stage 50 454 589 03 40 00 Counterholder Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.30-p-1700ff, Removing/installing the belt pulley ENGINES 134.9, 135.9 in MODEL 454.0

AR03.30-P-8002FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 701 · Applies to: 453 · AR: AR03.30-P-8002FF, AR25.10-P-0050FF

Removing/installing the flywheel 18.11.03 ENGINES 122.9, 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Flywheel 2 Bolts 3 Retaining lock
P03.30-2072-01 Removing/installing

1 Remove clutch AR25.10-P-0050FF 2 Mark installation position of flywheel (1) 3 Unscrew bolts (2) at flywheel (1) Replace bolts (2). *BA03.30-P-1001-01L

4 Remove retaining lock (3) *454589004000

5 Take off flywheel (1) Installation:

Check flywheel (1) for wear; replace if necessary. 6 Install in reverse order Flywheel, driven plate, vibration damper, starter ring gear

Number Designation Engine Engines 134.910/911, 122.950 135930/950 BA03.30-P-1001-01L Bolt for flywheel on crankshaft Stage Nm 132 30 ° Stage 2 - 50 454 589 00 40 00 Retaining lock Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.30-p-8002ff, Removing/installing the flywheel ENGINES 122.9, 134.9, 135.9 in MODEL 454.0

AR03.30-P-8002FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 702 · Applies to: 453 · AR: AR03.30-P-8002FG, AR25.10-P-0050FG

Removing/installing the flywheel 28.9.04 ENGINE 639.939 in MODEL 454.0 with TRANSMISSIONS 717.473 /475 1 Flywheel 2 Retaining lock 3 Bolts P03.30-2104-03 Removing/installing

1 Remove clutch AR25.10-P-0050FG 2 Remove screws (3) Installation:

Check flywheel (1), replace if necessary. Replace bolts (3) and tighten crosswise. Do not use a flexi-torque wrench for tightening to angle degrees in order to avoid any angle errors. *BA03.30-P-1003-01K

3 Remove flywheel (1) from the crankshaft Installation:

Observe cylindrical pin on flywheel (1). The installation position is fixed by the cylindrical pin on the flywheel (1) and the aligning bore on the crankshaft. 4 Remove retaining lock (2) Installation:

Only mount retaining lock (2) after fitting the flywheel (1). *454589004000

5 Install in reverse order Flywheel, driven plate, vibration damper, starter ring gear

Number Designation Engine 639.939 BA03.30-P-1003-01K Bolt for flywheel on crankshaft 1st stage Nm 45 ° Step 2 180

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar03.30-p-8002fg, Removing/installing the flywheel ENGINE 639.939 in MODEL 454.0 with TRANSMISSIONS 717.473 /475

AR05.00-P-2500FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 716 · Applies to: 453 · AR: AR05.00-P-2500FG, AR05.20-P-6292FG, AR05.20-P-6292FH

Removing and installing the cam follower 29.9.04 ENGINE 639.939 in MODEL 454.0 P05.00-2064-08 1 Hydraulic valve clearance compensation elements with 2 Cylinder head roller-type cam follower 1.1 Roller drag lever 1.2 Hydraulic valve clearance compensation element P05.00-2065-01 Removing/installing

1.1 Remove inlet camshaft When renewing the roller-type cam follower AR05.20-P-6292FG (1.1) on the intake valves. 1.2 Remove exhaust camshafts When renewing the roller-type cam follower AR05.20-P-6292FH (1.1) on the exhaust valves. 2 Remove hydraulic valve clearance Mark the hydraulic valve clearance compensation elements with roller-type cam compensation elements with roller-type cam follower (1) from the cylinder head (2) follower (1) to be reused and install again in the same position. 3 Unclip hydraulic valve clearance Do not disassemble hydraulic valve compensation element (1.2) from the roller- clearance compensation element (1.2) since type cam follower (1.1) spring (arrow) and this would destroy it. remove Observe correct seating of the spring (arrow). 4 Install in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.00-p-2500fg, Removing and installing the cam follower ENGINE 639.939 in MODEL 454.0

AR05.00-P-2310SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 717 · Applies to: 453 · AR: AR05.00-P-2310SR, AR05.20-P-6992SR, AR01.30-P-5800SR

Removing and installing the valves 21.07.2014 ENGINE 281 in MODEL 453 1 Valve tappet 2 Cylinder head 3 Basic bore P05.00-2104-06 Remove

1 Remove camshafts AR05.20-P-6992SR 2 Mark valve tappet (1) relative to the basic The valve tappet (1) must remain assigned

bores (3) to the respective basic bores (3). 3 Remove valve tappet (1) from basic bores (3)

in cylinder head (2)
Do not use magnets. Gathering of the smallest metal shavings can occur due to magnetization of the valve tappet (1) which can lead to damage to the valve tappet (1) and the camshafts. Check

4 Check ease of movement of the valve tappet If there are problems: (1) in the basic bores (3) and basic bores (3) for damage Replace valve tappet (1) and cylinder head (2). AR01.30-P-5800SR Install

5 Assign valve tappet (1) to the basic bores (3) Observe marking.

6 Lubricate valve tappet (1) with engine oil and insert in the basic bores (3) 7 Install camshafts AR05.20-P-6992SR Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.00-p-2310sr, Removing and installing the valves ENGINE 281 in MODEL 453

AR05.00-P-2310FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 718 · Applies to: 453 · AR: AR05.00-P-2310FF, AR05.20-P-6992FF, AR01.30-P-5800FF

Removing/installing a valve tappet 25.2.04 ENGINES 134.9, 135.9 in MODEL 454.0 P05.00-2050-08 Shown on engine 135.9 1 Intake camshaft 2 Exhaust camshaft 3 Valve tappet Removing/installing

1 Remove intake camshaft (1) or exhaust AR05.20-P-6992FF camshaft (2) over the relevant valve tappet (3) 2 Clean valve tappet (3) with clean rags The valve tappet (3) must be free of oil. 3 Remove valve tappet (3) Do not use a magnet. Magnetization of the valve tappet (3) can lead to gathering of the smallest iron chips which can lead to damage to the valve tappet (3) and intake camshaft (1)or exhaust camshaft (2). Installation:

When recycling the valve tappet (3) they must be reinstalled at the same location. Checking

4 Check basic bores on cylinder head Replace cylinder head if damaged. Refer to: Removing/installing cylinder head AR01.30-P-5800FF 5 Install in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.00-p-2310ff, Removing/installing a valve tappet ENGINES 134.9, 135.9 in MODEL 454.0

AR05.00-P-2011FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 719 · Applies to: 453 · AR: AR05.00-P-2011FG, AR05.20-P-6292FG, AR05.20-P-6292FH

Removing/installing hydraulic valve clearance compensation elements 17.9.04 ENGINE 639.939 in MODEL 454.0 P05.00-2064-08 1 Hydraulic valve clearance compensation elements with 2 Cylinder head roller-type cam follower 1.1 Roller drag lever 1.2 Hydraulic valve clearance compensation element P05.00-2065-01 Removing/installing

1.1 Remove inlet camshaft When replacing the hydraulic valve clearance AR05.20-P-6292FG compensation elements (1.2) on the intake valves. 1.2 Remove exhaust camshafts When replacing the hydraulic valve clearance AR05.20-P-6292FH compensation elements (1.2) on the exhaust valves. 2 Remove hydraulic valve clearance Mark the hydraulic valve clearance compensation elements with roller-type cam compensation elements with roller-type cam follower (1) from the cylinder head (2) follower (1) to be reused and install again in the same position. 3 Unclip hydraulic valve clearance Do not disassemble hydraulic valve compensation element (1.2) from the roller- clearance compensation element (1.2) since type cam follower (1.1) spring (arrow) and this would destroy it. remove Mark hydraulic valve clearance compensation elements (1.2) or roller-type cam follower (1.1) to be reused and install again in the same position. Observe correct seating of the spring (arrow). 4 Install in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.00-p-2011fg, Removing/installing hydraulic valve clearance compensation elements ENGINE 639.939 in MODEL 454.0

BE05.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 721 · Applies to: 453 · AR: BE05.00-Z-9999CZ

Test and adjustment values: Smart: Engine timing 18.09.2019 MODEL all Test values for valve seat rings ENGINE 160.910/920/921/922 BE05.30-P-1000-03D Valve clearance Engine 132.9, 134, 135 Engine 281 BE05.30-P-1000-06C Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be05.00-z-9999cz, Test and adjustment values: Smart: Engine timing MODEL all

AR05.10-P-6858SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 723 · Applies to: 453 · AR: AR05.10-P-6858SR, AR15.12-P-1010SR, AR01.20-P-5014SR

Check engine valve timing 02.05.2019 Engine 281 in model 453 Modification notes 25.04.2019 Remove/install cover over the poly-V-belt, added. Operation steps 3 and 14 Shown with CODE I01 (AAC) 7 Cover 8 Bolts P13.22-A005-06 P05.10-2543-07 1 Holding device 3 Mount dial indicator 4 Catches 2 Bracket Remove

1 Remove spark plugs. AR15.12-P-1010SR 2 Remove cylinder head cover. AR01.20-P-5014SR 3 Remove screws (8) and remove cover (7). 4 Remove filler neck for engine oil. Check

5 Attach holding device (1), as shown, without 281589014000 Holding device catches (4) with 2 screws of the cylinder head cover. 6 Attach dial indicator (3) with bracket (2) and 2 450589062100 Dial indicator with accessories measuring rod extensions, as shown, to determine the top dead center (TDC) of cylinder 1 to the holding device (1). Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.10-p-6858sr, Check engine valve timing Engine 281 in model 453

Position piston of cylinder 1 by turning the

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 724 · Applies to: 453 · AR: AR05.10-P-7602SR, AR01.20-P-5014SR, AR15.12-P-1010SR

7 Position piston of cylinder 1 by turning the crankshaft on the belt pulley to ignition TDC. 8 Remove dial indicator (3) with bracket (2). 9 Insert catches (4) into the holding device (1). *281589014000 Holding device If the catches (4) cannot be inserted, Remove timing chain and set timing. AR05.10-P-7602SR 10 Remove holding device (1) with catches (4). Clean

11 Clean sealing surface of the filler neck for engine oil. 12 Clean bore for the filler neck for engine oil in the timing case cover. Install

13 Attach filler neck for engine oil. 14 Install cover (7) with screws (8). 15 Install cylinder head cover. AR01.20-P-5014SR 16 Install spark plugs. AR15.12-P-1010SR 450 589 06 21 00 281 589 01 40 00 Dial indicator with accessories Holding device Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.10-p-6858sr, Check engine valve timing Engine 281 in model 453

AR05.10-P-8127FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 725 · Applies to: 453 · AR: AR05.10-P-8127FF, AR01.40-P-8000FF, AR05.10-P-7800FF

Remove, install tensioning rail 13.4.06 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 134.9 1 Chain tensioner 2 Bolt 3 Tensioning rail P05.10-2215-11 Remove/install

1 Remove timing case cover AR01.40-P-8000FF 2 Remove chain tensioner (1) AR05.10-P-7800FF 3 Remove bolts (2) *BA05.10-P-1002-01I

4 Remove tensioning rail (3) 5 Install in the reverse order Timing chain drive

Number Designation Engine Engine Engine Engine 134.910 134.911 135.930 135.950 BA05.10-P-1002-01I Bolt, timing chain tensioning rail to cylinder Nm 24 24 24 24 head Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.10-p-8127ff, Remove, install tensioning rail ENGINE 134.9, 135.9 in MODEL 454.0

AR05.10-P-7602SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 726 · Applies to: 453 · AR: AR05.10-P-7602SR, AR01.40-P-8000SR, AR15.12-P-1010SR, AR05.10-P-7800SR, AR05.10-P-8510SR (+2 more)

Remove, install timing chain 21.07.2014 ENGINE 281 in MODEL 453 1 Timing chain 5 Camshaft sprocket 6 Camshaft positioner 7 Crankshaft gear 8 Chain tensioner 9 Tensioning rail 10 Slide rail P05.10-2502-06 1 Timing chain 2 Marking 3 Marking 4 Marking 5 Camshaft sprocket 6 Camshaft positioner 7 Crankshaft gear P05.10-2501-06 Remove

1 Remove timing case cover AR01.40-P-8000SR 2 Remove spark plugs AR15.12-P-1010SR 3 Place engine at TDC for cylinder 1 The mark (4) on the crankshaft gear (7)

must point vertically downwards. The marking (2) on the camshaft sprocket (5) and the marking (3) on the camshaft positioner (6) must point upwards. 4 Remove chain tensioner (8) AR05.10-P-7800SR 5 Remove tensioning rail (9) AR05.10-P-8510SR 6 Remove slide rail (10) AR05.10-P-8480SR 7 Remove camshaft sprocket (5) AR05.20-P-6040SR Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar05.10-p-7602sr, Remove, install timing chain ENGINE 281 in MODEL 453

Remove timing chain (1) from camshaft

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 727 · Applies to: 453 · AR: AR05.20-P-6040SR, AR05.10-P-8480SR, AR05.10-P-8510SR, AR05.10-P-7800SR, AR15.12-P-1010SR (+1 more)

8 Remove timing chain (1) from camshaft positioner (6) and crankshaft gear (7) Install

9 Lay timing chain (1) onto camshaft positioner The color codings (arrows) on the timing

(6) and crankshaft gear (7) chain (1) must coincide with the mark (3) on the camshaft positioner (6) and the mark (4) on the crankshaft gear (7). 10 Install camshaft sprocket (5) AR05.20-P-6040SR 11 Install slide rail (10) AR05.10-P-8480SR 12 Install tensioning rail (9) AR05.10-P-8510SR 13 Install chain tensioner (8) AR05.10-P-7800SR 14 Install spark plugs AR15.12-P-1010SR 15 Install timing case cover AR01.40-P-8000SR Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar05.10-p-7602sr, Remove, install timing chain ENGINE 281 in MODEL 453

AR05.10-P-7800FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 728 · Applies to: 453 · AR: AR05.10-P-7800FF, AR18.40-P-3510FF

Remove/install chain tensioner 27.10.09 ENGINES 134.9, 135.9 in MODEL 454.0 Illustrated on removed engine 135.9 1 Oil dipstick guide tube 2 Bolts 3 Cap 4 Sealing surface 5 Allen wrench 6 Bolts 7 Chain tensioner P05.10-2200-11 Remove/install

1 Open engine hood 2 Remove the oil dipstick guide tube (1). AR18.40-P-3510FF 3 Remove the screws (2) of the cap (3) *BA01.40-P-1005-01O

4 Take off cap (3) Installation:

Clean the sealing surface (4) on the timing case cover and clean sealing surface on cap (3). Replace sealing compound. Sealing compound BR00.45-Z-1053-01A 5 Fix the chain tensioner (7) Fix the chain tensioner (7) with a suitable Allen wrench (5). 6 Remove the bolts (6) of the chain tensioner BA05.10-P-1003-01I

(7) 7 Take out chain tensioner (7) 8 Install in the reverse order Cylinder crankcase, timing case cover, end cover

Number Designation Engine Engine 134.911 134.910 BA01.40-P-1005-01O Torx bolt for chain tensioner cap on timing Nm 9 9 case cover Cylinder crankcase, timing case cover, end cover

Number Designation Engine Engine 135.930 135.950 BA01.40-P-1005-01O Torx bolt for chain tensioner cap on timing Nm 9 9 case cover Timing chain drive

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.10-p-7800ff, Remove/install chain tensioner ENGINES 134.9, 135.9 in MODEL 454.0

AR05.10-P-7800SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 730 · Applies to: 453 · AR: AR05.10-P-7800SR, AR01.40-P-8000SR

Remove/install chain tensioner 21.07.2014 ENGINE 281 in MODEL 453 P05.10-2507-09 1 Chain tensioner 3 Allen wrench 5 Tensioning rail 2 Piston 4 Clamping lever 6 Screw/bolt Remove

1 Remove timing case cover
AR01.40-P-8000SR 2 Insert a suitable Allen wrench (3) into the bore of the chain tensioner (1) and thus press the clamping lever (4) of the chain tensioner (1) as far as possible in the direction of the piston (2). 3 Push in piston (2) by pressing fully on the The chain tensioner (1) must be replaced

tensioning rail (5) into the chain tensioner (1) after each pressing in of the piston (2). 4 Pull the Allen wrench (3) out of the bore of the chain tensioner (1) then allow the piston (2) to shift slowly out of the chain tensioner (1) until the bores of the clamping lever (4) and the chain tensioner (1) are exactly opposing each other. 5 Insert Allen wrench (3) through the bores of the clamping lever (4) and the chain tensioner (1) 6 Remove screw/bolts (6)
7 Remove chain tensioner (1) from crankcase
8 Pull Allen wrench (3) out of the bore of the chain tensioner (1) Install

9 Lay new chain tensioner (1) on the crankcase

and tighten down with screw/bolts (6) Install a new chain tensioner (1) as a rule. Reuse of the chain tensioner (1) can lead to engine damage. *BA05.10-P-1004-01P Bolt, timing chain tensioner to crankcase 10 Remove the retainer installed at the works from the bore of the new chain tensioner (1). 11 Install timing case cover
AR01.40-P-8000SR Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar05.10-p-7800sr, Remove/install chain tensioner ENGINE 281 in MODEL 453

AR05.10-P-8484FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 732 · Applies to: 453 · AR: AR05.10-P-8484FF, AR01.40-P-8000FF, AR05.10-P-7800FF

Remove/install slide rail in timing case cover 13.4.06 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 134.9 1 Chain tensioner 2 Bolt 3 Slide rail P05.10-2214-11 Remove/install

1 Remove timing case cover AR01.40-P-8000FF 2 Remove chain tensioner (1) AR05.10-P-7800FF 3 Remove bolts (2) *BA05.10-P-1001-01I

4 Remove slide rail (3) 5 Install in the reverse order Timing chain drive

Number Designation Engine Engine Engine Engine 134.910 134.911 135.930 135.950 BA05.10-P-1001-01I Bolt, timing chain guide rail to crankcase Nm 10 10 10 10 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.10-p-8484ff, Remove/install slide rail in timing case cover ENGINE 134.9, 135.9 in MODEL 454.0

AR05.10-P-8484FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 733 · Applies to: 453 · AR: AR05.10-P-8484FG, AR01.10-P-2401FG, AR05.20-P-6010FH, AR01.40-P-8000FG, AR05.20-P-6040FG

Remove/install slide rail in timing case cover 17.1.06 ENGINE 639.9 in MODEL 454.0 1 Slide rail 2 Lower bearing pin 3 Upper bearing pin 4 Belt pulley P05.10-2318-06 Remove/install

1 Remove engine with transmission AR01.10-P-2401FG 2 Check basic position of camshafts AR05.20-P-6010FH When checking the basic inspection, the TDC marking is set on the belt pulley (4) to the positioning edge on the timing case cover (arrow A). The crankshaft must not turned anymore. 3 Remove timing case cover AR01.40-P-8000FG Installation: Before installing the cylinder

head cover, check the basic position of the camshaft, adjust if necessary. See Inspect basic position of camshaft AR05.20-P-6010FH 4 Remove camshaft sprocket AR05.20-P-6040FG 5 Take off timing chain 6 Remove upper bearing pin (2) with the puller *450589033300

Installation:

Screw bolt M6 into the upper bearing pin (2) and knock in the upper bearing pin (2) up to the stop in the cylinder head . Then unscrew the bolt M6 out of the upper bearing pin (2). 7 Remove the slide rail (1) from the lower bearing pin (3) and remove from below 8 Install in the reverse order 450 589 03 33 00 Puller Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.10-p-8484fg, Remove/install slide rail in timing case cover ENGINE 639.9 in MODEL 454.0

AR05.10-P-8480SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 734 · Applies to: 453 · AR: AR05.10-P-8480SR, AR05.10-P-7800SR

Remove/install slide rail of timing chain 21.07.2014 ENGINE 281 in MODEL 453 1 Slide rail 2 Chain tensioner 3 Screw/bolt 4 Timing chain P05.10-2503-06 Remove

1 Remove chain tensioner (2) AR05.10-P-7800SR 2 Remove screws/bolts (3) 3 Remove slide rail (1) from the timing chain (4) Observe installation position of slide rail

(1). Check

4 Check slide rail (1) for wear, galling and If there are problems: damage Replace slide rail (1). Install

5 Lay slide rail (1) on the timing chain (4) and Observe installation position of slide rail

tighten down with screw/bolts (3) (1). BA05.10-P-1002-01P Bolt, timing chain slide rail to cylinder head BA05.10-P-1003-01P Bolt, timing chain slide rail to crankcase 6 Install chain tensioner (2) AR05.10-P-7800SR Timing chain drive Number Designation ENGINE 281 BA05.10-P-1002-01P Bolt, timing chain slide rail to cylinder head Nm 25 Timing chain drive Number Designation ENGINE 281 BA05.10-P-1003-01P Bolt, timing chain slide rail to crankcase Nm 25 Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar05.10-p-8480sr, Remove/install slide rail of timing chain ENGINE 281 in MODEL 453

AR05.10-P-8510SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 735 · Applies to: 453 · AR: AR05.10-P-8510SR, AR05.10-P-7800SR

Remove/install tensioning rail timing chain 21.07.2014 ENGINE 281 in MODEL 453 1 Tensioning rail 2 Chain tensioner 3 Pin 4 Timing chain P05.10-2504-06 Remove

1 Remove chain tensioner (2) AR05.10-P-7800SR 2 Remove tensioning rail (1) from timing chain (4) and screw/bolts (3) Check

3 Check tensioning rail (1) for wear, galling and If there are problems: damage Replace tensioning rail (1). Install

4 Hook tensioning rail (1) onto screw/bolts (3) and lay timing chain (4) on the tensioning rail (1) 5 Install chain tensioner (2) AR05.10-P-7800SR Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.10-p-8510sr, Remove/install tensioning rail timing chain ENGINE 281 in MODEL 453

AR05.10-P-7800FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 736 · Applies to: 453 · AR: AR05.10-P-7800FG

Removing/installing the chain tensioner 17.9.04 ENGINE 639.939 in MODEL 454.0 P05.10-2315-07 1 Chain tensioner 2 Sealing ring Removing/installing

Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A toppling off the lifting platform. hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. 1 Lift vehicle on lifting platform. 2 Unscrew chain tensioner (1) and remove Installation: Install new sealing ring (2) *BA05.10-P-1002-01M

3 Install in reverse order Timing chain drive

Number Designation Engine 639.939 BA05.10-P-1002-01M Bolt for cam chain tensioner on cylinder Nm 80 head Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.10-p-7800fg, Removing/installing the chain tensioner ENGINE 639.939 in MODEL 454.0

AR05.10-P-4600FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 737 · Applies to: 453 · AR: AR05.10-P-4600FG, AR05.10-P-8484FG, AR18.10-P-6020FG, AR03.20-P-3638FG

Removing/installing the crankshaft sprocket 9.9.04 ENGINE 639.939 in MODEL 454.0 1 Crankshaft sprocket 2 Chain tensioner of oil pump chain 3 Belt pulley 4 Balance shaft 5 Oil pump chain P05.10-2319-06 Removing/installing

1 Remove sliding rail from timing case cover AR05.10-P-8484FG When removing the slide rail, the TDC marking on the belt pulley (3) is adjusted with respect to the positioning edge of the timing case cover (arrow A). The crankshaft must not be twisted any more. 2 Press the chain tensioner of the oil pump chain (2) all the way to the stop and secure with a drift having 3.5 mm diameter through the bore (arrow B) 3 Remove oil pump AR18.10-P-6020FG 4 Remove the oil pump chain (5) Do not twist the crankshaft. Installation: When laying on the oil pump

chain (5), pay attention to the basic position of the balance shaft (4). Refer to: Set the basic position of the balance shaft AR03.20-P-3638FG 5 Remove crankshaft gear (1) Installation: Align the Woodruff key with

the crankshaft; slide on crankshaft gear (1). 6 Install in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.10-p-4600fg, Removing/installing the crankshaft sprocket ENGINE 639.939 in MODEL 454.0

AR05.10-P-8127FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 738 · Applies to: 453 · AR: AR05.10-P-8127FG, AR01.10-P-2401FG, AR05.20-P-6010FH, AR01.40-P-8000FG, AR05.20-P-6040FG

Removing/installing the tensioning rail 17.9.04 ENGINE 639.939 in MODEL 454.0 1 Tensioning rail 2 Bearing pin 3 Belt pulley P05.10-2317-06 Removing/installing

1 Remove engine with transmission AR01.10-P-2401FG 2 Check basic position of camshafts AR05.20-P-6010FH When checking the basic position, the TDC marking on the belt pulley (3) is adjusted with respect to the positioning edge of the timing case cover (arrow A). The crankshaft must not be twisted any more. 3 Remove timing case cover AR01.40-P-8000FG Installation: Check and if necessary

correct the basic position of the camshaft before installing the cylinder head cover. Refer to: Inspect basic position of camshaft AR05.20-P-6010FH 4 Remove camshaft sprocket AR05.20-P-6040FG 5 Take off timing chain 6 Remove tensioning rail (1) from bearing pin (2) 7 Install in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.10-p-8127fg, Removing/installing the tensioning rail ENGINE 639.939 in MODEL 454.0

AR05.10-P-7601FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 739 · Applies to: 453 · AR: AR05.10-P-7601FF, AR01.40-P-8000FF, AR05.20-P-6010FG, AR05.10-P-7800FF

Replace timing chain 13.4.06 ENGINE 134.9, 135.9 in MODEL 454.0 P05.20-2219-09 Illustrated on removed engine 134.9 1 Timing chain 7 Chain link 13 Crankcase 2 Bolt 8 Intake camshaft 14 Marking 3 Camshaft sprocket 9 Marking 15 Marking 4 Exhaust camshaft 10 Crankshaft 16 Camshaft adjuster 5 Marking 11 Marking 6 Marking 12 Marking Removing

1 Remove timing case cover AR01.40-P-8000FF 2 Check basic position of camshafts AR05.20-P-6010FG 3 Remove chain tensioner AR05.10-P-7800FF 4 Remove bolt (2) and camshaft sprocket (3) To remove bolt (2) counterhold exhaust from the exhaust camshaft (4) camshaft (4) at hexagon. 5 Remove timing chain (1) from ring gear on camshaft adjuster (16) and crankshaft (10) Install

6 Check whether marking (12) on crankshaft Possibly also turn the crankshaft (10) at (10) and marking (11) on crankcase (13) the ring gear on flywheel. coincide with each other 7 Lay new timing chain (1) on the crankshaft There are three black chain link (7) (10) ring gear and camshaft adjuster (16) ring attached to the circumference of the timing gear in such a way that a black chain link (7) chain (1). lies opposite each of the markings (6, 9) Possibly turn camshaft adjuster (16) at hexagon on the intake camshaft (8). 8 Insert camshaft sprocket (3) in the timing chain (1) such a way that the marking (5) lies opposite a black chain link (7) 9 Place camshaft sprocket (3) on the exhaust The marking (14) on the camshaft camshaft (4) and tighten firmly with the bolt sprocket (3) and the marking (15) on the (2) camshaft adjuster (16) must coincide with each other. To tighten bolt (2), counterhold exhaust camshaft (4) at hexagon. *BA05.20-P-1005-01I

10 Installing chain tensioner AR05.10-P-7800FF 11 Turn crankshaft (10) through two revolutions Turn the crankshaft (10) at the ring gear clockwise (arrow) on the flywheel. 12 Once again check basic position of the AR05.20-P-6010FG camshafts 13 Install timing case cover AR01.40-P-8000FF Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.10-p-7601ff, Replace timing chain ENGINE 134.9, 135.9 in MODEL 454.0

AR05.10-P-7601FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 741 · Applies to: 453 · AR: AR05.10-P-7601FG, AR01.20-P-5014FG, AR40.10-P-1100FF, AR05.10-P-7800FG, AR05.20-P-6010FH

Replacing the timing chain 14.12.04 ENGINE 639.9 in MODEL 454.0 1 Timing chain 2 Belt pulley 3 Camshaft bearing cap 4 Tie-down set P05.10-2321-06 Removing

1 Remove cylinder head cover AR01.20-P-5014FG 2 Remove wheel at the right front AR40.10-P-1100FF 3 Position the piston of cylinder 1 to ignition The TDC marking on the belt pulley (2) TDC by rotating the engine at the belt pulley must align with the positioning edge on the (2). timing case cover (arrow). 4 Remove chain tensioner AR05.10-P-7800FG 5 Remove camshaft bearing cap (3) and fit hold Use bolts for camshaft bearing cap (3). down device (4) *640589014000

6 Separate old timing chain (1) AR05.10-P-7601-01FG Cover the chain slot and the cylinder head with a clean rag. *602589009800

*602589023300

*602589056300

*602589056301

*640589014000

Installing

7 Draw in new timing chain (1) AR05.10-P-7601-04FG *602589009800

*602589024000

*640589014000

8 Rivet the new timing chain (1) AR05.10-P-7601-02FG *602589003900

*602589009800

*640589014000

*640589016300

*602589036300

9 Installing chain tensioner AR05.10-P-7800FG 10 Remove hold-down device (4) and install *BA05.20-P-1002-01H

camshaft bearing cap (3) *640589014000

11 Check basic position of camshafts AR05.20-P-6010FH 12 Attach wheel at the right front AR40.10-P-1100FF 13 Install cylinder head cover AR01.20-P-5014FG Camshaft

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.10-p-7601fg, Replacing the timing chain ENGINE 639.9 in MODEL 454.0

AR05.20-P-6010FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 743 · Applies to: 453 · AR: AR05.20-P-6010FF, AR88.00-P-2792FF, AR01.20-P-5014FF, AR05.20-P-6020FF

Checking the basic position of camshafts 12.12.03 ENGINES 134.9, 135.9 in MODEL 454.0 Timing case cover built-in Shown on engine 134.9 1 Belt pulley 2 Camshaft adjuster 3 Camshaft sprocket 4 Timing case cover A Scribe marks P05.20-2176-06 Removing

1 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 2 Remove cylinder head cover AR01.20-P-5014FF Checking 3 Set piston on cylinder 1 to ignition TDC The TDC marking on the belt pulley (1) must align with the positioning edge on the timing case cover (arrow). The cams for the intake camshaft and of exhaust camshaft at cylinder 1 must be positioned upwards at an angle. 4 Check basic position of camshafts Markings (A) on the camshaft adjuster (2) and on the camshaft sprocket (3) must lie opposite to each other at the level of the upper edge of the timing case cover (4). Possibly also set the basic position of camshafts. Refer to: Set the basic position of camshafts AR05.20-P-6020FF Installing

5 Install cylinder head cover AR01.20-P-5014FF 6 Install covering on center section in front of AR88.00-P-2792FF windshield Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6010ff, Checking the basic position of camshafts ENGINES 134.9, 135.9 in MODEL 454.0 Timing case cover built-in

AR05.20-P-6010FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 744 · Applies to: 453 · AR: AR05.20-P-6010FG, AR05.20-P-6020FG

Checking the basic position of camshafts 24.8.04 ENGINE 134.9, 135.9 in MODEL 454.0 Timing case cover removed P05.20-2218-09 Illustrated on removed engine 134.9 1 Camshaft sprocket 4 Marking 7 Marking 2 Camshaft adjuster 5 Marking 8 Crankshaft 3 Marking 6 Crankcase 9 Marking 10 Marking Checking

1 Turn the crankshaft (8) clockwise (arrow) until The marking (4) on the camshaft sprocket the marking (4) on the camshaft sprocket (1) (1) consists of two points. lies opposite the marking (3) on the camshaft Marking (3) and marking (9) on the camshaft adjuster (2) adjuster (2) are identical in design and be confused with each other. Correct adjustment of camshafts is only given if the marking (3) lies opposite marking (4) and marking (9) is pointing upwards. 2 Check whether marking (7) on the crankshaft Marking (7) and marking (10) on the (8) lies opposite marking (5) on the crankcase crankshaft (8) are identical in design and be (6) confused with each other. Correct adjustment of the crankshaft (8) is only given if the marking (7) lies opposite marking (5) and marking (10) is pointing in the direction of the intake side. If marking (3) does not coincide with marking (4) or marking (5) does not coincide with marking (7) then basic setting of camshafts must be executed. Refer to: Set the basic position of camshafts AR05.20-P-6020FG Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6010fg, Checking the basic position of camshafts ENGINE 134.9, 135.9 in MODEL 454.0 Timing case cover removed

AR05.20-P-6010FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 745 · Applies to: 453 · AR: AR05.20-P-6010FH, AR01.20-P-5014FG, AR05.20-P-6020FH, AR05.20-P-6020FJ

Checking the basic position of camshafts 24.9.04 ENGINE 639.939 in MODEL 454.0 1 Intake camshaft gear wheel 2 Exhaust camshaft gear wheel 3 Belt pulley 4 Bore 5 Timing case cover P05.20-2224-06 Removing

1 Remove cylinder head cover AR01.20-P-5014FG Checking

2 Set piston on 1st cylinder to ignition TDC and The TDC marking (arrow D) on the belt check the basic position of the camshafts pulley (3) must be aligned with the positioning edge (arrow C) on the timing case cover (5). The marking (arrow A) on the intake camshaft (1) gear wheel must be exactly opposite the marking (arrow B) on the exhaust camshaft gear wheel (2). The camshafts can be locked using a drift in the bore (4) for further work. Adjust the camshaft appropriately if the basic position is incorrect. See: Adjust basic position of the intake camshaft or AR05.20-P-6020FH intake and exhaust camshaft Set basic position of exhaust camshaft AR05.20-P-6020FJ Installing

3 Install cylinder head cover AR01.20-P-5014FG Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6010fh, Checking the basic position of camshafts ENGINE 639.939 in MODEL 454.0

AR05.20-P-6292FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 746 · Applies to: 453 · AR: AR05.20-P-6292FG, AR01.30-P-5702FG, AR01.30-P-5700FG, AR05.20-P-6010FH, AR05.10-P-7800FG

Remove/install camshaft 17.1.06 ENGINE 639.9 in MODEL 454.0 Intake camshaft 1 Intake camshaft 2 Timing chain 3 Camshaft sprocket of timing chain 4 Bolts 5 Tie strap 6 Front camshaft bearing cap 7 Bolts 8 Rear camshaft bearing cap 9 Exhaust camshaft gearwheel 10 Bore 11 Intake camshaft gearwheel P05.20-2226-06 Remove/install

1 Remove rear cover at cylinder head AR01.30-P-5702FG 2 Remove front cover at cylinder head AR01.30-P-5700FG 3 Check basic position of camshafts AR05.20-P-6010FH 4 Loosen bolts (4) at timing chain camshaft *BA05.20-P-1001-01H

sprocket (3) 5 Secure timing chain (2) with cable tie (5) at the timing chain camshaft sprocket (3) 6 Remove chain tensioner AR05.10-P-7800FG 7 Unscrew bolts (4) at timing chain camshaft sprocket (3) 8 Remove the timing chain camshaft sprocket Installation:

By turning the timing chain (3) with the timing chain (2) from the intake camshaft sprocket (3), make sure that the camshaft (1) and place to one side bore of the timing chain camshaft sprocket (3) is aligned with the roll pin of the intake camshaft (1). 9 Unscrew the bolts (7) equally *BA05.20-P-1002-01H

10 Remove the front camshaft bearing cap (6) Mark installation position. and the rear camshaft bearing cap (8) 11 Remove intake camshaft (1) from above Note correct installation position. The bores (10) are aligned to the exhaust side. Installation: The marking (arrow A) on

the tooth of the intake camshaft gearwheel (11) must lie exactly opposite the marking (arrow B) on the gearwheel of the exhaust camshaft (9). 12.1 Remove the gearwheel of the high pressure When replacing the intake camshaft (1). AR07.02-P-1020-01FF pump The high-pressure pump gearwheel must always be replaced when the intake camshaft (1) is replaced. *BA07.16-P-1012-01G

001589503300 Puller 454589044000 Counterholder *640589013300 Bell-type puller 13 Install in the reverse order Camshaft

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6292fg, Remove/install camshaft ENGINE 639.9 in MODEL 454.0 Intake camshaft

AR05.20-P-7201FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 748 · Applies to: 453 · AR: AR05.20-P-7201FF, AR05.20-P-7295FF, AR88.40-P-3000FF, AR05.20-P-6010FF, AR05.10-P-7800FF

Remove/install camshaft adjusters 13.4.06 ENGINES 134.9, 135.9 in MODEL 454.0 P05.20-2178-08 Shown on engine 135.9 1 Intake camshaft 5 Screw 9 Bearing bridge 2 Exhaust camshaft 6 Camshaft adjuster 10 Camshaft bearing cap 3 Screw 7 Timing chain 11 Camshaft bearing cap 4 Camshaft sprocket 8 Cable tie Shown on engine 135.9 4 Camshaft sprocket 6 Camshaft adjuster 7 Timing chain P05.20-2188-01 Modification notes 25.10.04 Contents of document AR05.20-P-7295FF taken over and document rewritten Remove/install

1 Remove engine hood AR88.40-P-3000FF 2 Check basic position of camshafts AR05.20-P-6010FF 3 Remove chain tensioner AR05.10-P-7800FF 4 Loosen bolt (3) for camshaft sprocket (4) on Loosen bolt (3) smoothly to prevent the exhaust camshaft (2) damage to the exhaust camshaft (2). Counterhold exhaust camshaft (2) at hexagon (arrow A). *BA05.20-P-1005-01I

5 Loosen bolt (5) for camshaft adjuster (6) on Do not loosen bolt (5) jerkily otherwise the intake camshaft (1) there is a risk of damaging the intake camshaft (1). Counterhold intake camshaft (1) at hexagon (arrow B). *BA05.20-P-1004-01I

6 Fix timing chain (7) with cable tie (8) on the exhaust camshaft (2) camshaft sprocket (4) 7 Remove bearing bridge (9) and exhaust Observe the loosening sequence since camshaft (2) camshaft bearing cap (10) otherwise the exhaust camshaft (2) can get damaged. Engine 134.9 AR05.20-P-6992-04FG *BA05.20-P-1001-01I

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-7201ff, Remove/install camshaft adjusters ENGINES 134.9, 135.9 in MODEL 454.0

AR05.20-P-7201SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 750 · Applies to: 453 · AR: AR05.20-P-7201SR, AR05.10-P-7602SR

Remove/install camshaft adjusters 22.07.2014 Engine 281 in model 453 1 Camshaft positioner 2 Screw/bolt 3 Timing chain P05.20-2409-06 Remove/install

1 Remove timing chain (3) AR05.10-P-7602SR 2 Remove screw/bolt (2) from camshaft Counterhold intake camshaft using an

positioner (1) open end wrench. *BA05.20-P-1004-01M Bolt, camshaft adjuster to intake camshaft 3 Remove camshaft positioner (1) from intake Check gear for camshaft positioner (1) for

camshaft wear and damage. For wear or damage: Replace camshaft positioner (1) and timing chain (3). 4 Install in the reverse order Camshaft Number Designation Engine 281 BA05.20-P-1004-01M Bolt, camshaft adjuster to intake camshaft Nm 78 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-7201sr, Remove/install camshaft adjusters Engine 281 in model 453

AR05.20-P-0001SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 751 · Applies to: 453 · AR: AR05.20-P-0001SR

Remove/install camshaft position sensor 21.07.2014 ENGINE 281 in MODEL 453 P05.20-2419-09 Shown on engine 281.910 1 Cylinder head cover 3 Sealing ring 2 Screw/bolt B6/15 Intake camshaft Hall sensor Remove/install

1 Remove cover over engine
Installation: Only install cover over engine

after a leak test. 2 Disconnect electrical connection at intake camshaft Hall sensor (B6/15)
3 Remove screw/bolt (2) *BA05.20-P-1007-01M Bolt, Hall sensor for intake camshaft to cylinder head cover 4 Pull intake camshaft Hall sensor (B6/15) out Installation: Replace sealing ring (3).

of the cylinder head cover (1) 5 Install in the reverse order 6 Connect diagnostic unit and read out fault For replacement of the intake camshaft Hall memory sensor (B6/15). AD00.00-P-2000-06SR

Check

Risk of accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 7 Perform an engine test run and check engine in the area of the intake camshaft Hall sensor (B6/15) for leaktightness Camshaft Number Designation ENGINE 281 BA05.20-P-1007-01M Bolt, Hall sensor for intake camshaft to cylinder head cover Nm 10 Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar05.20-p-0001sr, Remove/install camshaft position sensor ENGINE 281 in MODEL 453

AR05.20-P-6040SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 752 · Applies to: 453 · AR: AR05.20-P-6040SR, AR01.40-P-8000SR, AR05.10-P-7800SR, AR05.10-P-8510SR, AR05.10-P-8480SR

Remove/install camshaft sprocket 21.07.2014 ENGINE 281 in MODEL 453 1 Timing chain 5 Camshaft sprocket 6 Camshaft positioner 7 Crankshaft gear 8 Chain tensioner 9 Tensioning rail 10 Slide rail P05.10-2502-06 1 Timing chain 2 Marking 3 Marking 4 Marking 5 Camshaft sprocket 6 Camshaft positioner 7 Crankshaft gear P05.10-2501-06 Remove

1 Remove timing case cover AR01.40-P-8000SR 2 Place engine at TDC for cylinder 1 The marking (4) on the crankshaft gear (7)

must point vertically downwards. The marking (2) on the camshaft sprocket (5) and the marking (3) on the camshaft positioner (6) must coincide point upwards. 3 Remove chain tensioner (8) AR05.10-P-7800SR 4 Remove tensioning rail (9) AR05.10-P-8510SR 5 Remove slide rail (10) AR05.10-P-8480SR 6 Remove screw/bolt from camshaft sprocket Counterhold exhaust camshaft with open

(5) end wrench. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6040sr, Remove/install camshaft sprocket ENGINE 281 in MODEL 453

Remove camshaft sprocket (5) from exhaust

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 753 · Applies to: 453 · AR: AR05.10-P-7602SR, AR05.10-P-8480SR, AR05.10-P-8510SR, AR05.10-P-7800SR, AR01.40-P-8000SR

7 Remove camshaft sprocket (5) from exhaust camshaft and timing chain (1) Check

8 Check camshaft sprocket (5) for wear and If there are problems: damage Replace camshaft sprocket (5) and timing chain (1). AR05.10-P-7602SR Install

9 Offset timing chain (1) on camshaft positioner The color codings (arrows) on the timing

(6) and on crankshaft gear (7) chain (1) must exactly match with the marking (3) on camshaft positioner (6) and the marking (4) on crankshaft gear (7). 10 Retract camshaft sprocket (5) in the timing The color coding (arrow) on the timing

chain (1) and tighten down on the exhaust chain (1) must coincide with the marking (2) on camshaft the camshaft sprocket (5). *BA05.20-P-1005-01M Bolt, camshaft sprocket to exhaust camshaft 11 Install slide rail (10) AR05.10-P-8480SR 12 Install tensioning rail (9) AR05.10-P-8510SR 13 Install chain tensioner (8) AR05.10-P-7800SR 14 Install timing case cover AR01.40-P-8000SR Camshaft Number Designation ENGINE 281 BA05.20-P-1005-01M Bolt, camshaft sprocket to exhaust camshaft Nm 78 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6040sr, Remove/install camshaft sprocket ENGINE 281 in MODEL 453

AR05.20-P-6992SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 754 · Applies to: 453 · AR: AR05.20-P-6992SR, AR05.10-P-7602SR, AR05.20-P-7201SR, AR07.61-P-1401SR, AR09.41-P-1311SR

Remove/install camshafts 19.08.2019 Engine 281 in model 453 Modification notes 19.08.2019 Information document AH00.00-P-0500-01MNE added. Operation step 5. 19.08.2019 Information document AH05.20-P-1000-09SZ added. Check operation step group, prior to operation step 12. P05.20-2420-09 Shown on ENGINE 281.920 1 Intake camshaft 4 Bearing bridge 6 Cover 2 Exhaust camshaft 5 Cylinder head 7 Bolts 3 Camshaft bearing cap Remove/install

1 Remove timing chain. AR05.10-P-7602SR 2 Remove the camshaft positioner. When replacing the intake camshaft (1). AR05.20-P-7201SR 3.1 Remove the throttle valve actuator. Engine 281.920 in model 453 AR07.61-P-1401SR 3.2 Remove charge air pipe. Engine 281.910 in model 453 AR09.41-P-1311SR 4 Unscrew screws (7). Engine 281.910 in model 453 The cover (6) is fastened to the cylinder head (7) by three screw/bolts (5). 5 Unfasten the cover (6) from cylinder head (5) and remove it. Notes on application of flange sealants to seal AH00.00-P-0500-01MNE major assemblies Installation: Coat sealant on sealing

surface of timing case cover (6). Sealing compound *BR00.45-Z-1053-01A Clean

6 Remove sealant residue in the area of the sealing surface of the cylinder head (5) and the sealing surface of the cover (6). Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6992sr, Remove/install camshafts Engine 281 in model 453

AR05.20-P-7296SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 756 · Applies to: 453 · AR: AR05.20-P-7296SR

Remove/install intake camshaft solenoid valve 22.07.2014 ENGINE 281 in MODEL 453 P05.20-2424-09 Shown on engine 281.910 1 Electrical connection 3 Timing case cover Y49/10 Variable camshaft adjustment valve 2 Screw/bolt 4 Sealing ring Remove/install

1 Remove covering over engine Installation: Only install covering over

engine after a leak test. 2 Disconnect electrical connection (1) on variable camshaft adjustment valve (Y49/10) 3 Remove screw/bolt (2) *BA05.20-P-1009-01M Bolt, valve for variable camshaft adjustment to timing case cover 4 Remove variable camshaft adjustment valve Installation: Replace sealing ring (4).

(Y49/10) from the timing case cover (3) 5 Install in the reverse order 6 Connect diagnostic unit and read out fault For replacing the variable camshaft memory adjustment valve (Y49/10). AD00.00-P-2000-06SR

Check

Risk of accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 7 Perform engine test run and check engine for leaktightness in area of variable camshaft adjustment valve (Y49/10) Camshaft Number Designation ENGINE 281 BA05.20-P-1009-01M Bolt, valve for variable camshaft adjustment to timing case cover Nm 10 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-7296sr, Remove/install intake camshaft solenoid valve ENGINE 281 in MODEL 453

AR05.20-P-7215SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 757 · Applies to: 453 · AR: AR05.20-P-7215SR

Remove/install oil duct cover for camshaft positioner 22.07.2014 ENGINE 281 in MODEL 453 Shown on removed engine 1 Oil duct cover 2 Timing case cover 3 Screw/bolt 4 Filler neck 5 Screw/bolt P05.20-2422-06 1 Oil duct cover 6 Sealing rings 7 Sealing ring 8 Sealing ring 9 Sealing rings P05.20-2423-05 Remove/install

1 Remove covering over engine Installation: Only install covering over

engine after a leak test. 2 Remove screw/bolt (3) and pull filler neck (4) Check sealing ring, replace if necessary.

out of the timing case cover (2) 3 Remove screw/bolts (5) *BA05.20-P-1008-01M Bolt, oil duct cover for camshaft positioner to timing case cover 4 Pull oil duct cover (1) out of the intake Installation: Replace sealing rings (8, 9).

camshaft and timing case cover (2) Clean

5 Clean sealing surface on timing case cover (2). Check

6 Check sealing rings (6, 7) for damage. If there are problems: replace oil duct cover(1). 7 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-7215sr, Remove/install oil duct cover for camshaft positioner ENGINE 281 in MODEL 453

AR05.20-P-7295FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 759 · Applies to: 453 · AR: AR05.20-P-7295FF

Remove/install solenoid camshaft 2.12.09 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Electrical connector 2 Bolt Y49 Adjustable camshaft timing solenoid P05.20-2157-06 Remove/install

1 Disconnect electrical connector (1) on adjustable camshaft timing solenoid (Y49) 2 Remove bolt (2) on adjustable camshaft *BA05.20-P-1006-01I

timing solenoid (Y49) 3 Pull adjustable camshaft timing solenoid Installation: Replace sealing ring on (Y49) out of cylinder head adjustable camshaft timing solenoid (Y49). 4 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not touch hot or rotating parts. engine as it is running 5 Start engine and check cylinder head in the area of the adjustable camshaft timing solenoid (Y49) for leaks Camshaft

Number Designation Engine Engine Engine Engine 134.910 134.911 135.930 135.950 BA05.20-P-1006-01I Bolt, camshaft adjuster to cylinder head Nm 8 8 8 8 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-7295ff, Remove/install solenoid camshaft ENGINE 134.9, 135.9 in MODEL 454.0

AR05.20-P-6292FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 760 · Applies to: 453 · AR: AR05.20-P-6292FH, AR01.20-P-5014FG, AR05.20-P-6010FH

Removing/installing a camshaft 19.10.04 ENGINE 639.939 in MODEL 454.0 Exhaust camshaft P05.20-2227-09 1 Front camshaft bearing cap 3 Rear camshaft bearing cap 6 Intake camshaft gear wheel 2 Exhaust camshaft 4 Bolt 7 Bore 2.1 Exhaust camshaft gear wheel 5 Bolt Removing/installing

1 Remove cylinder head cover AR01.20-P-5014FG 2 Check basic position of camshafts AR05.20-P-6010FH 3 Unscrew bolt (5) on front camshaft bearing *BA05.20-P-1002-01H

cap (1) and bolt (4) on rear camshaft bearing cap (3) 4 Remove front camshaft bearing cap (1) and Mark installation position of front camshaft rear camshaft bearing cap (3) for exhaust bearing cap (1) and rear camshaft bearing camshaft (2) cap (3). 5 Remove exhaust camshaft (2) upwards Note correct installation positions. The bore (7) on the intake camshaft (6) gearwheel and the exhaust camshaft (2.1) gearwheel point to the exhaust side. Installation: The marking (arrow A) on

the tooth of the intake camshaft (6) gearwheel must stand exactly opposite to the marking (arrow B) on the exhaust camshaft (2.1) gearwheel. 6 Install in reverse order Camshaft

Number Designation Engine 639.939 BA05.20-P-1002-01H Bolt for camshaft bearing cap on cylinder Nm 12 head Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6292fh, Removing/installing a camshaft ENGINE 639.939 in MODEL 454.0 Exhaust camshaft

AR05.20-P-6040FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 761 · Applies to: 453 · AR: AR05.20-P-6040FG, AR01.30-P-5700FG, AR05.20-P-6010FH, AR05.10-P-7800FG

Removing/installing a camshaft sprocket 29.9.04 ENGINE 639.939 in MODEL 454.0 P05.20-2225-07 1 Timing chain 2 Timing chain camshaft sprocket 3 Bolts Removing/installing

1 Remove front cover on cylinder head AR01.30-P-5700FG 2 Check basic position of camshafts AR05.20-P-6010FH 3 Slacken bolts (3) on timing chain (2) camshaft *BA05.20-P-1001-01H

sprocket 4 Remove chain tensioner AR05.10-P-7800FG 5 Unscrew bolts (3) on timing chain (2) camshaft sprocket 6 Release timing chain (2) camshaft sprocket Installation:

Turn the timing chain (2) from the intake camshaft camshaft sprocket to ensure that that the bore on the timing chain (2) camshaft sprocket coincides with the intake camshaft roll pin. 7 Remove timing chain (1) and remove timing Prevent timing chain (1) from dropping chain (2) camshaft sprocket down. 8 Install in reverse order Camshaft

Number Designation Engine 639.939 BA05.20-P-1001-01H Bolt for camshaft sprocket on camshaft Nm 18 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6040fg, Removing/installing a camshaft sprocket ENGINE 639.939 in MODEL 454.0

AR05.20-P-7102FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 762 · Applies to: 453 · AR: AR05.20-P-7102FG, AR05.20-P-6292FG

Removing/installing camshaft bearings 29.9.04 ENGINE 639.939 in MODEL 454.0 External camshaft bearing for intake camshaft P05.20-2228-07 1.1 Front camshaft bearing cap 2 Intake camshaft 3.2 Rear camshaft bearing shell 1.2 Front camshaft bearing shell 3.1 Rear camshaft bearing cap Removing/installing

1 Remove inlet camshaft (2) AR05.20-P-6292FG 2 Remove front camshaft bearing shell (1.2) Mark installation position and rear camshaft bearing shell (3.2) from Only replace front camshaft bearing shell cylinder head (1.2) with the front camshaft bearing cap (1.1) and only replace the rear camshaft bearing shell (3.2) with the front camshaft bearing cap (3.1). 3 Install in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-7102fg, Removing/installing camshaft bearings ENGINE 639.939 in MODEL 454.0 External camshaft bearing for intake camshaft

AR05.20-P-6992FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 763 · Applies to: 453 · AR: AR05.20-P-6992FF, AR88.40-P-3000FF, AR05.20-P-6010FF, AP05.30-P-0560FF, AR05.10-P-7800FF

Removing/installing camshafts 8.3.04 ENGINES 134.9, 135.9 in MODEL 454.0 P05.20-2178-08 Shown on ENGINE 135.950 1 Intake camshaft 5 Bolt 9 Bearing bridge 2 Exhaust camshaft 6 Camshaft adjuster 10 Camshaft bearing cap 3 Bolt 7 Timing chain 11 Camshaft bearing cap 4 Camshaft sprocket 8 Tie strap Shown on ENGINE 135.950 4 Camshaft sprocket 6 Camshaft adjuster 7 Timing chain P05.20-2188-01 Removing/installing

The intake camshaft (1) can only be removed

together with the exhaust camshaft (2) 1 Remove engine hood AR88.40-P-3000FF 2 Check basic position of camshafts AR05.20-P-6010FF Installation: Check the valve clearance

and adjust if necessary before installing the cylinder head cover. Refer to: Set valve clearance AP05.30-P-0560FF

3 Remove chain tensioner AR05.10-P-7800FF 4 Counterhold exhaust camshaft (2) at hexagon Do not loosen bolt (3) jerkily otherwise the (arrow A) and loosen bolt (3) on camshaft exhaust camshaft (2) can be damaged. sprocket (4) *BA05.20-P-1005-01I

5 Counterhold exhaust camshaft (1) at hexagon Do not loosen bolt (5) jerkily otherwise the (arrow B) and loosen bolt (5) on camshaft intake camshaft (1) can be damaged. adjuster (6) *BA05.20-P-1004-01I

6 Fix timing chain (7) using a cable tie (8) onto the exhaust camshaft (2) camshaft sprocket (4) 7 Loosen camshaft sprocket (4) from exhaust Installation:

Ensure correct seating of the camshaft (2) seat camshaft sprocket (4) on the exhaust camshaft (2). 8 Remove bearing bridge (9) and camshaft Observe loosening and tightening bearing cap (10) on exhaust camshaft (2) sequence otherwise the exhaust camshaft (2) can be damaged. Engine 134.9 AR05.20-P-6992-04FG Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6992ff, Removing/installing camshafts ENGINES 134.9, 135.9 in MODEL 454.0

AR05.20-P-6020FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 765 · Applies to: 453 · AR: AR05.20-P-6020FG, AR05.20-P-6010FG, AR05.10-P-7800FF

Set basic position of camshafts 2.12.09 ENGINES 134.9, 135.9 in MODEL 454.0 Timing case cover removed P05.20-2219-09 Illustrated on removed engine 134.910 1 Timing chain 2 Screw 6 Marking 11 Marking 3 Camshaft sprocket 7 Chain link 12 Marking 4 Exhaust camshaft 8 Intake camshaft 13 Cylinder crankcase 5 Marking 9 Marking 14 Marking 10 Crankshaft 15 Marking 16 Camshaft adjuster Removing

1 Check basic position of camshafts AR05.20-P-6010FG 2 Remove chain tensioner AR05.10-P-7800FF 3 Counterhold exhaust camshaft (4) at the Do not loosen bolt (2) jerkily otherwise the hexagon, remove bolt (2) and camshaft exhaust camshaft (4) can be damaged. sprocket (3) 4 Remove timing chain (1) from ring gear on camshaft adjuster (16) and crankshaft (10) Install

5 Check whether the marking (12) on the Possibly also turn the crankshaft (10) at crankshaft (10) and the marking (11) on the the ring gear on the flywheel. crankcase (13) coincide with each other 6 Lay timing chain (1) on the crankshaft (10) There are three black chain link (7) ring gear in such a way that the black chain attached to the circumference of the timing link (7) lies opposite the marking (9). chain (1). Select the installation position of the timing chain (1) in such a way that black chain links (7) coincide with the markings (5, 6, 9). 7 Place timing chain (1) with the black chain link Possibly turn camshaft adjuster (16) at (7) at the marking (6) on the camshaft hexagon on the intake camshaft (8). adjuster (16) ring gear 8 Insert camshaft sprocket (3) into the timing Insert camshaft sprocket (3) in the timing chain (1) chain (1) such a way that the marking (5) lies opposite to a black chain link (7). 9 Place camshaft sprocket (3) on the exhaust Do not tighten bolt (2) jerkily and camshaft (4) and tighten firmly with the bolt counterhold exhaust camshaft (4) at hexagon (2) otherwise the exhaust camshaft (2) can be damaged. The marking (14) on the camshaft sprocket (3) and the marking (15) on the camshaft adjuster (16) must coincide with each other. *BA05.20-P-1005-01I

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6020fg, Set basic position of camshafts ENGINES 134.9, 135.9 in MODEL 454.0 Timing case cover removed

Install chain tensioner

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 766 · Applies to: 453 · AR: AR05.10-P-7800FF, AR05.20-P-6010FG

10 Install chain tensioner AR05.10-P-7800FF 11 Turn crankshaft (10) through two revolutions clockwise (arrow) 12 Inspect basic position of camshafts; re-adjust AR05.20-P-6010FG if necessary Camshaft

Number Designation Engine Engine Engine Engine 134.910 134.911 135.930 135.950 BA05.20-P-1005-01I Bolt connecting camshaft sprocket to Nm 88 88 88 88 exhaust camshaft Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6020fg, Set basic position of camshafts ENGINES 134.9, 135.9 in MODEL 454.0 Timing case cover removed

AR05.20-P-6020FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 767 · Applies to: 453 · AR: AR05.20-P-6020FF, AR05.20-P-6992FF

Setting the basic position of camshafts 12.12.03 ENGINE 134.9, 135.9 in MODEL 454.0 Timing case cover built-in Removing/installing

1 Remove camshafts AR05.20-P-6992FF Adjustment of the basic position is only possible through removal of camshafts for an installed timing case cover. 2 Install in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6020ff, Setting the basic position of camshafts ENGINE 134.9, 135.9 in MODEL 454.0 Timing case cover built-in

AR05.20-P-6020FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 768 · Applies to: 453 · AR: AR05.20-P-6020FH, AR05.20-P-6010FH, AR01.30-P-5702FG, AR01.30-P-5700FG, AR05.10-P-7800FG

Setting the basic position of camshafts 29.9.04 ENGINE 639.939 in MODEL 454.0 Intake camshaft or intake and exhaust camshaft 1 Intake camshaft 2 Timing chain 3 Timing chain camshaft sprocket 4 Bolts 5 Tie strap P05.20-2230-04 P05.20-2229-08 1 Intake camshaft 8 Rear camshaft bearing cap 12 Exhaust camshaft 1.1 Intake camshaft gear wheel 9 Cylinder head 12.1 Exhaust camshaft gear wheel 6 Front camshaft bearing cap 10 Camshaft bearing cap 13 Bore 7 Bolts 11 Bolt Removing/installing

1 Check basic position of camshafts AR05.20-P-6010FH The TDC marking on the crankshaft belt pulley must match the positioning edge on the timing case cover and the bores (13) must point to the exhaust side. 2 Remove rear cover on cylinder head (9) AR01.30-P-5702FG 3 Remove front cover on cylinder head (9) AR01.30-P-5700FG 4 Slacken bolts (4) on timing chain (3) camshaft *BA05.20-P-1001-01H

sprocket 5 Fix timing chain (2) with a tie strap (5) on the timing chain (3) camshaft sprocket 6 Remove chain tensioner AR05.10-P-7800FG 7 Unscrew bolts (4) on timing chain (3) camshaft sprocket 8 Remove timing chain (3) camshaft sprocket Installation:

The timing chain (3) with the timing chain (2) from the intake camshaft sprocket must be positioned with its camshaft (1) and lay to one side bore on the intake camshaft (1) bolt. 9 Remove bolts (7) *BA05.20-P-1002-01H

10 Remove front camshaft bearing cap (6) and rear camshaft bearing cap (8) 11 Unscrew bolts (11) on camshaft bearing caps *BA05.20-P-1002-01H

(10) for exhaust camshaft (12) 12 Remove camshaft bearing cap (10) for Note installation position of the camshaft exhaust camshaft (12) bearing cap (10). Adjusting Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6020fh, Setting the basic position of camshafts ENGINE 639.939 in MODEL 454.0 Intake camshaft or intake and exhaust camshaft

AR05.20-P-6020FJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 770 · Applies to: 453 · AR: AR05.20-P-6020FJ, AR01.20-P-5014FG

Setting the basic position of camshafts 29.9.04 ENGINE 639.939 in MODEL 454.0 Exhaust camshaft P05.20-2227-09 1 Front camshaft bearing cap 3 Rear camshaft bearing cap 6 Intake camshaft gear wheel 2 Exhaust camshaft 4 Bolt 7 Bore 2.1 Exhaust camshaft gear wheel 5 Bolt Remove

1 Remove cylinder head cover AR01.20-P-5014FG 2 Set piston on 1st cylinder to ignition TDC The TDC marking on the crankshaft belt pulley must match the positioning edge on the timing case cover and the bore (7) in the intake camshaft gearwheel (6) and the bore in the exhaust camshaft gearwheel (2.1) must point towards the exhaust side. 3 Insert suitable drift in the intake camshaft bore (7) 4 Unscrew bolt (5) on front camshaft bearing cap (1) and bolt (4) on rear camshaft bearing cap (3) of exhaust camshaft (2) 5 Remove front camshaft bearing cap (1) and Note correct installation positions. rear camshaft bearing cap (3) for exhaust camshaft (2) Adjust 6 Remove exhaust camshaft (2) upwards and Note installation position of the exhaust insert again in such a way that the marking camshaft (2). (arrow A) on the tooth of the intake camshaft The bore (7) on the intake camshaft (6) (6) gearwheel stands exactly opposite the gearwheel and the exhaust camshaft (2.1) marking (arrow B) on the exhaust camshaft gearwheel point to the exhaust side. (2.1) gearwheel Installing

7 Position front camshaft bearing cap (1) and Note correct installation positions. rear camshaft bearing cap (3) for exhaust camshaft (2) 8 Tighten bolt (5) on front camshaft bearing cap *BA05.20-P-1002-01H

(1) and bolt (4) on rear camshaft bearing cap (3) 9 Remove drift for locking the intake camshaft out of the bore (7) 10 Install cylinder head cover AR01.20-P-5014FG Camshaft

Number Designation Engine 639.939 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.20-p-6020fj, Setting the basic position of camshafts ENGINE 639.939 in MODEL 454.0 Exhaust camshaft

AR05.30-P-3030FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 772 · Applies to: 453 · AR: AR05.30-P-3030FF, AR05.00-P-2310FF, AP15.10-P-1580FF

Remove/install valve springs (cylinder head installed) 8.1.07 ENGINE 134.9, 135.9 in MODEL 454.0 P05.30-2103-09 1 Valve tappet 5 Valve collet 9 Valve stem seal 6 Upper valve spring retainer 2 Spark plug adapter 10

Pliers 7 Valve spring 3 Countersupport 11 Drift

8 Lower valve spring retainer 4 Pressure fork

Remove/install

1 Remove valve tappet (1) AR05.00-P-2310FF 2 Remove spark plug of cylinder having compressed air applied to it Replace spark plugs AP15.10-P-1580FF

3 Screw spark plug adapter (2) into spark plug *450589052100

bore and attach compressed air hose 4 Apply compressed air to the cylinder This avoids the valve falling into the combustion chamber. 5 Screw counter stay (3) for removing valve *452589019900

spring (7) in the area of the respective valve into a suitable threaded hole on the cylinder head 6 Attach lever handle and thrust piece to thrust *452589019900

fork (4) and hook into the counter stay (3) 7 Position thrust piece in the middle on the *452589019900

upper valve spring retainer (6) and press valve spring (7) together through pressing together the lever handle 8 Remove valve collets (5) using suitable *452589019900

magnets and also remove thrust fork (4) using a thrust piece and lever handle 9 Remove upper valve spring retainer (6), valve Observe installation position of the valve spring (7) and lower valve spring retainer (8) spring (7) and lower valve spring retainer (8). 10 Use pliers (10) to pull out valve stem seals (9) Only when replacing the valve stem seal (9). The pliers (10) are contained in the valve repair tool set. Installation:

Lubricate new valve stem seal (9) with engine oil. Plug in protective sleeve onto valve stem and press on valve stem seal (9) using a drift (11). *452589019900

*452589019910

11 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.30-p-3030ff, Remove/install valve springs (cylinder head installed) ENGINE 134.9, 135.9 in MODEL 454.0

AR05.30-P-3020FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 774 · Applies to: 453 · AR: AR05.30-P-3020FF

Remove/install valve springs (cylinder head removed) 8.1.07 ENGINE 134.9, 135.9 in MODEL 454.0 1 Cylinder head 2 Countersupport

3 Pressure fork

4 Valve collet 5 Upper valve spring retainer 6 Valve spring 7 Lower valve spring retainer 8 Valve stem seal P05.30-2104-06 Remove/install

1 Screw counter stay (2) for removing valve *452589019900

spring (6) in the area of the respective valve into a suitable threaded hole on the cylinder head (1) 2 Attach lever handle and thrust piece to thrust *452589019900

fork (3) and hook into the counter stay (2) 3 Position thrust piece in the middle on the *452589019900

upper valve spring retainer (5) and press valve spring (6) together through pressing together the lever handle 4 Remove valve collets (4) using suitable *452589019900

magnets and also remove thrust fork (3) using a thrust piece and lever handle 5 Remove upper valve spring retainer (5), valve Observe installation position of the valve spring (6) and lower valve spring retainer (7) spring (6) and lower valve spring retainer (7). 6 Pull out valve stem seal (8) with pliers Only when replacing the valve stem seal (8). The pliers are contained in the valve repair tool set. Installation:

Lubricate new valve stem seal (8) with engine oil. Plug in protective sleeve onto valve stem and press on valve stem seal (8) using a drift. *452589019900

*452589019910

7 Install in the reverse order 452 589 01 99 00 452 589 01 99 10 Repair tools for valves Drift Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.30-p-3020ff, Remove/install valve springs (cylinder head removed) ENGINE 134.9, 135.9 in MODEL 454.0

AR05.30-P-3511FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 775 · Applies to: 453 · AR: AR05.30-P-3511FF, AR01.30-P-5800FF

Remove/install valves 8.1.07 ENGINE 134.9, 135.9 in MODEL 454.0 1 Cylinder head 2 Countersupport

3 Pressure fork

4 Valve collet 5 Upper valve spring retainer 6 Valve spring 7 Lower valve spring retainer 8 Valve stem seal 9 Valve P05.30-2105-06 Remove/install

1 Remove cylinder head (1) AR01.30-P-5800FF 2 Remove intake manifold from cylinder head Installation:

Replace sealing rings for (1) intake manifold and clean sealing surfaces on intake manifold and cylinder head (1). Tighten intake manifold bolts from the inside outwards. *BA09.20-P-1001-01M

3 Lay cylinder head (1) on a suitable base 4 Screw counter stay (2) in the area of valve (9) *452589019900

to be removed into a suitable threaded hole on the cylinder head (1) 5 Attach lever handle and thrust piece to thrust *452589019900

fork (3) and hook into the counter stay (2) 6 Position thrust piece in the middle on the *452589019900

upper valve spring retainer (5) and press valve spring (6) together through pressing together the lever handle 7 Remove valve collets (4) using suitable *452589019900

magnets and also remove thrust fork (3) using a thrust piece and lever handle 8 Remove upper valve spring retainer (5), valve Observe installation position of the valve spring (6) and lower valve spring retainer (7) spring (6) and lower valve spring retainer (7). 9 Pull out valve stem seal (8) with pliers The pliers are contained in the valve repair tool set. Installation:

Lubricate new valve stem seal (8) with engine oil. Plug in protective sleeve onto valve stem and press on valve stem seal (8) using a drift. *452589019900

*452589019910

10 Lift cylinder head (1) and remove valve (9) Check surfaces of valve stems, valve downwards out of the cylinder head (1) seats and valve guides by means of a visual inspection for roughness and ridging; replace valves (9) or cylinder head (1) if necessary. 11 Install in the reverse order Intake manifold, intake manifold preheater Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.30-p-3511ff, Remove/install valves ENGINE 134.9, 135.9 in MODEL 454.0

AR05.30-P-3511SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 777 · Applies to: 453 · AR: AR05.30-P-3511SR, AR05.30-P-3510SR

Remove/install valves 07.08.2019 Engine 281 in model 453 Modification notes 07.08.2019 Reference document AH05.30-P-1000-02SZ added. Operation step 4. P05.30-2187-08 1 Cylinder head 3 Inlet valves 5 Valve stem seal 2 Exhaust valves 4 Valve spring retainer (below) Remove

1 Remove the valve stem seals(5). AR05.30-P-3510SR 2 Remove the valve spring retainers (4) from the cylinder head (1). 3 Mark the installation position of the inlet valves (3) and outlet valves (2). 4 Turn the cylinder head (1) over and remove the inlet valves (3) and outlet valves (2) from the cylinder head (1). General information on checking valves, valve AH05.30-P-1000-02SZ seats and valve guides Check

5 Visually inspect the surfaces of the valve If problems exist, stems, valve seats and valve guides for roughness and burrs. Replace the intake valves (3), exhaust valves (2) or cylinder head (1). Install

6 Insert the inlet valves (3) and outlet valves (2) Note markings.

in the cylinder head (1). 7 Turn the cylinder head (1) over and insert the valve spring retainers (4) in the cylinder head. 8 Install new valve stem seals (5). AR05.30-P-3510SR Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.30-p-3511sr, Remove/install valves Engine 281 in model 453

AR05.30-P-3512FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 778 · Applies to: 453 · AR: AR05.30-P-3512FF, AR05.00-P-2310FF, AP15.10-P-1580FF

Replace valve stem seals where with installed cylinder head 8.1.07 ENGINE 134.9, 135.9 in MODEL 454.0 P05.30-2103-09 1 Valve tappet 5 Valve collet 9 Valve stem seal 6 Upper valve spring retainer 2 Spark plug adapter 10

Pliers 7 Valve spring 3 Countersupport 11 Drift

8 Lower valve spring retainer 4 Pressure fork

Remove/install

1 Remove valve tappet (1) AR05.00-P-2310FF 2 Remove spark plug for cylinder having compressed air applied to it Replace spark plugs AP15.10-P-1580FF

3 Screw spark plug adapter (2) into spark plug *450589052100

bore and attach compressed air hose 4 Apply compressed air to the cylinder This avoids the valve falling into the combustion chamber. 5 Screw counter stay (3) for removing valve *452589019900

stem seal (9) in the area of the respective valve into a suitable threaded hole on the cylinder head 6 Attach lever handle and thrust piece to thrust *452589019900

fork (4) and hook into the counter stay (3) 7 Position thrust piece in the middle on the *452589019900

upper valve spring retainer (6) and press valve spring (7) together through pressing together the lever handle 8 Remove valve collets (5) using suitable *452589019900

magnets and also remove thrust fork (4) using a thrust piece and lever handle 9 Remove upper valve spring retainer (6), valve Observe installation position of the valve spring (7) and lower valve spring retainer (8) spring (7) and lower valve spring retainer (8). 10 Use pliers (10) to pull out valve stem seals (9) The pliers (10) are contained in the valve repair tool set. Installation:

Lubricate new valve stem seal (9) with engine oil. Plug in protective sleeve onto valve stem and press on valve stem seal (9) using a drift (11). *452589019900

*452589019910

11 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.30-p-3512ff, Replace valve stem seals where with installed cylinder head ENGINE 134.9, 135.9 in MODEL 454.0

AR05.30-P-3512SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 780 · Applies to: 453 · AR: AR05.30-P-3512SR

Replace valve stem seals with cylinder head installed 21.10.2014 ENGINE 281 in MODEL 453 1 Cylinder head 2 Counter stay 3 Thrust fork 4 Depressor 12 Adapter 13 Compressed air hose 14 Pressure loss tester P05.30-2190-06 1 Cylinder head 5 Valve lock 6 Upper valve spring retainer 7 Valve spring 8 Lower valve spring retainer 9 Valve stem seal P05.30-2186-05 P05.20-2415-07 9 Valve stem seal 10 Valve stem 11 Drift Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.30-p-3512sr, Replace valve stem seals with cylinder head installed ENGINE 281 in MODEL 453

Remove

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 781 · Applies to: 453 · AR: AR15.12-P-1010SR, AR05.00-P-2310SR, AR03.30-P-5000SR

1 Remove spark plugs AR15.12-P-1010SR 2 Remove valve tappet AR05.00-P-2310SR 3 Install retaining lock for crankshaft/starter ring AR03.30-P-5000SR gear 4 Screw adapter (12) into the respective spark 451589009100 Adapter plug bore 5 Connect compressed air hose (13) to 450589172100 Pressure loss tester pressure loss tester (14)
6 Connect pressure loss tester (14) to adapter Observe operating instructions for the

(12)
pressure loss tester (14). 450589172100 Pressure loss tester 451589009100 Adapter 7 Apply compressed air to cylinder 8 Screw in counter stay (2) in the area of the 111589256100 Valve assembly tools kit respective valves into a threaded hole on the cylinder head (1)
9 Attach lever handle and depressor (4) to the 111589256100 Valve assembly tools kit thrust fork (3) and hook into the counter stay (2)
10 Position depressor (4) in the middle on the upper valve spring retainer (6) and press valve spring (7) together through pressing together the lever handle 11 Remove valve locks (5) using suitable magnets and also remove thrust fork (3) using a depressor (4) and lever handle
12 Remove upper valve spring retainer (6) and valve spring (7)
13 Pull valve stem seals (9) off valve guide
*606589003700 Pliers Install

14 Lubricate new valve stem seal (9) with engine oil
15 Insert new valve stem seal (9) on the valve

stem (10) and press on using drift (11)
The new valve stem seal (9) must not removed again from the valve stem (10). The valve stem seal (9) is damaged during removal and is therefore unusable. 16 Insert valve spring (7) and upper valve spring retainer (6)
17 Hook thrust fork (3) with depressor (4) and lever handle into the counter stay (2)
18 Position depressor (4) in the middle on the upper valve spring retainer (6) and press together valve spring (7) through pressing down the lever handle, insert the valve locks (5) on the valve stem (10) in the cutout and then relieve the upper valve spring retainer (6)
19 Remove thrust fork (3) with depressor (4) and lever handle
20 Remove counter stay (2) on cylinder head (1)
21 Relieve compressed air in the cylinder 22 Attach compressed air hose (13) 23 Remove pressure loss tester (14) and adapter (12) 24 Repeat operation steps 4 to 22 until all valve stem seals (9) are replaced 25 Remove retaining lock for crankshaft/ starter AR03.30-P-5000SR ring gear 26 Install valve tappet AR05.00-P-2310SR 27 Install spark plugs AR15.12-P-1010SR 451 589 00 91 00 111 589 25 61 00 606 589 00 37 00 450 589 17 21 00 Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar05.30-p-3512sr, Replace valve stem seals with cylinder head installed ENGINE 281 in MODEL 453

AR05.30-P-3510SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 785 · Applies to: 453 · AR: AR05.30-P-3510SR, AR01.30-P-5800SR, AR05.00-P-2310SR

Replace valve stem seals. 21.10.2014 ENGINE 281 in MODEL 453 P05.30-2189-08 1 Cylinder head 4 Depressor 7 Valve spring 2 Counter stay 5 Valve lock 8 Lower valve spring retainer 3 Thrust fork 6 Upper valve spring retainer 9 Valve stem seal P05.20-2415-07 9 Valve stem seal 10 Valve stem 11 Drift Remove

1 Remove cylinder head (1) AR01.30-P-5800SR 2 Remove valve tappet AR05.00-P-2310SR 3 Cut fuel hose with an inside diameter of 6 mm to a length of about 5 cm
4 Lay cylinder head (1) on the contact surface and lay the cut to size fuel hose in th combustion chamber under the respective valve
5 Screw in counter stay (2) in the area of the 111589256100 Valve assembly tools kit respective valves into a threaded hole on the cylinder head (1)
6 Attach lever handle and depressor (4) to the 111589256100 Valve assembly tools kit thrust fork (3) and hook into the counter stay (2)
Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar05.30-p-3510sr, Replace valve stem seals. ENGINE 281 in MODEL 453

Position depressor (4) in the middle on the

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 786 · Applies to: 453 · AR: AR05.00-P-2310SR, AR01.30-P-5800SR

7 Position depressor (4) in the middle on the upper valve spring retainer (6) and press valve spring (7) together through pressing together the lever handle 8 Remove valve locks (5) using suitable magnets and also remove thrust fork (3) using a depressor (4) and lever handle
9 Remove upper valve spring retainer (6) and valve spring (7)
10 Pull valve stem seals (9) off valve guide
*606589003700 Pliers Install

11 Lubricate new valve stem seal (9) with engine oil
12 Insert new valve stem seal (9) on the valve

stem (10) and press on using drift (11)
The new valve stem seal (9) must not removed again from the valve stem (10). The valve stem seal (9) is damaged during removal and is therefore unusable. 13 Insert valve spring (7) and upper valve spring retainer (6)
14 Hook thrust fork (3) with depressor (4) and lever handle into the counter stay (2)
15 Position depressor (4) in the middle on the upper valve spring retainer (6) and press together valve spring (7) through pressing down the lever handle, insert the valve locks (5) on the valve stem (10) in the cutout and then relieve the upper valve spring retainer (6)
16 Remove thrust fork (3) with depressor (4) and lever handle
17 Remove counter stay (2) on cylinder head (1)
18 Repeat operation steps 4 to 17 until all valve stem seals (9) are replaced 19 Install valve tappet AR05.00-P-2310SR 20 Install cylinder head (1)
AR01.30-P-5800SR 111 589 25 61 00 606 589 00 37 00 Valve assembly tools kit Pliers Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar05.30-p-3510sr, Replace valve stem seals. ENGINE 281 in MODEL 453

AP05.30-P-0560FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 789 · Applies to: 453 · AR: AP05.30-P-0560FF, AR01.20-P-5014FF, AR05.00-P-2310FF

Set valve clearance 24.10.03 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 P05.30-2094-11 Remove/Install

1 Remove cylinder head cover Remove/install cylinder head cover AR01.20-P-5014FF

2 Check valve clearance on all valves Do not crank the engine at the camshaft under any circumstances, otherwise the camshaft can be damaged. Crank engine at crankshaft in direction of rotation of engine and determine valve clearance between camshaft and valve tappets (arrow) using feeler gauge. The cylinder to be adjusted must be positioned at ignition TDC, the synchronous cylinder must be at valve overlap TDC. Intake valve BE05.30-P-1001-06C Exhaust valve BE05.30-P-1002-06C *454589002300

3.1 Set valve clearance Only if valve clearance is too high or too low. The respective valve tappet must be exchanged to adjust the valve clearance, see: Remove/install valve tappet AR05.00-P-2310FF

4 Install in the reverse order Valve clearance test values Number Designation Engine Engine 134 135 0.22 0.04 0.22 BE05.30-P-1001-06C Intake valve On cold engine (approx. 20°C) mm 0.04 0.30 0.04 0.30 BE05.30-P-1002-06C Exhaust valve On cold engine (approx. 20°C) mm 0.04 Page 1 of 2 © Mercedes-Benz AG, 5/20/18, L/07/20, ap05.30-p-0560ff, Set valve clearance ENGINE 134.9, 135.9 in MODEL 454.0

AR07.00-P-1502SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 800 · Applies to: 453 · AR: AR07.00-P-1502SR

Check fuel pressure 07.06.2017 Engine 281 in model 453 P07.00-2247-09 1 Fuel line 3 Adapter 5 Pressure hose 2 Fuel distributor 4 Pressure gage Risk of explosion No fires, sparks, open flames or smoking. Danger caused by fuel igniting, risk AS47.00-Z-0001-01A

of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. Check

1 Remove subwoofer Engine 281 in model 453 with code 556 (Radio 56A MM2012 with DAB and PREMIUM SOUND) Engine 281 in model 453 with code 557 (RADIO 57A MM2012 without DAB) Engine 281 in model 453 with code 561 (Radio 61C - PREMIUM without DAB with PREMIUM SOUND) Engine 281 in model 453 with code 562 (Radio 62C - R0 with DAB and PREMIUM SOUND) 2 Remove covering over engine 3 Clean the area at the connection between fuel line (1) and fuel distributor (2) and clad with clean cloths 4 Connect the pressure gage (4) with the 103589002101 Pressure gauge pressure hose (5) and the adapter (3) 103589002104 Pressure hose *607589029100 Adapter 5 Disconnect the fuel line (1) from the fuel distributor (2) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.00-p-1502sr, Check fuel pressure Engine 281 in model 453

BE07.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 807 · Applies to: 453 · AR: BE07.00-Z-9999CZ

Test and adjustment values: Smart: Mixture formation 18.09.2019 MODEL all Fuel pressure Engine 281 in model 453 BE07.61-P-1000-01SR Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be07.00-z-9999cz, Test and adjustment values: Smart: Mixture formation MODEL all

AR07.02-P-1020FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 809 · Applies to: 453 · AR: AR07.02-P-1020FF, AR88.00-P-2792FF, AR09.10-P-1150FG

Remove/install high-pressure pump 18.04.2019 Engine 639.9 in model 454.0 Modification notes 07.11.2005 Remove gearwheel at high-pressure pump, added Operation step 11.1 AR07.02-P-1020-01FF P07.02-2049-08 1 Connector 5 Fuel line 8 Banjo bolt 2 Connector 6 High pressure pump B50 Fuel temperature sensor 3 High pressure pipe 7 Sealing ring Y94 Quantity control valve 4 Bolts Remove/install

Risk of explosion No fires, sparks, open flames or smoking. Danger caused by fuel igniting, risk AS47.00-Z-0001-01A

of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Risk of explosion Keep all ignition sources out of hazard area. Danger caused by fuel igniting. AS07.16-Z-0001-01A

Risk of injury to skin and eyes caused by fuel Do not carry out any work on system when it is spraying out at high pressure pressurized. Notes about Common-Rail components AH07.16-P-0002-01TX 1 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 2 Remove air filter housing AR09.10-P-1150FG 3 Remove connectors (1, 2) 4 Remove high pressure line (3) Installation: Install new high-pressure

line(3). BA07.16-P-1003-01G Nut, pressure line on high pressure pump BA07.16-P-1004-01G Nut, pressure line to rail 5 Remove banjo bolt (8) Installation: Replace sealing rings (7).

*BA07.16-P-1006-01G Banjo bolt to high pressure pump 6 Remove fuel line (5) at high-pressure pump (6) 7 Unscrew fuel temperature sensor (B50) When replacing high-pressure pump (6). Installation: Replace sealing ring.

*BA07.16-P-1011-01G Fuel temperature sensor to high-pressure pump 8 Remove the quantity control valve (Y94) When replacing high-pressure pump (6). Installation: Replace sealing ring.

9 Remove screws (4) of high-pressure pump (6) Installation: Replace screws/bolts (4).

*BA07.16-P-1007-01G Bolt, high-pressure pump to cylinder head 10 Remove high-pressure pump (6) Installation: Replace seal of high-

pressure pump (6). Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.02-p-1020ff, Remove/install high-pressure pump Engine 639.9 in model 454.0

Remove gearwheel at high-pressure pump (6) When replacing high-pressure pump (6) or

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 810 · Applies to: 453 · AR: AR05.20-P-6292FG

11 Remove gearwheel at high-pressure pump (6) When replacing high-pressure pump (6) or when replacing gearwheel of high-pressure pump (6). AR07.02-P-1020-01FF BA07.16-P-1012-01G Nut, gearwheel to high pressure pump 001589503300 Puller 454589044000 Counterholder 640589013300 Bell-type puller If gearwheel of high-pressure pump (6) will be replaced, intake camshaft must also be replaced. Remove/install camshaft AR05.20-P-6292FG 12 Install in the reverse order Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 13 Perform engine test run and check leaktightness of fuel system in area of high- pressure pump (6) Common rail diesel injection (CDI) Number Designation Engine 639.9 BA07.16-P-1003-01G Nut, pressure line on high pressure pump Nm 22 Common rail diesel injection (CDI) Number Designation Engine 639.9 BA07.16-P-1004-01G Nut, pressure line to rail Stage 1 Nm 20 ° Stage 2 60 Common rail diesel injection (CDI) Number Designation Engine 639.9 BA07.16-P-1006-01G Banjo bolt to high pressure pump Nm 20 Common rail diesel injection (CDI) Number Designation Engine 639.9 BA07.16-P-1007-01G Bolt, high-pressure pump to cylinder head Nm 20 Common rail diesel injection (CDI) Number Designation Engine 639.9 BA07.16-P-1011-01G Fuel temperature sensor to high-pressure pump Nm 15 Common rail diesel injection (CDI) Number Designation Engine 639.9 BA07.16-P-1012-01G Nut, gearwheel to high pressure pump Nm 70 Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.02-p-1020ff, Remove/install high-pressure pump Engine 639.9 in model 454.0

AR07.03-P-1450SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 812 · Applies to: 453 · AR: AR07.03-P-1450SR

Remove fuel distributor with injection valves 23.07.2014 ENGINE 281 in MODEL 453 Shown on engine 281.920 1 Fuel distributor 2 Electrical connections 3 Fuel line 4 Screw/bolt P07.03-2346-06 Risk of explosion No fires, sparks, open flames or smoking. Danger ! caused by fuel igniting, risk AS47.00-Z-0001-01A

of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Notes on avoiding damage through AH00.00-P-5000-01A

contamination and foreign objects Remove/install

1 Remove covering over engine
Installation: Only install covering over

engine after the leak test. 2 Separate electrical connections (2) 3 Unlock and detach fuel line (3) on fuel Catch leaking fuel in a suitable vessel.

distributor (1) 4 Remove screws/bolts (4) BA07.52-P-1002-01D ENGINE 281.910 in MODEL 453 BA07.52-P-1001-01D ENGINE 281.920 in MODEL 453 5 Remove fuel distributor (1) together with fuel Installation: Replace sealing rings for

injection valves
injection valves. 6 Install in the reverse order Check

Risk of accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 7 Perform an engine test run and check engine for leaktightness around fuel distributor (1) Fuel distributor Number Designation ENGINE 281 BA07.52-P-1001-01D Screw/bolt, fuel distributor to intake manifold Nm 10 Fuel distributor Number Designation ENGINE 281 BA07.52-P-1002-01D Screw/bolt, fuel distributor to charge air distributor Nm 10 Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar07.03-p-1450sr, Remove fuel distributor with injection valves ENGINE 281 in MODEL 453

AR07.03-P-9105FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 813 · Applies to: 453 · AR: AR07.03-P-9105FF, AR07.09-P-0001FF

Remove/install leak oil line to injectors 18.04.2019 Engine 639.939 in model 454.0 1 Securing clamp 2 Leak oil line P07.16-2687-06 Remove/install

Risk of explosion No fires, sparks, open flames or smoking. Danger caused by fuel igniting, risk AS47.00-Z-0001-01A

of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. 1 Remove vacuum reservoir AR07.09-P-0001FF 2 Detach leak oil line (2) (arrow) 3 Remove safety clips (1) 4 Pull leak oil line (2) out of the injectors Notes about Common-Rail components AH07.16-P-0002-01TX Installation: Install new sealing rings of

the leak oil line (2). 5 Install in the reverse order Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 6 Perform engine test run and check fuel system in the area of the leak oil line (2) for leak tightness Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.03-p-9105ff, Remove/install leak oil line to injectors Engine 639.939 in model 454.0

AR07.03-P-0003FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 814 · Applies to: 453 · AR: AR07.03-P-0003FG, AR09.10-P-1150FG

Remove/install quantity control valve 18.04.2019 Engine 639.939 in model 454.0 1 Connector Y94 Quantity control valve P07.03-2147-04 Remove/install

Risk of explosion No fires, sparks, open flames or smoking. Danger caused by fuel igniting, risk AS47.00-Z-0001-01A

of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. 1 Remove air filter housing AR09.10-P-1150FG 2 Pull plug (1) 3 Unscrew screws of quantity control valve (Y94) 4 Remove quantity control valve (Y94) Notes about Common-Rail components AH07.16-P-0002-01TX Installation: Replace sealing ring.

5 Install in the reverse order Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 6 Perform engine test run and check leaktightness of fuel system in area of quantity control valve (Y94) Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.03-p-0003fg, Remove/install quantity control valve Engine 639.939 in model 454.0

AR07.03-P-1010FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 815 · Applies to: 453 · AR: AR07.03-P-1010FG, AR83.25-P-1402FF, AR07.16-P-1080FF

Remove/install rail 18.04.2019 Engine 639.939 in model 454.0 P07.16-2682-08 1 Connector 6 Leak oil line 10 Rail 2 Connector 7 Sealing ring 11 Screw 3 Connector 8 Banjo bolt B4/6 Rail pressure sensor 4 Cable duct 9 Fuel hose Y74 Pressure regulator valve 5 Securing clamp Remove/install

Risk of explosion No fires, sparks, open flames or smoking. Danger caused by fuel igniting, risk AS47.00-Z-0001-01A

of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Risk of explosion Keep all ignition sources out of hazard area. Danger caused by fuel igniting. AS07.16-Z-0001-01A

Risk of injury to skin and eyes caused by fuel Do not carry out any work on system when it is spraying out at high pressure pressurized. Notes about Common-Rail components AH07.16-P-0002-01TX 1 Remove water collector AR83.25-P-1402FF 2 Remove injection lines of common rail diesel AR07.16-P-1080FF injection (CDI) 3 Detach plugs (1, 2, 3) 4 Remove screws of the cable duct (4) The cable duct (4) is fastened with three

screws. 5 Remove safety clips (5) and remove leak oil Installation: Install new sealing rings of

line (6) the leak oil line (6). 6 Remove banjo bolt (8) and remove fuel hose Installation: Replace sealing rings (7).

(9) BA07.16-P-1006-01G Banjo bolt to high pressure pump 7 Release rail pressure sensor (B4/6) Only when installing a new rail (10). BA07.16-P-1010-01G Rail pressure sensor to rail 8 Loosen union nut of the pressure regulating Only when installing a new rail (10). valve (Y74) BA07.16-P-1009-01G Pressure regulator valve on rail 9 Remove screw/bolts (11) BA07.16-P-1008-01G Bolt, rail to cylinder head cover 10 Remove rail (10) 11 Remove rail pressure sensor (B4/6) Only when installing a new rail (10). 12 Remove union nut of the pressure regulating Only when installing a new rail (10). valve (Y74) and remove pressure regulating valve (Y74) with sealing ring Installation: Replace sealing ring.

13 Remove fuel hose (9) from rail (10) Only when installing a new rail (10). 14 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.03-p-1010fg, Remove/install rail Engine 639.939 in model 454.0

AR07.03-P-6522FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 817 · Applies to: 453 · AR: AR07.03-P-6522FF, AR07.03-P-1450FF

Removing and installing injection valves 4.6.03 ENGINES 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Fuel distributor 2 Sealing ring 3 Securing clamp Y62/1 Cylinder 1 fuel injection valve Y62/2 Cylinder 2 fuel injection valve Y62/3 Cylinder 3 fuel injection valve Y62/4 Fuel injector on cylinder 4 (only for engine 135.9) P07.03-2122-12 Removing/installing

Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by ignition of AS47.00-Z-0001-01A

flammable products, risk of poisoning Only pour fuels into suitable and appropriately

caused by inhaling fuel vapors or swallowing marked containers. fuel as well as risk of injury to skin and eyes Wear protective clothing when handling fuel. exposed to fuel. 1 Removing fuel rail with injection valves AR07.03-P-1450FF 2 Detach securing clamps (3) Inspect condition of securing clamps(3);
replace if necessary. 3 Pull fuel injection valves (Y62/1, Y62/2, Y62/3, Fuel injector on cylinder 4 (Y62/4); only for Y62/4) out of fuel distributor (1) engine 135.9. Installation: Replace sealing rings (2) and lightly oil them in order to facilitate the assembly. 4 Install in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.03-p-6522ff, Removing and installing injection valves ENGINES 134.9, 135.9 in MODEL 454.0

AR07.04-P-0012FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 818 · Applies to: 453 · AR: AR07.04-P-0012FF, AR01.20-P-5015FF

Remove, install pressure differential sensor (DPF) 20.3.06 ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter P07.04-2490-07 1 Bracket 3 Nut 5 Hose clamp 2 Electrical connector 4 Purge line B28/8 Pressure differential sensor (DPF) Remove/install

1 Remove trim panel of cylinder head cover AR01.20-P-5015FF 2 Remove hose clamps (5) at regeneration lines Only hose clamps(5) on pressure lines for (4) and regeneration lines (4) catalytic converter diesel particulate filter unit should be detached. When detaching hose clamps at pressure differential sensor (DPF) (B28/8), hairline cracks can arise and thus damage to the pressure differential sensor (DPF) (B28/8). Pay attention to installation position of regeneration lines (4). 3 Unclip regeneration lines (4) for catalytic converter diesel particulate filter unit from bracket (1) 4 Unscrew nut (3) on pressure differential sensor (DPF) (B28/8) and pressure differential sensor (DPF) (B28/8) 5 Install in the reverse order 6 Read fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.04-p-0012ff, Remove, install pressure differential sensor (DPF) ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter

AR07.04-P-0005FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 819 · Applies to: 453 · AR: AR07.04-P-0005FF, AR01.20-P-5015FF, AR61.20-P-1105FF

Remove/install diesel particulate filter temperature sensor 9.3.10 ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter P07.04-2489-09 1 Pressure line 5 Bracket B19/9 Temperature sensor upstream of diesel particulate filter 2 Wiring harness 6 Bolt B19/9x1 Temperature sensor connector 3 Tie strap 7 Lower regeneration line upstream of diesel particulate 4 Bracket 8 Union nut filter Remove/install

1 Remove trim panel of cylinder head cover AR01.20-P-5015FF 2 Disconnect temperature sensor connector upstream of diesel particulate filter (B19/9x1) 3 Remove cable binder (3) and detach wiring harness (2) for temperature sensor upstream of diesel particulate filter (B19/9) from bracket (4) 4 Unscrew bolt (6) and take off bracket (5) for lower regeneration line (7) 5 Detach lower engine compartment paneling AR61.20-P-1105FF 6 Remove lower regeneration line (7) at *BA49.10-P-1007-01P

catalytic converter diesel particulate filter unit 7 Remove temperature sensor upstream of *BA07.04-P-1002-01J

diesel particulate filter (B19/9) from catalytic converter diesel particulate filter unit Installation: Coat temperature sensor

upstream of diesel particulate filter (B19/9) with heat-resistant lubricant before installing. Paste *BR00.45-Z-1005-06A 8 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 9 Check engine test run while checking exhaust system in the area of temperature sensor upstream of diesel particulate filter (B19/9) and lower regeneration line (7) for leaks 10 Read fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Sensors

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.04-p-0005ff, Remove/install diesel particulate filter temperature sensor ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter

AR07.04-P-0071FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 821 · Applies to: 453 · AR: AR07.04-P-0071FF, AR01.20-P-5015FF

Remove/install exhaust gas temperature sensor 9.3.10 ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter 1 Wiring harness 2 Bracket 3 Tie strap B19/11 Temperature sensor upstream of turbocharger B19/11x1 Temperature sensor connector upstream of turbocharger P07.04-2488-05 Remove/install

1 Remove trim panel of cylinder head cover AR01.20-P-5015FF 2 Disconnect temperature sensor connector upstream of turbocharger (B19/11x1) 3 Remove cable binder (3) and detach wiring harness (1) for temperature sensor upstream of turbocharger (B19/11) from bracket (2) 4 Remove temperature sensor upstream of *BA07.04-P-1003-01J

turbocharger (B19/11) from exhaust manifold Installation: Coat temperature sensor

upstream of turbochargerB19/11) with heat- resistant lubricant before installing. Paste *BR00.45-Z-1005-06A 5 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 6 Carry out engine test run and in doing so, check exhaust system in the area of the temperature sensor upstream of turbocharger (B19/11) for leaks 7 Read fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Sensors

Number Designation Engine 639.9 BA07.04-P-1003-01J Temperature sensor on exhaust manifold Nm 20 Repair materials Number Designation Order number BR00.45-Z-1005-06A Paste, hot lubrication 1 kg, DB supply specification 6879.20 A 000 989 76 51 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.04-p-0071ff, Remove/install exhaust gas temperature sensor ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter

AR07.04-P-0008FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 822 · Applies to: 453 · AR: AR07.04-P-0008FF

Remove/install high-pressure pump's fuel temperature sensor 23.04.2019 Engine 639.939 in model 454.0 1 Connector B50 Fuel temperature sensor P07.04-2291-04 Remove/install

Risk of explosion No fires, sparks, open flames or smoking. Danger caused by fuel igniting, risk AS47.00-Z-0001-01A

of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Risk of explosion Keep all ignition sources out of hazard area. Danger caused by fuel igniting. AS07.16-Z-0001-01A

Risk of injury to skin and eyes caused by fuel Do not carry out any work on system when it is spraying out at high pressure pressurized. 1 Remove air filter housing upper part AR09.10-P-1150-02FG 2 Pull plug (1) 3 Remove fuel temperature sensor (B50) Notes about Common-Rail components AH07.16-P-0002-01TX Installation: Replace sealing ring.

*BA07.16-P-1011-01G Fuel temperature sensor to high-pressure pump 4 Install in the reverse order Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 5 Perform engine test run and check leak tightness of the fuel system in the area of the fuel temperature sensor (B50) 6 Read out fault memory AD00.00-P-2000-04FF

Common rail diesel injection (CDI) Number Designation Engine 639.9 BA07.16-P-1011-01G Fuel temperature sensor to high-pressure pump Nm 15 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.04-p-0008ff, Remove/install high-pressure pump's fuel temperature sensor Engine 639.939 in model 454.0

AR07.04-P-0100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 823 · Applies to: 453 · AR: AR07.04-P-0100FF

Remove/install intake manifold pressure sensor 2.12.09 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Connector 2 Bolt 3 Intake manifold B28 Pressure sensor P07.04-2208-04 Remove/install

1 Unplug plug (1) at pressure sensor (B28) 2 Remove bolt (2) on pressure sensor (B28) *BA07.04-P-1001-01H

3 Pull pressure sensor (B28) out of the intake Installation:

Replace sealing ring at manifold (3) pressure sensor (B28). 4 Install in the reverse order 5 Read out fault memory Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Sensors

Number Designation Engine Engine Engine Engine 134.910 134.911 135.930 135.950 BA07.04-P-1001-01H Bolt, pressure sensor to intake manifold Nm 6 6 6 6 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.04-p-0100ff, Remove/install intake manifold pressure sensor ENGINE 134.9, 135.9 in MODEL 454.0

AR07.04-P-0100SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 824 · Applies to: 453 · AR: AR07.04-P-0100SR, AR01.00-P-3050SR

Remove/install intake manifold pressure sensor 23.07.2014 ENGINE 281 in MODEL 453 P07.04-2804-09 1 Intake manifold 3 Sealing rings 2 Electrical connection B28 Pressure sensor (intake manifold pressure) Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Lower rear drive module
AR01.00-P-3050SR 2 Disconnect electrical connection (2) from (intake manifold pressure) pressure sensor (B28)
3 Pull (intake manifold pressure) pressure Installation: Check sealing rings (3) on

sensor (B28) out of the intake manifold (1) (intake manifold pressure) pressure sensor (B28). If damage is present: Replace sealing rings (3). 4 Install in the reverse order 5 Connect diagnostic unit, read out fault memory When replacing the (intake manifold pressure) pressure sensor (B28). Connect diagnostic unit, read out fault memory AD00.00-P-2000-06SR

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.04-p-0100sr, Remove/install intake manifold pressure sensor ENGINE 281 in MODEL 453

AR07.04-P-0050FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 825 · Applies to: 453 · AR: AR07.04-P-0050FF, AR83.25-P-1402FF

Remove/install pressure sensor 18.5.04 ENGINE 639.939 in MODEL 454.0 1 Screws B5/1 Charge pressure sensor P07.04-2290-04 Remove/Install

1 Remove water collector AR83.25-P-1402FF 2 Disconnect plug (arrowed) from charge pressure sensor (B5/1) 3 Remove bolts (1) 4 Take out charge pressure sensor (B5/1) Installation:

Install new sealing ring for charge pressure sensor (B5/1). 5 Install in the reverse order 6 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 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, ar07.04-p-0050ff, Remove/install pressure sensor ENGINE 639.939 in MODEL 454.0

AR07.04-P-0070FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 826 · Applies to: 453 · AR: AR07.04-P-0070FF, AR83.25-P-1402FF

Remove/install temperature sensor 18.5.04 ENGINE 639.939 in MODEL 454.0 1 Plug B17/8 Charge air temperature sensor P07.04-2289-04 Remove/Install

1 Remove water collector AR83.25-P-1402FF 2 Disconnect plug (1) 3 Press strikers (arrowed) together and pull out Installation:

Install new sealing ring for charge air temperature sensor (B17/8) charge air temperature sensor (B17/8). 4 Install in the reverse order 5 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 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, ar07.04-p-0070ff, Remove/install temperature sensor ENGINE 639.939 in MODEL 454.0

AR07.04-P-1620FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 827 · Applies to: 453 · AR: AR07.04-P-1620FF, AR20.00-P-1142FG, AR09.41-P-1325FG

Removing and installing a coolant temperature sensor 11.5.04 ENGINE 639.939 in MODEL 454.0 P07.04-2308-07 1 Connector 3 Securing clamp B11/4 Coolant temperature sensor 2 Connector Modification notes 25.10.04 Cross-reference to removing intake air throttle - added Stage 2 Removing/installing

1 Drain coolant AR20.00-P-1142FG 2 Remove intake air throttle AR09.41-P-1325FG 3 Unplug plugs (1, 2) 4 Pull out securing clamp (3) 5 Pull out coolant temperature sensor (B11/4) Installation:

Replace sealing ring on coolant temperature sensor (B11/4). 6 Install in reverse order 7 Read out fault memory Connect up STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.04-p-1620ff, Removing and installing a coolant temperature sensor ENGINE 639.939 in MODEL 454.0

AR07.07-P-7008FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 828 · Applies to: 453 · AR: AR07.07-P-7008FG

Remove/install volume air flow meter 28.5.04 ENGINE 639.939 in MODEL 454.0 P07.07-2047-08 1 Clamp 3 Air cleaner housing 5 Screw 2 Hose 4 Sealing ring B2/5 Hot film mass air flow sensor Remove/Install

1 Open engine hood See Operating Instructions 2 Release clamp (1) and disconnect hose (2). 3 Pull out plug at hot film mass air flow sensor (B2/5) 4 Remove screws (5) of hot film mass air flow sensor (B2/5) 5 Pull hot film mass air flow sensor (B2/5) out of Installation:

Check sealing ring (4), air cleaner housing (3). replace if necessary. 6 Install in the reverse order 7 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 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, ar07.07-p-7008fg, Remove/install volume air flow meter ENGINE 639.939 in MODEL 454.0

AR07.08-P-7008SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 833 · Applies to: 453 · AR: AR07.08-P-7008SR, AR68.30-P-4700SRC, AR68.30-P-4800SR, AR68.30-P-4800SRA

Remove/install injection system control unit 13.01.2016 Engine 281 in model 453 Shown on model 453.0 1 Electrical connection 2 Electrical connection 3 Electrical connection 4 Screw/bolts N3/10 ME-SFI [ME] control unit P07.08-2237-11 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Perform initial startup of ME-SFI [ME] control When replacing the ME-SFI [ME] control unit unit (N3/10) (N3/10). AD00.00-P-2000-06SR

2 Switch off ignition and remove transmitter key
3 Remove right paneling in cargo area Engine 281 in model 453.4 AR68.30-P-4700SRC Engine 281 in model 453.0 AR68.30-P-4800SR Engine 281 in model 453.3 AR68.30-P-4800SRA 4 Release and disconnect electrical connection (1)
5 Release and disconnect electrical connection (2)
6 Release and disconnect electrical connection (3)
7 Remove screw/bolts (4) and remove from ME- SFI [ME] control unit (N3/10) 8 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.08-p-7008sr, Remove/install injection system control unit Engine 281 in model 453

AR07.08-P-7006FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 834 · Applies to: 453 · AR: AR07.08-P-7006FF, AR54.10-P-0005FF

Removing/installing the electronic diesel system (electronic diesel transmission) 23.6.04 control unit ENGINE 639.939 in MODEL 454.0 1 Bolt 2 Nuts 3 Locking lever 4 Connector 5 Carrier plate 6 Bolt N3/9 EDG control unit P07.08-2096-06 Removing/installing

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

components due to electrostatic discharge 1 Remove battery AR54.10-P-0005FF 2 Unscrew bolt (1) 3 Unscrew nuts (2) 4 Remove clip (arrow) using appropriate toil from carrier plate (5) 5 Pull out striker (3) and pull plug (4) out of Pay attention to the gaskets in the plugs electronic diesel transmission control unit (4). (N3/9) 6 Remove electronic diesel transmission control unit (N3/9) with carrier plate (5) 7.1 Unscrew screws (6) and remove electronic Only when replacing the control unit electronic diesel transmission control unit (N3/9) diesel transmission (N3/9). 8 Install in the reverse order 9 Read out fault memory and program The electronic diesel transmission control electronic diesel transmission control unit unit (N3/9) is only programmed when it is (N3/9) replaced. Connect up STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.08-p-7006ff, Removing/installing the electronic diesel system (electronic diesel transmission) control unit ENGINE 639.939 in MODEL 454.0

AR07.08-P-7008FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 835 · Applies to: 453 · AR: AR07.08-P-7008FF, AR54.10-P-0005FF

Removing/installing the injection system control unit 8.10.03 ENGINES 122.9, 134.9, 135.9 in MODEL 454.0 P07.08-2077-09 Shown on engine 135.9 1 Nuts 6 Bow 11 Carrier plate 2 Cover 7 Connector 12 Fish-plate 3 Bolt 8 Fish-plate 13 Bolts 4 Clip 9 Bracket 5 Nuts 10 Connector N3/10 Motor electronics control unit Removing/installing

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

components due to electrostatic discharge 1 Remove battery AR54.10-P-0005FF 2 Unscrew nuts (1) and remove cover (2) 3 Unscrew bolt (3). 4 Unscrew nuts (5) and remove clip (4) 5 Press fish-plate (12), fold up bracket (6) and unplug plug (7) 6 Press fish-plate (8), fold up bracket (9) and unplug plug (10) 7 Take out motor electronics control unit (N3/10) with carrier plate (11) 8.1 Remove bolts (13) and remove motor Only when replacing the motor electronics electronics control unit (N3/10) from carrier control unit (N3/10). plate (11) 9 Install in reverse order 10 Read out fault memory and program motor Only program motor electronics control electronics control unit (N3/10) unit (N3/10) when replacing it. Connect up STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.08-p-7008ff, Removing/installing the injection system control unit ENGINES 122.9, 134.9, 135.9 in MODEL 454.0

AR07.09-P-0001FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 836 · Applies to: 453 · AR: AR07.09-P-0001FF, AR88.00-P-2792FF

Remove/install pressure reservoir 18.5.04 ENGINE 639.939 in MODEL 454.0 1 Pressure reservoir 2 Vacuum line 3 Vacuum line 4 Screws 5 Bracket P07.09-2016-04 Remove/Install

1 Remove paneling on center piece in front of AR88.00-P-2792FF windshield 2 Detach vacuum lines (2, 3) 3 Remove screws (4) 4 Remove pressure reservoir (1) Installation:

Pay attention to bracket (5) 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.09-p-0001ff, Remove/install pressure reservoir ENGINE 639.939 in MODEL 454.0

PE07.10-P-2702BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 837 · Applies to: 453 · AR: PE07.10-P-2702BBA

Electrical function diagram for ignition OFF 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for ignition OFF PE07.10-P-2702-97BBA Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2702bba, Electrical function diagram for ignition OFF Engine 281.910 in model 453.0/3/4

PE07.10-P-2704BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 838 · Applies to: 453 · AR: PE07.10-P-2704BBA

Electrical function diagram for injection control 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for injection PE07.10-P-2704-97BBA control Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2704bba, Electrical function diagram for injection control Engine 281.910 in model 453.0/3/4

PE07.10-P-2716BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 839 · Applies to: 453 · AR: PE07.10-P-2716BBA

Electrical function schematic for camshaft adjustment 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for camshaft PE07.10-P-2716-97BBA adjustment Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2716bba, Electrical function schematic for camshaft adjustment Engine 281.910 in model 453.0/3/4

PE07.10-P-2714BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 840 · Applies to: 453 · AR: PE07.10-P-2714BBA

Electrical function schematic for deceleration fuel shutoff 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for deceleration PE07.10-P-2714-97BBA fuel shutoff Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2714bba, Electrical function schematic for deceleration fuel shutoff Engine 281.910 in model 453.0/3/4

PE07.10-P-2719BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 841 · Applies to: 453 · AR: PE07.10-P-2719BBA

Electrical function schematic for engine limp-home mode 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for engine limp- PE07.10-P-2719-97BBA home mode Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2719bba, Electrical function schematic for engine limp-home mode Engine 281.910 in model 453.0/3/4

PE07.10-P-2722BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 842 · Applies to: 453 · AR: PE07.10-P-2722BBA

Electrical function schematic for engine timing start stop 11.05.2016 Engine 281.910 in model 453.0/3/4 with code B03 (ECO start/stop function) Electrical function schematic for engine timing, PE07.10-P-2722-97BBA start/stop Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2722bba, Electrical function schematic for engine timing start stop Engine 281.910 in model 453.0/3/4 with code B03 (ECO start/stop function)

PE07.10-P-2703BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 843 · Applies to: 453 · AR: PE07.10-P-2703BBA

Electrical function schematic for fuel supply 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for fuel supply PE07.10-P-2703-97BBA Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2703bba, Electrical function schematic for fuel supply Engine 281.910 in model 453.0/3/4

PE07.10-P-2705BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 844 · Applies to: 453 · AR: PE07.10-P-2705BBA

Electrical function schematic for ignition system 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for ignition PE07.10-P-2705-97BBA system Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2705bba, Electrical function schematic for ignition system Engine 281.910 in model 453.0/3/4

PE07.10-P-2715BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 845 · Applies to: 453 · AR: PE07.10-P-2715BBA

Electrical function schematic for knock control 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for knock control PE07.10-P-2715-97BBA Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2715bba, Electrical function schematic for knock control Engine 281.910 in model 453.0/3/4

PE07.10-P-2710BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 848 · Applies to: 453 · AR: PE07.10-P-2710BBA

Electrical function schematic for lambda control 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for lambda PE07.10-P-2710-97BBA control Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2710bba, Electrical function schematic for lambda control Engine 281.910 in model 453.0/3/4

PE07.10-P-2720BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 849 · Applies to: 453 · AR: PE07.10-P-2720BBA

Electrical function schematic for on-board diagnosis 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for OBD PE07.10-P-2720-97BBA Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2720bba, Electrical function schematic for on-board diagnosis Engine 281.910 in model 453.0/3/4

PE07.10-P-2708BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 854 · Applies to: 453 · AR: PE07.10-P-2708BBA

Electrical function schematic for rpm control 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for rpm control PE07.10-P-2708-97BBA Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2708bba, Electrical function schematic for rpm control Engine 281.910 in model 453.0/3/4

PE07.10-P-2708BBF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 855 · Applies to: 453 · AR: PE07.10-P-2708BBF

Electrical function schematic for rpm control 13.11.15 Engine 281.920 in model 453.0/3/4 Electrical function schematic for rpm control PE07.10-P-2708-97BBF Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe07.10-p-2708bbf, Electrical function schematic for rpm control Engine 281.920 in model 453.0/3/4

PE07.10-P-2733BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 856 · Applies to: 453 · AR: PE07.10-P-2733BBA

Electrical function schematic for safety fuel shutoff 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for safety fuel PE07.10-P-2733-97BBA shutoff Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2733bba, Electrical function schematic for safety fuel shutoff Engine 281.910 in model 453.0/3/4

PE07.10-P-2711BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 857 · Applies to: 453 · AR: PE07.10-P-2711BBA

Electrical function schematic for smooth running control 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for smooth PE07.10-P-2711-97BBA running control Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2711bba, Electrical function schematic for smooth running control Engine 281.910 in model 453.0/3/4

PE07.10-P-2707BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 858 · Applies to: 453 · AR: PE07.10-P-2707BBA

Electrical function schematic for start phase, post-start phase and warm-up 17.11.15 enrichment Engine 281.910 in model 453.0/3/4 Electrical function schematic for start phase, PE07.10-P-2707-97BBA post-start phase and warm-up enrichment Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2707bba, Electrical function schematic for start phase, post-start phase and warm-up enrichment Engine 281.910 in model 453.0/3/4

PE07.10-P-2701BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 859 · Applies to: 453 · AR: PE07.10-P-2701BBA

Electrical function schematic for starting 11.05.2016 Engine 281.910 in model 453.0/3/4 Electrical function schematic for starting PE07.10-P-2701-97BBA Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2701bba, Electrical function schematic for starting Engine 281.910 in model 453.0/3/4

PE07.10-P-2712BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 860 · Applies to: 453 · AR: PE07.10-P-2712BBA

Electrical function schematic for thermal management 11.05.2016 Engine 281.910 in model 453.0/3/4 Electrical function schematic for heat PE07.10-P-2712-97BBA management Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2712bba, Electrical function schematic for thermal management Engine 281.910 in model 453.0/3/4

PE07.10-P-2713BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 861 · Applies to: 453 · AR: PE07.10-P-2713BBA

Electrical function schematic for torque coordination 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for torque PE07.10-P-2713-97BBA coordination Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2713bba, Electrical function schematic for torque coordination Engine 281.910 in model 453.0/3/4

PE07.10-P-2709BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 862 · Applies to: 453 · AR: PE07.10-P-2709BBA

Electrical function schematic, alternator interface 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for alternator PE07.10-P-2709-97BBA interface Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2709bba, Electrical function schematic, alternator interface Engine 281.910 in model 453.0/3/4

PE07.10-P-2700BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 863 · Applies to: 453 · AR: PE07.10-P-2700BBA

Electrical function schematic, ignition ON 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic, ignition ON PE07.10-P-2700-97BBA Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2700bba, Electrical function schematic, ignition ON Engine 281.910 in model 453.0/3/4

PE07.10-P-2706BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 864 · Applies to: 453 · AR: PE07.10-P-2706BBA

Electrical function schematic, synchronization of the injection and firing order 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic, synchronization PE07.10-P-2706-97BBA of the injection and firing order Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.10-p-2706bba, Electrical function schematic, synchronization of the injection and firing order Engine 281.910 in model 453.0/3/4

PE07.16-P-2201ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 865 · Applies to: 453 · AR: PE07.16-P-2201ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+4 more)

Block diagram of the electronic diesel transmission control (EDG) 16.12.03 ENGINE 639.939 in MODEL 454 PE07.16-P-2201-99ZA Block diagram of the electronic diesel PE07.16-P-2201-99ZA transmission control (EDG) PE07.16-P-2201-60ZA Legend for the block diagram of the electronic PE07.16-P-2201-60ZA diesel transmission control (EDG) 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 the cable and GF00.19-P-1000ZA plug 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 (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 PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE82.00-P-1100ZA Further wiring diagrams PE82.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.16-p-2201za, Block diagram of the electronic diesel transmission control (EDG) ENGINE 639.939 in MODEL 454

AR07.16-P-1080FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 866 · Applies to: 453 · AR: AR07.16-P-1080FF, AR07.09-P-0001FF

Remove/install injection lines of common rail direct injection 23.04.2019 Engine 639.9 in model 454.0 Modification notes 01.12.2005 Fundamental replacement of the high-pressure line and Operation steps 2 and 3 injection lines omitted. P07.16-2679-08 1 Screw 2 High pressure pipe 3 Injection line Remove/install

Risk of explosion Keep all ignition sources out of hazard area. Danger caused by fuel igniting. AS07.16-Z-0001-01A

Risk of injury to skin and eyes caused by fuel Do not carry out any work on system when it is spraying out at high pressure pressurized. Risk of explosion No fires, sparks, open flames or smoking. Danger caused by fuel igniting, risk AS47.00-Z-0001-01A

of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. 1 Remove vacuum reservoir Remove/install vacuum reservoir AR07.09-P-0001FF 2 Remove screw (1) and remove high-pressure line (2) Notes about Common-Rail components AH07.16-P-0002-01TX Use suitable stop plugs to seal the

openings. Check sealing cone on the high-pressure line (2); replace in the event of pressure marks on the high-pressure line (2). BA07.16-P-1001-01G Bolt, pressure line bracket to cylinder head cover BA07.16-P-1003-01G Nut, pressure line on high pressure pump *BA07.16-P-1004-01G Nut, pressure line to rail 3 Remove injection lines (3) Notes about Common-Rail components AH07.16-P-0002-01TX Use suitable stop plugs to seal the

openings. Check sealing cone on the injection lines (3); replace in the event of pressure marks on the injection line (3). BA07.16-P-1002-01G Nut, pressure line to injectors BA07.16-P-1004-01G Nut, pressure line to rail 4 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.16-p-1080ff, Remove/install injection lines of common rail direct injection Engine 639.9 in model 454.0

AR07.16-P-1000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 868 · Applies to: 453 · AR: AR07.16-P-1000FF, AR07.16-P-1080FF

Remove/install injectors 23.04.2019 Engine 639.939 in model 454.0 Modification notes 15.12.2005 Screw/bolt, clamping claw to injector BA07.16-P-1005-01G P07.16-2686-08 1 Securing clamp 4 Clamping claw Y76/1 Cylinder 1 fuel injector 2 Leak oil line 5 Sealing ring Y76/2 Cylinder 2 fuel injector 3 Screw 6 Seal Y76/3 Cylinder 3 fuel injector Remove/install

Risk of explosion No fires, sparks, open flames or smoking. Danger caused by fuel igniting, risk AS47.00-Z-0001-01A

of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Risk of explosion Keep all ignition sources out of hazard area. Danger caused by fuel igniting. AS07.16-Z-0001-01A

Risk of injury to skin and eyes caused by fuel Do not carry out any work on system when it is spraying out at high pressure pressurized. Notes about Common-Rail components AH07.16-P-0002-01TX 1 Remove injection lines of common rail diesel AR07.16-P-1080FF injection (CDI) 2 Remove safety clips (1) and pull leak oil line Seal connections using suitable stop

(2) out of the fuel injectors (Y76/1, Y76/2, plugs. Y76/3) 3 Remove screws (3) Installation: Replace screw/bolts (3).

*BA07.16-P-1005-01G Bolt, clamping claw to injector 4 Mark fuel injectors (Y76/1, Y76/2, Y76/3) and Installation: Grease fuel injectors (Y76/1,

pull out with clamping claw (4) Y76/2, Y76/3) with special grease. Replace the sealing ring (5) and seal (6). Special grease *BR00.45-Z-1036-06A 5 Install in the reverse order 6 Read out fault memory AD00.00-P-2000-04FF

When installing new fuel injectors (Y76/1,

Y76/2, Y76/3), the classification must be carried out. Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.16-p-1000ff, Remove/install injectors Engine 639.939 in model 454.0

AR07.16-P-1055FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 870 · Applies to: 453 · AR: AR07.16-P-1055FF, AR88.00-P-2792FF

Remove/install rail pressure sensor 23.04.2019 Engine 639.939 in model 454.0 1 Connector B4/6 Rail pressure sensor P07.16-2669-04 Remove/install

Risk of explosion No fires, sparks, open flames or smoking. Danger caused by fuel igniting, risk AS47.00-Z-0001-01A

of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Risk of explosion Keep all ignition sources out of hazard area. Danger caused by fuel igniting. AS07.16-Z-0001-01A

Risk of injury to skin and eyes caused by fuel Do not carry out any work on system when it is spraying out at high pressure pressurized. 1 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 2 Pull plug (1) 3 Remove rail pressure sensor (B4/6) Notes about Common-Rail components AH07.16-P-0002-01TX *BA07.16-P-1010-01G Rail pressure sensor to rail 4 Install in the reverse order Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 5 Perform engine test run and check leak tightness of the fuel system in the area of the rail pressure sensor (B4/6) 6 Read out fault memory AD00.00-P-2000-04FF

Common rail diesel injection (CDI) Number Designation Engine 639.9 BA07.16-P-1010-01G Rail pressure sensor to rail Nm 27 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.16-p-1055ff, Remove/install rail pressure sensor Engine 639.939 in model 454.0

PE07.16-P-2200ZD

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 871 · Applies to: 453 · AR: PE07.16-P-2200ZD, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+5 more)

Wiring diagram for electronic diesel transmission control (EDG) 8.3.06 ENGINE 639.939 in MODEL 454 as of 3.4.06 sheet 2 PE07.16-P-2200-99ZD Wiring diagram of electronic diesel PE07.16-P-2200-99ZD transmission control (EDG) PE07.16-P-2200-60ZD Legend of wiring diagram for electronic diesel PE07.16-P-2200-60ZD transmission control (EDG) 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 PE07.00-P-1100ZA Further wiring diagrams PE07.00-P-1100ZA PE15.00-P-1100ZA Further wiring diagrams PE15.00-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE83.00-P-1100ZA Further wiring diagrams PE83.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.16-p-2200zd, Wiring diagram for electronic diesel transmission control (EDG) ENGINE 639.939 in MODEL 454 as of 3.4.06 sheet 2

PE07.16-P-2200ZC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 872 · Applies to: 453 · AR: PE07.16-P-2200ZC, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram of electronic diesel transmission control (EDG) 8.3.06 ENGINE 639.939 in MODEL 454 as of 3.4.06 Sheet 1 PE07.16-P-2200-99ZC Wiring diagram of electronic diesel PE07.16-P-2200-99ZC transmission control (EDG) PE07.16-P-2200-60ZC Legend of wiring diagram for electronic diesel PE07.16-P-2200-60ZC transmission control (EDG) 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 PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.16-p-2200zc, Wiring diagram of electronic diesel transmission control (EDG) ENGINE 639.939 in MODEL 454 as of 3.4.06 Sheet 1

PE07.16-P-2200ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 873 · Applies to: 453 · AR: PE07.16-P-2200ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram of the electronic diesel transmission control (EDG) 16.12.03 ENGINE 639.939 in MODEL 454 up to 2.4.06 Blatt 1 PE07.16-P-2200-99ZA Wiring diagram of the electronic diesel PE07.16-P-2200-99ZA transmission control (EDG) PE07.16-P-2200-60ZA Legend for the wiring diagram of the PE07.16-P-2200-60ZA electronic diesel transmission control (EDG) 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 the cable and GF00.19-P-1000ZA plug 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 (wiring connections in wiring harness) PE07.00-P-1100ZA Further wiring diagrams PE07.00-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, pe07.16-p-2200za, Wiring diagram of the electronic diesel transmission control (EDG) ENGINE 639.939 in MODEL 454 up to 2.4.06 Blatt 1

PE07.16-P-2200ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 874 · Applies to: 453 · AR: PE07.16-P-2200ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+4 more)

Wiring diagram of the electronic diesel transmission control (EDG) 16.12.03 ENGINE 639.939 in MODEL 454 up to 2.4.06 Blatt 2 PE07.16-P-2200-99ZB Wiring diagram of the electronic diesel PE07.16-P-2200-99ZB transmission control (EDG) PE07.16-P-2200-60ZB Legend for the wiring diagram of the PE07.16-P-2200-60ZB electronic diesel transmission control (EDG) 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 the cable and GF00.19-P-1000ZA plug 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 (wiring connections in wiring harness) PE00.19-P-1100ZA Further wiring diagrams PE00.19-P-1100ZA PE07.00-P-1100ZA Further wiring diagrams PE07.00-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE83.00-P-1100ZA Further wiring diagrams PE83.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.16-p-2200zb, Wiring diagram of the electronic diesel transmission control (EDG) ENGINE 639.939 in MODEL 454 up to 2.4.06 Blatt 2

AR07.17-P-1060FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 875 · Applies to: 453 · AR: AR07.17-P-1060FF, AR83.25-P-1402FF, AR07.09-P-0001FF

Remove/install pressure control valve 23.04.2019 Engine 639.939 in model 454.0 P07.16-2678-08 1 High pressure pipe 4 Connector 6 Union nut 2 Connector 5 Cable duct Y74 Pressure regulator valve 3 Connector Remove/install

Risk of explosion No fires, sparks, open flames or smoking. Danger caused by fuel igniting, risk AS47.00-Z-0001-01A

of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Risk of explosion Keep all ignition sources out of hazard area. Danger caused by fuel igniting. AS07.16-Z-0001-01A

Risk of injury to skin and eyes caused by fuel Do not carry out any work on system when it is spraying out at high pressure pressurized. 1 Remove water collector AR83.25-P-1402FF 2 Remove vacuum reservoir AR07.09-P-0001FF 3 Detach plugs (2, 3, 4) 4 Remove high-pressure line (1) Notes about Common-Rail components AH07.16-P-0002-01TX Installation: Replace high-pressure line

(1). BA07.16-P-1001-01G Bolt, pressure line bracket to cylinder head cover BA07.16-P-1003-01G Nut, pressure line on high pressure pump *BA07.16-P-1004-01G Nut, pressure line to rail 5 Remove screws of the cable duct (5) The cable duct (5) is fastened with three

screws. 6 Remove union nut (6) of the pressure regulating valve (Y74) and remove pressure regulating valve (Y74) with sealing ring Notes about Common-Rail components AH07.16-P-0002-01TX Installation: Install new sealing ring of the

pressure regulating valve (Y74). *BA07.16-P-1009-01G Pressure regulator valve on rail 7 Install in the reverse order Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 8 Perform engine test run and check leak tightness of the fuel system in the area of the pressure regulating valve (Y74) 9 Read out fault memory STAR DIAGNOSIS diagnosis system Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.17-p-1060ff, Remove/install pressure control valve Engine 639.939 in model 454.0

PE07.61-P-2201ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 877 · Applies to: 453 · AR: PE07.61-P-2201ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+5 more)

Block diagram of the engine electronics - electronic accelerator - transmission 16.12.03 (MEG) with clutch ENGINE 134.910, 135.930 /950 in MODEL 454 PE07.61-P-2201-99ZA Block diagram of the engine electronics - PE07.61-P-2201-99ZA electronic accelerator - transmission (MEG) with clutch PE07.61-P-2201-60ZA Legend for the block diagram of engine PE07.61-P-2201-60ZA electronics - electronic accelerator - transmission (MEG) with clutch 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 the cable and GF00.19-P-1000ZA plug 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 (wiring connections in wiring harness) PE07.00-P-1100ZA Further wiring diagrams PE07.00-P-1100ZA PE15.00-P-1100ZA Further wiring diagrams PE15.00-P-1100ZA PE42.00-P-1100ZA Further wiring diagrams PE42.00-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE82.00-P-1100ZA Further wiring diagrams PE82.00-P-1100ZA PE83.00-P-1100ZA Further wiring diagrams PE83.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.61-p-2201za, Block diagram of the engine electronics - electronic accelerator - transmission (MEG) with clutch ENGINE 134.910, 135.930 /950 in MODEL 454

GF07.61-P-9997KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 878 · Applies to: 453 · AR: GF07.61-P-9997KJ

Overview of system components motor electronics (ME-SFI) fuel injection and 10.05.2016 ignition system Engine 281.910 in model 453.0/3/4 P07.61-3891-79 Vehicle view from the front left shown on model 453.3 A1 IC (for code K35 (IC with F11 Internal combustion engine fuse N10/11 Driver-side SAM control unit monochrome display)) or (for and relay module code K36 (IC with 8.9 cm (3.5") color display)) A15 Additional instruments F11k1 Engine function circuit 87 relay N15/13 DKG control unit (only for code 429 (twinamic)) A45/1 Steering wheel clock spring F11k2 Fan relay N22/1 Climate control control unit (only contact for code I01 (Automatic air conditioning)) A89 Distance warning function F11k3 Ignition coils/fuel pump actuation N30/4 Electronic Stability Program controller unit with radar sensor relay control unit (only for code 252 (Distance warning function)) F1 Power supply fuse and relay K32 Fan solenoid switch, internal N49 Steering wheel angle sensor module combustion engine cooling ICE (for code I01 (AAC) or for code I77 (Manual A/C)) F1k1 Fan relay (for code I78 (Heating N2/10 Supplemental restraint system N93/2 Distance warning function system)) control unit gateway (only for code 252 (Distance warning function)) F2 Vehicle interior fuse and relay N3/10 ME-SFI [ME] control unit X11/4 Diagnostic connector module F2k5 Starter relay N10/10 Center SAM control unit Page 1 of 11 © Mercedes-Benz AG, 5/21/18, L/07/20, gf07.61-p-9997kj, Overview of system components motor electronics (ME-SFI) fuel injection and ignition system Engine 281.910 in model 453.0/3/4

AR07.61-P-1401SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 889 · Applies to: 453 · AR: AR07.61-P-1401SR, AR09.41-P-8621SR

Remove/install throttle valve actuator 23.07.2014 ENGINE 281 in MODEL 453 P07.61-3882-08 Shown on engine 281.920 1 Air intake hose 5 Bracket 2 Electrical connection 6 Screw/bolts 3 Cable duct M16/6 Throttle valve actuator 4 Screw/bolts Notes on avoiding damage through AH00.00-P-5000-01A

contamination and foreign objects Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Remove covering over engine ENGINE 281.920 in MODEL 453 2 Remove air intake hose (1)
ENGINE 281.920 in MODEL 453 3 Remove charge air hose ENGINE 281.910 in MODEL 453 AR09.41-P-8621SR 4 Disconnect electrical connection (2) at throttle valve actuator (M16/6)
5 Unclip cable duct (3) and remove from working area 6 Unfasten screws/bolts (4) on holder (5) 7 Remove screw/bolts (6) *BA07.61-P-1003-01B Screw/bolt, throttle valve actuator to intake manifold/charge air pipe 8 Remove throttle valve actuator (M16/6)
Installation: Ensure correct seating of the

throttle valve actuator (M16/6). 9 Install in the reverse order 10 Connect diagnostic unit, read out fault memory If replacing throttle valve actuator (M16/6). AD00.00-P-2000-06SR

ME-SFI [ME] gasoline injection and ignition system Number Designation ENGINE 281 BA07.61-P-1003-01B Screw/bolt, throttle valve actuator to intake manifold/charge air pipe Nm 10 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar07.61-p-1401sr, Remove/install throttle valve actuator ENGINE 281 in MODEL 453

GF07.61-P-0999KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 890 · Applies to: 453 · AR: GF07.61-P-0999KJ, GF07.61-P-0001KJ, GF07.10-P-1000KJ, GF07.10-P-1001KJ, GF07.10-P-1002KJ (+5 more)

Table of contents for function description of motor electronics (ME-SFI) fuel 17.11.15 injection and ignition system Engine 281.910 in model 453.0/3/4 Motor electronics (ME-SFI) fuel injection and GF07.61-P-0001KJ ignition system, function Ignition ON, function GF07.10-P-1000KJ Starting, function GF07.10-P-1001KJ Ignition OFF, function GF07.10-P-1002KJ Fuel supply, function GF07.10-P-1003KJ Injection regulation, function GF07.10-P-1004KJ Ignition system function GF07.10-P-1005KJ Synchronize fuel injection and firing order GF07.10-P-1006KJ function Start, post-start phase and warm-up GF07.10-P-1007KJ enrichment, function Rpm control, function GF07.10-P-1008KJ Alternator interface function GF07.10-P-1009KJ Lambda control, function GF07.10-P-1010KJ Smooth running control, function GF07.10-P-1011KJ Thermal management, function GF07.10-P-1012KJ Torque coordination, function GF07.10-P-1013KJ Deceleration fuel shutoff, function GF07.10-P-1014KJ Knock control, function GF07.10-P-1015KJ Camshaft adjustment, function GF07.10-P-1016KJ Engine limp-home mode, function GF07.10-P-1019KJ On-board diagnosis, function GF07.10-P-1020KJ Engine timing start-stop function Vehicles with CODE B03 (ECO start/stop GF07.10-P-1041KJ function) Charging, function GF09.00-P-2000KJ Exhaust treatment function GF14.00-P-3000KJ Electronic accelerator function GF30.20-P-3015KJ On-board refueling vapor recovery function Engine 281.910 in model 453.3/4 GF47.10-P-3004KJ with code 494 (US version) Purging function GF47.30-P-3015KJ Purging system with leak test function Engine 281.910 in model 453.3/4 GF47.30-P-3016KJ with code 494 (US version) Overview of system components motor GF07.61-P-9997KJ electronics (ME-SFI) fuel injection and ignition system Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf07.61-p-0999kj, Table of contents for function description of motor electronics (ME-SFI) fuel injection and ignition system Engine 281.910 in model 453.0/3/4

PE07.61-P-2101BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 920 · Applies to: 453 · AR: PE07.61-P-2101BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram for ME-SFI (ME) gasoline injection and ignition system control 09.08.2019 unit Engine 281 in model 453.0/3/4 up to model year 2020 Connector AA Wiring diagram for ME-SFI [ME] gasoline PE07.61-P-2101-97BBA injection and ignition system control unit 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, pe07.61-p-2101bba, Wiring diagram for ME-SFI (ME) gasoline injection and ignition system control unit Engine 281 in model 453.0/3/4 up to model year 2020 Connector AA

PE07.61-P-2101BBB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 921 · Applies to: 453 · AR: PE07.61-P-2101BBB, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram for ME-SFI (ME) gasoline injection and ignition system control 09.08.2019 unit Engine 281 in model 453.0/3/4 up to model year 2020 Connector AC Wiring diagram for ME-SFI [ME] gasoline PE07.61-P-2101-97BBB injection and ignition system control unit 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, pe07.61-p-2101bbb, Wiring diagram for ME-SFI (ME) gasoline injection and ignition system control unit Engine 281 in model 453.0/3/4 up to model year 2020 Connector AC

PE07.61-P-2101BBC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 922 · Applies to: 453 · AR: PE07.61-P-2101BBC, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram for ME-SFI (ME) gasoline injection and ignition system control 09.08.2019 unit Engine 281 in model 453.0/3/4 up to model year 2020 Connector AB Wiring diagram for ME-SFI [ME] gasoline PE07.61-P-2101-97BBC injection and ignition system control unit 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, pe07.61-p-2101bbc, Wiring diagram for ME-SFI (ME) gasoline injection and ignition system control unit Engine 281 in model 453.0/3/4 up to model year 2020 Connector AB

PE07.61-P-2200ZE

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 923 · Applies to: 453 · AR: PE07.61-P-2200ZE, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram for engine electronics - electronic accelerator - transmission (MEG) 8.3.06 with clutch ENGINE 134.910, 135.930 /950 in MODEL 454 as of 3.4.06 sheet 1 PE07.61-P-2200-99ZE Wiring diagram of engine electronics - PE07.61-P-2200-99ZE electronic accelerator - transmission (MEG) with clutch PE07.61-P-2200-60ZE Legend of wiring diagram for engine PE07.61-P-2200-60ZE electronics - electronic accelerator - transmission (MEG) with clutch 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 PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.61-p-2200ze, Wiring diagram for engine electronics - electronic accelerator - transmission (MEG) with clutch ENGINE 134.910, 135.930 /950 in MODEL 454 as of 3.4.06 sheet 1

PE07.61-P-2200ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 924 · Applies to: 453 · AR: PE07.61-P-2200ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram of engine electronics - electronic accelerator - transmission (MEG) 8.3.06 with clutch ENGINE 134.910, 135.930 /950 in MODEL 454 up to 2.4.06 sheet 1 PE07.61-P-2200-99ZA Wiring diagram for engine electronics - PE07.61-P-2200-99ZA electronic accelerator - transmission (MEG) with clutch PE07.61-P-2200-60ZA Legend of wiring diagram for engine PE07.61-P-2200-60ZA electronics - electronic accelerator - transmission (MEG) with clutch 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 PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe07.61-p-2200za, Wiring diagram of engine electronics - electronic accelerator - transmission (MEG) with clutch ENGINE 134.910, 135.930 /950 in MODEL 454 up to 2.4.06 sheet 1

PE07.61-P-2200ZF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 925 · Applies to: 453 · AR: PE07.61-P-2200ZF, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+4 more)

Wiring diagram of engine electronics - electronic accelerator - transmission (MEG) 8.3.06 with clutch ENGINE 134.910, 135.930 /950 in MODEL 454 as of 3.4.06 sheet 2
PE07.61-P-2200-99ZF Wiring diagram for engine electronics - PE07.61-P-2200-99ZF electronic accelerator - transmission (MEG) with clutch PE07.61-P-2200-60ZF Legend of wiring diagram for engine PE07.61-P-2200-60ZF electronics - electronic accelerator - transmission (MEG) with clutch 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 PE07.00-P-1100ZA Further wiring diagrams PE07.00-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, pe07.61-p-2200zf, Wiring diagram of engine electronics - electronic accelerator - transmission (MEG) with clutch ENGINE 134.910, 135.930 /950 in MODEL 454 as of 3.4.06 sheet 2

PE07.61-P-2200ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 926 · Applies to: 453 · AR: PE07.61-P-2200ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+3 more)

Wiring diagram of the engine electronics - electronic accelerator - transmission 16.12.03 (MEG) with clutch ENGINE 134.910, 135.930 /950 in MODEL 454 up to 2.4.06 Blatt 2
PE07.61-P-2200-99ZB Wiring diagram of the engine electronics - PE07.61-P-2200-99ZB electronic accelerator - transmission (MEG) with clutch PE07.61-P-2200-60ZB Legend for the wiring diagram of the engine PE07.61-P-2200-60ZB electronics - electronic accelerator - transmission (MEG) with clutch 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 the cable and GF00.19-P-1000ZA plug 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 (wiring connections in wiring harness) PE00.19-P-1100ZA Further wiring diagrams PE00.19-P-1100ZA PE07.00-P-1100ZA Further wiring diagrams PE07.00-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, pe07.61-p-2200zb, Wiring diagram of the engine electronics - electronic accelerator - transmission (MEG) with clutch ENGINE 134.910, 135.930 /950 in MODEL 454 up to 2.4.06 Blatt 2

PE08.00-P-2000BEA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 940 · Applies to: 453 · AR: PE08.00-P-2000BEA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, GF54.15-P-0800KJ (+1 more)

Wiring diagram of high-voltage lines and interlock circuit 09.08.2019 Engine 780.997 in model 453.091/391/491 up to model year 2020 Wiring diagram of high-voltage lines and PE08.00-P-2000-97BEA interlock circuit 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) Fuse and relay box, as-built configuration GF54.15-P-0800KJ 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-1909BEA Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe08.00-p-2000bea, Wiring diagram of high-voltage lines and interlock circuit Engine 780.997 in model 453.091/391/491 up to model year 2020

PE09.00-P-2050BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 951 · Applies to: 453 · AR: PE09.00-P-2050BBA

Electrical function schematic for charging 11.05.2016 Engine 281.910 in model 453.0/3/4 Electrical function schematic for charging PE09.00-P-2050-97BBA Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe09.00-p-2050bba, Electrical function schematic for charging Engine 281.910 in model 453.0/3/4

AP09.10-P-0980FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 954 · Applies to: 453 · AR: AP09.10-P-0980FG

Install new air filter element 27.5.04 ENGINE 122.950, 639.939 in MODEL 454.0 Shown on engine 639.939 1 Top part of air filter housing 2 Air filter element P09.10-2115-06 Remove/Install

1 Open engine hood 2 Remove top part of air filter housing (1). Remove/install top part of air filter housing Engine 639.939 AR09.10-P-1150-02FG

Engine 122.950 AR09.10-P-1150-02FB 3 Remove air filter element (2). Clean bottom part of air filter housing with rag. 4 Install in the reverse order 5 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 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, ap09.10-p-0980fg, Install new air filter element ENGINE 122.950, 639.939 in MODEL 454.0

AR09.10-P-1150FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 955 · Applies to: 453 · AR: AR09.10-P-1150FF, AP09.10-P-0980FF

Remove/install air filter housing 15.9.03 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on ENGINE 135.950 1 Air intake 2 Engine intake air duct hose 3 Air filter housing 4 Hose M16/6 Throttle valve actuator P09.10-2096-04 Remove/Install

1 Remove air intake (1) 2 Remove hose (4) at engine intake air duct hose (2) 3 Remove engine air intake air duct hose (2) at throttle valve actuator (M16/6) 4 Unscrew screw (arrow) 5 Push air filter housing (3) to the rear out of the bracket 6 Take out air filter housing (3). 7.1 Remove air filter element Only when replacing the air filter housing (3). Replace air filter element AP09.10-P-0980FF

8.1 Remove engine air intake air duct hose (2) at Only when replacing the air filter housing (3). air filter housing (3) 9 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.10-p-1150ff, Remove/install air filter housing ENGINE 134.9, 135.9 in MODEL 454.0

AR09.10-P-1150SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 956 · Applies to: 453 · AR: AR09.10-P-1150SR, AR20.40-P-5614SR

Remove/install air filter housing 02.12.2014 ENGINE 281 in MODEL 453 P09.10-2324-08 Shown on engine 281.910 1 Air filter housing 5 Electrical wiring harness 2 Clamp 6 Screw/bolt 3 Air intake hose 7 Air duct 4 Vacuum line 8 Guide pins Remove/install

1 Remove fan AR20.40-P-5614SR 2 Loosen clamp (2) 3 Detach air intake hose (3) from air filter housing (1) 4 Unclip vacuum line (4) on air filter housing (1) 5 Unclip electrical wiring harness (5) at air filter housing (1) 6 Remove air duct (7) on air filter housing (1) 7 Remove screw/bolt (6) 8 Remove air filter housing (1) upwards Installation: Ensure correct seating of the

guide pins (8). 9 Remove air filter element When replacing air filter housing (1). AP09.10-P-0980S

10 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.10-p-1150sr, Remove/install air filter housing ENGINE 281 in MODEL 453

AR09.10-P-1150FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 957 · Applies to: 453 · AR: AR09.10-P-1150FG, AP09.10-P-0980FG

Removing/installing the air filter housing 27.5.04 ENGINES 122.950, 639.939 in MODEL 454.0 P09.10-2116-08 Shown on engine 639.939 1 Air intake 4 Electrical line (only for engine 5 Air filter housing 639.939) 2 Bolt 3 Rubber bushing Removing/installing

1 Remove air filter element Replace air filter element AP09.10-P-0980FG

2 Remove air intake (1) 3 Unscrew screw (2) Installation: Check rubber mount (3) and replace if necessary. 4.1 Unclip electrical line (4) on air filter housing Only for engine 639.939 (5) 5 Take out air filter housing (5). 6 Install in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.10-p-1150fg, Removing/installing the air filter housing ENGINES 122.950, 639.939 in MODEL 454.0

AP09.10-P-0980FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 958 · Applies to: 453 · AR: AP09.10-P-0980FF

Replace air filter element 6.10.03 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.950 1 Clamps 2 Air filter element 3 Housing cover P09.10-2095-06 Remove/Install

1 Loosen clamps (1) and fold up housing cover (3) 2 Remove air filter element (2) Clean air filter housing with rag. 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/20/18, L/07/20, ap09.10-p-0980ff, Replace air filter element ENGINE 134.9, 135.9 in MODEL 454.0

AR09.20-P-1313FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 960 · Applies to: 453 · AR: AR09.20-P-1313FF, AR09.10-P-1150FG

Remove, install intake port shutoff actuator motor 13.4.06 ENGINE 639.9 in MODEL 454.0 P09.20-2217-09 1 Bolts 5 Charge air pipe 9 Bolts 2 Clip 6 Charge air distribution pipe 3 Venting hose 7 Electrical connector M55 Intake port shutoff motor 4 Charge air hose 8 Cable duct Remove/install

1 Remove air filter housing AR09.10-P-1150FG 2 Loosen the clamp (2) 3 Undo bolts (1) and pull vent hose (3) up and Installation:

Ensure that the vent hose (3) out of the guide at transmission is seated correctly 4 Pull the charge air hose (4) from the charge air pipe (5) 5 Place charge air pipe (5) to one side. 6 Remove bolt at cable duct (8) in the area of the intake port shutoff motor (M55) and push cable duct (8) to the side 7 Remove bolts (9) and Intake port shutoff Installation:

Ensure correct seating of motor (M55) at charge air distribution pipe (6) intake port shutoff motor (M55) at charge air distribution pipe (6). 8 Disconnect electrical connector (7) and remove intake port shutoff motor (M55) 9 Install in the reverse order 10 Read fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.20-p-1313ff, Remove, install intake port shutoff actuator motor ENGINE 639.9 in MODEL 454.0

AR09.20-P-1310FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 961 · Applies to: 453 · AR: AR09.20-P-1310FF, AR07.51-P-1401FF

Remove/install intake manifold 4.6.03 ENGINE 134.9, 135.9 in MODEL 454.0 P09.20-2105-09 Shown on ENGINE 135.950 1 Intake manifold 5 Fuel distributor 10 Sealing rings 2 Vent line 6 Cylinder head cover 11 Bracket 3 Brake booster vacuum line 7 Tubing 4 Connector 8 Wiring harness B28 Pressure sensor 9 Cylinder head M16/6 Throttle valve actuator Remove/Install

1 Remove coolant hoses from throttle valve Do not remove throttle valve actuator actuator (M16/6) and separate electrical (M16/6) from intake manifold (1). connector from throttle valve actuator (M16/6) Refer to: Remove/install throttle valve actuator AR07.51-P-1401FF 2 Detach vent line (2) from intake manifold (1) 3 Remove brake booster vacuum line (3) from intake manifold (1) 4 Detach connector (4) from pressure sensor (B28) 5 Detach crankcase ventilation hose (7) from cylinder head cover (6) 6 Unscrew screws (arrows) at fuel distributor (5) *BA07.52-P-1001-01F

7 Remove electrical wiring harness (8) from intake manifold (1) 8 Remove bracket (11) of intake manifold (1) on transmission 9 Remove clip on bracket (11) 10 Remove intake manifold (1) from cylinder Installation:

Clean sealing surfaces on head (9) and cover intake ports of cylinder intake manifold (1) and cylinder head (9). head (9) using a suitable rag Replace seals (10). Tighten intake manifold bolts (1) from the inside. *BA09.20-P-1001-01M

11.1 Remove hose (7), throttle valve actuator When replacing the intake manifold (1). (M16/6), bracket (11) and pressure sensor (B28) from intake manifold (1) *BA07.04-P-1001-01H

*BA07.61-P-1001-01C

*BA09.20-P-1002-01M

12 Install in the reverse order 13 Read fault memory, erase if necessary 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, ar09.20-p-1310ff, Remove/install intake manifold ENGINE 134.9, 135.9 in MODEL 454.0

AR09.20-P-1330FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 963 · Applies to: 453 · AR: AR09.20-P-1330FG, AR88.40-P-3000FF, AR83.25-P-1402FF

Remove/install mixing chamber with exhaust gas recirculation 16.12.08 ENGINE 639.939 in MODEL 454.0 P09.20-2158-09 1 Connector 5 Intake air restrictor 9 Mixing chamber 2 Connector 6 Vacuum line 10 Bolts 3 Fuse 7 Exhaust gas recirculation valve 11 Air duct housing 4 Charge air hose 8 Connection fitting Remove/install

1 Remove engine hood AR88.40-P-3000FF 2 Remove water collector AR83.25-P-1402FF 3 Unscrew bolts (arrows). 4 Unlock connector (1, 2) and disconnect 5 Unlock retainer (3) by pulling and pull charge air hose (4) out of the intake air throttle (5) 6 Detach vacuum line (6) on exhaust gas recirculation valve (7) 7 Unscrew bolts (10) and pull out connection Installation:

Replace seals. fitting (8) *BA14.20-P-1001-01H

8 Remove and take out mixing chamber (9) on The mixing chamber (9) is attached with air duct housing (11) four bolts on the air duct housing (11). Installation:

Install new gasket *BA09.41-P-1001-01K

9 Remove intake air throttle (5) and exhaust gas Only if installing new mixing chamber (9). recirculation valve (7) from mixing chamber (9) Installation:

Replace seals. *BA09.41-P-1003-01K

*BA14.20-P-1004-01H

10 Install in the reverse order Charge air pipe/charge air cooling

Number Designation Engine 639.939 BA09.41-P-1001-01K Bolt, mixing chamber to air duct housing Nm 12 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.20-p-1330fg, Remove/install mixing chamber with exhaust gas recirculation ENGINE 639.939 in MODEL 454.0

AR09.40-P-0017SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 965 · Applies to: 453 · AR: AR09.40-P-0017SR

Remove/install boost pressure control flap 12.11.2019 Model 453 with engine 281.910 1 Exhaust system 2 Electrical connector 3 Heat shield 4 Link rod 5 Bolts 6 Retaining ring Y120 Boost pressure control flap P09.40-A041-06 Risk of injury. Skin or eye injuries may result Wear protective gloves, protective clothing AS00.00-Z-0002-01A Warning

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

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Remove

1 Switch off ignition and store transmitter key outside of transmitter range (min. 2 m). 2 Raise vehicle. AR00.60-P-1006A 3 Unhook left exhaust system (1), lower, and *453589003700 Pliers support with a suitable tool. 4 Release and disconnect the electrical connector (2). 5 Bend heat shield (3) to one side. 6 Release retaining ring (6) and remove link rod (4). 7 Remove screws (5). 8 Remove boost pressure control flap (Y120). Install

9 Position boost pressure control flap (Y120). 10 Attach link rod (4) and secure with retaining The link rod (4) must not be moved.

ring (6). Install new retaining ring(6).

11 Screw in screws (5). Replace screw/bolts (5).

12 Bend back heat shield (3) into the original position. 13 Connect and lock electrical connector (2). 14 Install exhaust system (1). 15 Lower vehicle. AR00.60-P-1006A Calibrate 16 Calibrate boost pressure control flap (Y120) with diagnostic system. AD00.00-P-2000-06SR

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.40-p-0017sr, Remove/install boost pressure control flap Model 453 with engine 281.910

AR09.40-P-6022SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 967 · Applies to: 453 · AR: AR09.40-P-6022SR, AR49.10-P-6905SR

Remove/install oil feed line for turbocharger 19.08.2014 ENGINE 281.910 in MODEL 453 1 Oil feed line 2 Banjo bolt 3 Screw/bolt P09.40-2497-06 P09.40-2498-08 1 Oil feed line 4 Banjo bolt Risk of death Danger ! caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

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

when handling hot or glowing objects. and safety glasses, if necessary. Remove/install

1 Remove heat shield over the CAT AR49.10-P-6905SR Installation: Only install heat shield after

the leak test. 2 Remove banjo bolt (2) *BA09.40-P-1002-02A Banjo bolt, oil feed line to cylinder head Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.40-p-6022sr, Remove/install oil feed line for turbocharger ENGINE 281.910 in MODEL 453

AR09.40-P-6022FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 969 · Applies to: 453 · AR: AR09.40-P-6022FG, AR01.20-P-5015FF

Remove/install oil feed line of turbocharger 30.4.04 ENGINE 639.939 in MODEL 454.0 P09.40-2170-07 1 Oil feed line 3 Exhaust manifold 5 Banjo bolt 2 Screw 4 Screw Remove/Install

1 Remove trim panel of cylinder head cover AR01.20-P-5015FF 2 Remove screw (2) 3 Unscrew nut (arrow) of oil feed line (1) at Replace self-locking nut (arrow). exhaust manifold (3) *BA14.10-P-1001-01K

4 Unscrew banjo bolt (5) Installation: Replace sealing rings of

banjo bolt (5). *BA09.40-P-1002-01I

5 Unscrew bolt (4) Use new bolt (4) when assembling. *BA09.40-P-1003-01I

6 Remove oil feed line (1) Plug openings with appropriate plugs. Installation:

replace sealing ring of oil feed line (1). 7 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 8 Carry out engine test run and check oil feed line (1) for leaks 9 Check engine oil level by means of oil dipstick Engine oil level must be between "Min" and "Max", otherwise engine damage could occur. Turbocharger

Number Designation Engine 639.939 BA09.40-P-1002-01I Banjo bolt of oil feed line to turbocharger Nm 15 BA09.40-P-1003-01I Torx bolt, oil feed line to crankcase Nm 12 Exhaust manifold

Number Designation Engine 639.939 BA14.10-P-1001-01K Nut of exhaust manifold to cylinder head Nm 30 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.40-p-6022fg, Remove/install oil feed line of turbocharger ENGINE 639.939 in MODEL 454.0

AR09.40-P-6021SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 970 · Applies to: 453 · AR: AR09.40-P-6021SR, AR49.10-P-6905SR

Remove/install oil return flow line of turbocharger 19.08.2014 ENGINE 281.910 in MODEL 453 P09.40-2493-09 1 Oil return line 3 Hose 2 Screw/bolts 4 Crankcase 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. Remove/install

1 Remove heat shield over the CAT AR49.10-P-6905SR Installation: Only install heat shield after

the leak test. 2 Remove screw/bolts (2) *BA09.40-P-1004-02A Screw/bolt, oil return flow line to exhaust gas turbocharger 3 Remove hose (3) for oil return line (1) on Installation: Replace clamp if necessary.

crankcase (4) *003589033700 Hose clamp pliers 4 Remove oil return line (1) 5 Install in the reverse order Check

6 Check engine oil level AP18.00-P-0101S

Risk of accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 7 Carry out engine test run and check engine for leaktightness around the oil return line (1) Exhaust gas turbocharger Number Designation ENGINE 281.910 BA09.40-P-1004-02A Screw/bolt, oil return flow line to exhaust gas turbocharger Nm 12 Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar09.40-p-6021sr, Remove/install oil return flow line of turbocharger ENGINE 281.910 in MODEL 453

AR09.40-P-6020FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 972 · Applies to: 453 · AR: AR09.40-P-6020FF, AR61.20-P-1105FF, AR49.10-P-5500FG, AR49.10-P-5501FF, AR09.10-P-1150FG

Remove/install turbocharger 20.3.06 ENGINE 639.9 in MODEL 454.0 1 Shield 2 Hose 3 Bolt 4 Exhaust manifold 5 Bracket 6 Oil return line 7 Air hose 8 Turbocharger 9 Charge air hose 10 Charge air pipe 11 Charge air hose 12 Vacuum line 13 Vacuum reservoir 14 Nut 15 Banjo bolt P14.10-2063-06 16 Bolt 18 Cylinder head 17 Oil feed line 19 Bolts Remove/install

1 Remove lower engine compartment paneling AR61.20-P-1105FF 2.1 Remove catalytic converter On vehicles without code (K13) Diesel AR49.10-P-5500FG particulate filter 2.2 Remove catalytic converter diesel particulate On vehicles with code (K13) Diesel particulate AR49.10-P-5501FF filter unit filter 3 Unscrew bolt (3). 4 Detach hose (2) at cylinder head (18) 5 Remove shield (1) 6 Remove bolts (19) on bracket (5) and bracket (5) 7 Detach oil return line (6) at AR09.40-P-6020-06FG turbocharger (8) *BA09.40-P-1001-01I

8 Detach air hose (7) at turbocharger (8) 9 Remove air filter housing AR09.10-P-1150FG 10 Detach charge air hose (11) at turbocharger (8) 11 Detach charge air hose (9) at charge air pipe (10) 12 Detach vacuum line (12) at vacuum unit (13) 13 Remove nut (14) for exhaust manifold (4) with Installation:

Replace self-locking which oil return line (6) is fixed in place nut (14). *BA14.10-P-1001-01K

14 Unscrew banjo bolt (15) Installation: Replace sealing rings of

banjo bolt (15). *BA09.40-P-1002-01I

15 Unscrew bolt (16) on oil feed line (17) from Installation:

Install new self-locking bolt cylinder head (18) (16) *BA09.40-P-1003-01I

16 Pull oil feed line (17) out of cylinder Installation:

Replace sealing ring of oil head (18) feed line (17). 17 Unscrew nuts of exhaust manifold (4) The exhaust manifold (4) is secured with a further seven nuts. Installation: Install new self-locking nuts. *BA14.10-P-1001-01K

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.40-p-6020ff, Remove/install turbocharger ENGINE 639.9 in MODEL 454.0

AR09.40-P-6020SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 974 · Applies to: 453 · AR: AR09.40-P-6020SR

Remove/install turbocharger 15.07.2016 Engine 281.910 in model 453 (except 453.062/362/462) P09.40-2494-08 1 ATL 8 Coolant hose 2 Air intake hose 9 Coolant hose 3 Securing clamp 10 Screw/bolts 4 Control rod 11 Oil return line 5 Exhaust manifold 1 ATL 6 Electrical connection 7 Electrical connection P09.40-2495-05 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.40-p-6020sr, Remove/install turbocharger Engine 281.910 in model 453 (except 453.062/362/462)

Remove bracket (13)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 976 · Applies to: 453 · AR: AR20.00-P-1142SR

16 Remove bracket (13) 17 Unfasten clamp (14) and take off 18 Remove banjo bolt (15) BA09.40-P-1003-02A Banjo bolt, oil feed line to exhaust gas turbocharger 19 Detach oil feed line (16) at ATL (1) 20 Remove screws/bolts (17) BA09.40-P-1001-02A Screw/bolt, charge air hose to exhaust gas turbocharger 21 Detach charge air hose (18) from ATL (1) Installation: Replace seal.

22 Raise vehicle with vehicle lift 23 Unfasten ATL (1) from exhaust manifold (5) Installation: Ensure that ATL (1) is

and remove downwards correctly seated. 24 Install in the reverse order 25 Pour in coolant and bleed cooling system AR20.00-P-1142SR Check

26 Check engine oil level AP18.00-P-0101S

Risk of accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 27 Perform an engine test run and check engine for leaktightness around ATL (1) Exhaust gas turbocharger Number Designation Engine 281.910 BA09.40-P-1001-02A Screw/bolt, charge air hose to exhaust gas turbocharger Nm 8 Exhaust gas turbocharger Number Designation Engine 281.910 BA09.40-P-1003-02A Banjo bolt, oil feed line to exhaust gas turbocharger Nm 12 Exhaust gas turbocharger Number Designation Engine 281.910 BA09.40-P-1004-02A Screw/bolt, oil return flow line to exhaust gas turbocharger Nm 12 003 589 03 37 00 Hose clamp pliers Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.40-p-6020sr, Remove/install turbocharger Engine 281.910 in model 453 (except 453.062/362/462)

AR09.40-P-6025SB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 977 · Applies to: 453 · AR: AR09.40-P-6025SB

Remove/install turbocharger with exhaust manifold 15.07.2016 Engine 281.910 in model 453.062/362/462 P09.40-2494-08 1 ATL 8 Coolant hose 2 Air intake hose 9 Coolant hose 3 Securing clamp 10 Screw/bolts 4 Control rod 11 Oil return line 5 Exhaust manifold 1 ATL 6 Electrical connection 7 Electrical connection P09.40-2495-05 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.40-p-6025sb, Remove/install turbocharger with exhaust manifold Engine 281.910 in model 453.062/362/462

Remove screw/bolts (17)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 979 · Applies to: 453 · AR: AR20.00-P-1142SR

16 Remove screw/bolts (17) *BA09.40-P-1001-02A Screw/bolt, charge air hose to exhaust gas turbocharger 17 Unfasten charge air hose (18) from ATL (1) Installation: Replace seal.

18 Raise vehicle with vehicle lift 19 Unscrew nuts for exhaust manifold (5) on Installation: Screw on nuts evenly up to

cylinder head stop. *BA49.10-P-1002-02C Nut, exhaust manifold to cylinder head 20 Unfasten ATL (1) together with exhaust Installation: Ensure correct seating of the

manifold (5) and remove downwards ATL (1) and the exhaust manifold (5). 21 Remove seal and clean sealing surface on Installation: Replace seal.

cylinder head and on exhaust manifold (5) 22 Install in the reverse order 23 Pour in coolant and bleed cooling system AR20.00-P-1142SR Check

24 Check engine oil level AP18.00-P-0101S

Risk of accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 25 Perform an engine test run and check engine for leaktightness around ATL (1) and check the exhaust manifold (5) for leaktightness Exhaust gas turbocharger Number Designation Engine 281.910 BA09.40-P-1001-02A Screw/bolt, charge air hose to exhaust gas turbocharger Nm 8 Exhaust gas turbocharger Number Designation Engine 281.910 BA09.40-P-1003-02A Banjo bolt, oil feed line to exhaust gas turbocharger Nm 12 Exhaust gas turbocharger Number Designation Engine 281.910 BA09.40-P-1004-02A Screw/bolt, oil return flow line to exhaust gas turbocharger Nm 12 Exhaust system Number Designation Engine 281.910 BA49.10-P-1002-02C Nut, exhaust manifold to cylinder head Nm 35 003 589 03 37 00 Hose clamp pliers Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.40-p-6025sb, Remove/install turbocharger with exhaust manifold Engine 281.910 in model 453.062/362/462

AR09.40-P-6021FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 980 · Applies to: 453 · AR: AR09.40-P-6021FG, AR09.10-P-1150FG, AR61.20-P-1105FF

Removing/installing oil return flow line for turbocharger 12.7.05 ENGINE 639.9 in MODEL 454.0 Shown with TWC removed 1 Bolts 2 Oil return line 3 Turbocharger 4 Crankcase 5 Coolant pipe P09.40-2275-05 Removing/installing

1 Remove air intake See: Removing/installing air filter housing AR09.10-P-1150FG 2 Detach coolant pipe (5) bracket on The coolant pipe (5) it attached by two transmission brackets on the transmission. 3 Remove lower engine compartment paneling AR61.20-P-1105FF 4 Remove bolts (1) on oil return line (2) Installation: Install new bolts (1).

*BA09.40-P-1001-01I

5 Swivel oil return line (2) forwards and remove Installation: Replace gasket between seal between turbocharger (3) and oil return turbocharger (3) and oil return line (2). line (2) 6 Detach oil return line (2) from crankcase (4) Installation:

Check rubber grommet on oil return line (2); replace if necessary. 7 Install in reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns during Do not grasp hot or rotating parts. starting procedure or when working near engine 8 Carry out an engine test run and check the oil return line (2) for leaks 9 Check engine oil level by means of oil dipstick Engine oil level must be between "Min" and "Max", otherwise engine damage could occur. Turbocharger

Number Designation Engine 639.939 BA09.40-P-1001-01I Torx bolt for oil return line on turbocharger Nm 7.6 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.40-p-6021fg, Removing/installing oil return flow line for turbocharger ENGINE 639.9 in MODEL 454.0

AR09.41-P-2004FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 982 · Applies to: 453 · AR: AR09.41-P-2004FF, AR09.10-P-1150FG

Boost pressure control pressure transducer 19.6.04 ENGINE 639.939 in MODEL 454.0 P14.20-2168-07 1 Clip 5 Charge air pipe 9 Bracket 2 Clip 6 Vacuum hose 3 Bolts 7 Vacuum hose Y31/5 Boost pressure control pressure transducer 4 Bleed hose 8 Connector Remove/Install

1 Remove air cleaner housing AR09.10-P-1150FG 2 Slacken clamps (1, 2) 3 Remove screws (3) Replace bolts (3). 4 Pull vent hose (4) upward out of guide at Installation:

Ensure that the vent hose (4) transmission and remove is seated correctly 5 Pull charge air hoses out at charge air pipe (5) and remove charge air pipe (5) 6 Detach vacuum hoses (6, 7) at boost pressure control pressure transducer (Y31/5) 7 Unplug connector (8) from boost pressure control vacuum transducer (Y31/5). 8 Dismantle boost pressure control pressure transducer (Y31/5) at bracket (9) 9 Install in the reverse order 10 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 Commercially available tools Number Designation STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 WH58.30-Z-1048-13A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.41-p-2004ff, Boost pressure control pressure transducer ENGINE 639.939 in MODEL 454.0

AR09.41-P-0004SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 983 · Applies to: 453 · AR: AR09.41-P-0004SR

Remove/install boost pressure sensor downstream of throttle valve 19.08.2014 ENGINE 281.910 in MODEL 453 1 Electrical connection 2 Screw/bolt 3 Charge air distributor 4 Sealing ring B28/7 Pressure sensor downstream of throttle valve P09.41-2787-06 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Remove covering over engine 2 Disconnect electrical connection (1) 3 Remove screw/bolt (2) 4 Pull pressure sensor downstream of throttle Installation: Replace sealing ring (4).

valve (B28/7) out of charge air distributor (3) 5 Install in the reverse order 6 Connect diagnostic unit, read out fault memory When replacing the pressure sensor downstream of throttle valve (B28/7). AD00.00-P-2000-06SR

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.41-p-0004sr, Remove/install boost pressure sensor downstream of throttle valve ENGINE 281.910 in MODEL 453

AR09.41-P-0003SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 984 · Applies to: 453 · AR: AR09.41-P-0003SR

Remove/install boost pressure sensor upstream of throttle valve 21.11.2014 ENGINE 281.910 in MODEL 453 1 Electrical connection 2 Screw/bolt 3 Charge air hose 4 Seal B28/6 Pressure sensor upstream of throttle valve P09.41-2797-06 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Remove covering over engine 2 Disconnect electrical connection (1) 3 Remove screw/bolt (2) 4 Pull pressure sensor upstream of throttle Installation: Replace sealing ring (4).

valve (B28/6) out of charge air hose (3) 5 Install in the reverse order 6 Connect diagnostic unit, read out fault memory When replacing the pressure sensor upstream of throttle valve (B28/6). AD00.00-P-2000-06SR

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.41-p-0003sr, Remove/install boost pressure sensor upstream of throttle valve ENGINE 281.910 in MODEL 453

AR09.41-P-6817SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 985 · Applies to: 453 · AR: AR09.41-P-6817SR, AR09.41-P-1311SR

Remove/install charge air cooler 19.08.2014 ENGINE 281.910 in MODEL 453 P09.41-2781-08 1 Charge air cooler 3 Screw/bolts 2 Charge air pipe 4 Charge air distributor Risk of injury Do not open cooling system unless coolant Danger ! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

Remove/install

1 Remove charge air pipe (2) AR09.41-P-1311SR 2 Remove screws/bolts (3) 3 Take charge air cooler (1) out of charge air Collect escaping coolant in a suitable

distributor (4) container. Installation: Ensure correct seating of

guide rails for charge air cooler (1) in the charge air distributor (4). 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.41-p-6817sr, Remove/install charge air cooler ENGINE 281.910 in MODEL 453

AR09.41-P-8621SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 986 · Applies to: 453 · AR: AR09.41-P-8621SR

Remove/install charge air hose upstream of charge air cooler 25.09.2014 ENGINE 281.910 in MODEL 453 1 Charge air hose 2 Vent line 3 Oil separator 4 Electrical connection 5 Electrical connection 6 Screw/bolts 7 Screw/bolts P09.41-2767-06 Remove/install

1 Remove covering over engine 2 Unlock vent line (2) on oil separator (3), detach and remove from the working area 3 Disconnect electrical connection (4) 4 Disconnect electrical connection (5) 5 Remove screw/bolts (6) BA09.41-P-1004-01W Screw/bolt, charge air hose to throttle valve actuator 6 Remove screw/bolts (7) BA09.40-P-1001-02A Screw/bolt, charge air hose to exhaust gas turbocharger 7 Remove charge air hose (1) Installation: Replace seals on charge air

hose (1). 8 Install in the reverse order Exhaust gas turbocharger Number Designation ENGINE 281.910 BA09.40-P-1001-02A Screw/bolt, charge air hose to exhaust gas turbocharger Nm 8 Charge air pipe/charge air cooling Number Designation ENGINE 281.910 BA09.41-P-1004-01W Screw/bolt, charge air hose to throttle valve actuator Nm 8 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.41-p-8621sr, Remove/install charge air hose upstream of charge air cooler ENGINE 281.910 in MODEL 453

AR09.41-P-1310SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 987 · Applies to: 453 · AR: AR09.41-P-1310SR

Remove/install charge air manifold 19.08.2014 ENGINE 281.910 in MODEL 453 P09.41-2769-09 1 Charge air distributor 6 Screw/bolts 2 Fuel distributor 7 Screw/bolt 3 Electrical connection 9 Screw/bolts 4 Guide tube 10 Charge air cooler 5 Electrical connection 1 Charge air distributor 4 Guide tube 8 Nuts P09.41-2739-06 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.41-p-1310sr, Remove/install charge air manifold ENGINE 281.910 in MODEL 453

Charge air distributor

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 988 · Applies to: 453 · AR: AR01.00-P-3050SR, AR54.10-P-0003SR, AR07.03-P-1450SR, AR18.40-P-3510SR

1 Charge air distributor 11 Sealing rings 12 Seal P09.41-2770-11 Notes on avoiding damage through AH00.00-P-5000-01A

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

Remove/install

1 Lower rear wheel drive module AR01.00-P-3050SR 2 Disconnect ground line of battery AR54.10-P-0003SR 3 Remove fuel distributor (2) AR07.03-P-1450SR 4 Remove guide tube (4) AR18.40-P-3510SR 5 Disconnect electrical connection (3) 6 Disconnect electrical connection (5) 7 Remove screw/bolts (6) BA09.41-P-1001-01W Bolt, charge air pipe to charge air distributor 8 Remove screw/bolt (7) BA09.41-P-1002-01W Screw/bolt, charge air distributor to bracket 9 Remove nuts (8) *BA09.41-P-1003-01W Nut, charge air distributor to cylinder head 10 Unfasten charge air distributor (1) from cylinder head 11 Remove screws/bolts (9) at charge air cooler (10) 12 Pull charge air cooler (10) out of charge air distributor (1) and place to one side 13 Installation: Replace seals (11, 12). Remove charge air distributor (1)

Ensure correct seating of the seals (11, 12). 14 Install in the reverse order Charge air pipe/charge air cooling Number Designation ENGINE 281.910 BA09.41-P-1001-01W Bolt, charge air pipe to charge air distributor Nm 8 Charge air pipe/charge air cooling Number Designation ENGINE 281.910 BA09.41-P-1002-01W Screw/bolt, charge air distributor to bracket Nm 10 Charge air pipe/charge air cooling Number Designation ENGINE 281.910 BA09.41-P-1003-01W Nut, charge air distributor to cylinder head Nm 10 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.41-p-1310sr, Remove/install charge air manifold ENGINE 281.910 in MODEL 453

AR09.41-P-1311SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 989 · Applies to: 453 · AR: AR09.41-P-1311SR, AR07.61-P-1401SR

Remove/install charge air pipe 25.09.2014 ENGINE 281.910 in MODEL 453 P09.41-2768-09 1 Charge air pipe 6 Screw/bolts 2 Coolant hoses 7 Vent line 3 Vacuum line 8 Charge air distributor 4 Vent line M16/6 Throttle valve actuator 5 Electrical wiring harness Risk of injury Do not open cooling system unless coolant Danger ! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

Remove/install

1 Remove maintenance flap 2 Turn cap on engine coolant expansion reservoir a half turn counterclockwise, relieve overpressure and then unscrew the cap 3 Remove throttle valve actuator (M16/6) AR07.61-P-1401SR 4 Remove coolant hoses (2) Collect escaping coolant in a suitable

container. Installation: Replace clamps.

003589033700 Hose clamp pliers 5 Unlock and detach vacuum line (3) on charge air pipe (1) 6 Unlock and detach bleed line (4) on charge air pipe (1) 7 Unclip electrical wiring harness (5) at charge air pipe (1) 8 Remove screw/bolts (6) BA09.41-P-1001-01W Bolt, charge air pipe to charge air distributor 9 Detach charge air pipe (1) from charge air distributor (8) Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar09.41-p-1311sr, Remove/install charge air pipe ENGINE 281.910 in MODEL 453

Unlock and detach bleed line (7) on charge air

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 990 · Applies to: 453 · AR: AR20.00-P-1142SR

10 Unlock and detach bleed line (7) on charge air pipe (1) 11 Remove charge air pipe (1) Installation: Replace seal on charge air

pipe (1). 12 Install in the reverse order 13 Pour in coolant and bleed cooling system AR20.00-P-1142SR Charge air pipe/charge air cooling Number Designation ENGINE 281.910 BA09.41-P-1001-01W Bolt, charge air pipe to charge air distributor Nm 8 003 589 03 37 00 Hose clamp pliers Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar09.41-p-1311sr, Remove/install charge air pipe ENGINE 281.910 in MODEL 453

AR09.41-P-0005SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 991 · Applies to: 453 · AR: AR09.41-P-0005SR, AR09.41-P-1310SR

Remove/install charge air temperature sensor downstream of throttle valve 09.01.2015 ENGINE 281.910 in MODEL 453 1 Charge air distributor 2 Catch hook 3 Sealing ring B17/8 Charge air temperature sensor P09.41-2814-04 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove

1 Remove charge air distributor (1) AR09.41-P-1310SR 2 Unlock catch hook (2) using a suitable tool in charge air distributor (1) and remove charge air temperature sensor (B17/8) at the same time Check

3 Check catch hook (2) for damage If there are problems: Replace charge air temperature sensor (B17/8) Install

4 Install new sealing ring (3) 5 Install charge air temperature sensor (B17/8) Ensure correct seating of the charge air

in charge air distributor (1) temperature sensor (B17/8) in charge air distributor (1). 6 Install charge air distributor (1) AR09.41-P-1310SR 7 Connect diagnostic unit, read out fault memory When replacing the charge air temperature sensor (B17/8). AD00.00-P-2000-06SR

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.41-p-0005sr, Remove/install charge air temperature sensor downstream of throttle valve ENGINE 281.910 in MODEL 453

AR09.41-P-0006SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 992 · Applies to: 453 · AR: AR09.41-P-0006SR

Remove/install charge air temperature sensor upstream of throttle valve 09.01.2015 ENGINE 281.910 in MODEL 453 P09.41-2815-07 1 Charge air temperature sensor upstream of throttle valve 3 Securing clamp 2 Electrical connection 4 Charge air hose Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Remove covering over engine 2 Release and disconnect electrical connection (2) 3 Remove safety clamp (3) 4 Pull charge air temperature sensor upstream Installation: Replace sealing ring on

of throttle valve (1) out of charge air hose (4) charge air temperature sensor upstream of throttle valve (1). 5 Install in the reverse order 6 Connect diagnostic unit, read out fault memory When replacing the charge air temperature sensor upstream of throttle valve (1). AD00.00-P-2000-06SR

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.41-p-0006sr, Remove/install charge air temperature sensor upstream of throttle valve ENGINE 281.910 in MODEL 453

AR09.41-P-1325FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 993 · Applies to: 453 · AR: AR09.41-P-1325FG, AR88.40-P-3000FF, AR88.00-P-2792FF

Remove/install the intake air throttle 29.9.04 ENGINE 639.939 in MODEL 454.0 P09.41-2339-07 1 Intake air throttle 4 Connector B5/1 Charge pressure sensor 2 Fuse 5 Mixing chamber B17/8 Charge air temperature sensor 3 Charge air hose Remove/Install

1 Remove engine hood AR88.40-P-3000FF 2 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 3 Lift fuse (2) and pull charge air hose (3) out of the intake air throttle (1) 4 Unscrew screws (arrows). 5 Pull out connector (4) and remove charge air temperature sensor (B17/8) 6 Remove intake air throttle (1) at mixing The intake air throttle (1) is secured to the chamber (5) mixing chamber (5) using three bolts. Installation:

Install new sealing ring. When replacing the intake air throttle (1), modify the boost pressure sensor (B5/1) . *BA09.41-P-1003-01K

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 Charge air pipe/charge air cooling Number Designation Engine 639.939 BA09.41-P-1003-01K Bolt, intake air throttle to mixing chamber Nm 12 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, ar09.41-p-1325fg, Remove/install the intake air throttle ENGINE 639.939 in MODEL 454.0

AR09.41-P-1321FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 994 · Applies to: 453 · AR: AR09.41-P-1321FG, AR09.10-P-1150FG

Removing and installing the throttle valve actuator 29.9.04 ENGINE 639.939 in MODEL 454.0 P09.41-2340-09 1 Bolts 5 Charge air pipe 8 Cable duct 2 Clip 6 Charge air distribution pipe 3 Bleed hose 7 Connector M16/6 Throttle valve actuator 4 Charge air hose Remove/Install

1 Remove air cleaner housing AR09.10-P-1150FG 2 Slacken clamp (2) 3 Undo bolts (1) and pull vent hose (3) up and Installation:

Ensure that the vent hose (3) out of the guide at the transmission is seated correctly 4 Pull the charge air hose (4) from the charge air pipe (5) 5 Place charge air pipe (5) to one side. 6 Undo bolts at cable duct (8) around throttle valve actuator (M16/6) and press cable duct (8) to the side 7 Remove throttle valve actuator (M16/6) at The throttle valve actuator (M16/6) is charge air distribution pipe (6) secured to the charge air distribution pipe (6) with three bolts. Installation:

ensure the throttle valve actuator (M16/6) is seated correctly at the charge air distribution pipe (6). 8 Remove connector (7) and take out throttle valve actuator (M16/6) 9 Install in the reverse order 10 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 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, ar09.41-p-1321fg, Removing and installing the throttle valve actuator ENGINE 639.939 in MODEL 454.0

AR09.41-P-6817FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 995 · Applies to: 453 · AR: AR09.41-P-6817FF, AR82.10-P-4725FF, AR61.20-P-1105FF

Removing/installing the charge air cooler 30.4.04 ENGINES 122.950, 639.939 in MODEL 454.0 Shown on engine 639.939 and a removed CBS front 1 Charge air hose 2 Charge air hose 3 Charge air cooler 4 Bolt 5 Bolt 6 Bolt 7 Rubber bushing 8 Air duct P09.41-2310-06 Removing/installing

1 Remove left turn signal lamp AR82.10-P-4725FF Do not separate electrical connection at left turn signal lamp. 2 Remove lower engine compartment paneling AR61.20-P-1105FF 3 Detach charge air hoses (1, 2) at the charge Installation:

Ensure that the charge air air cooler (3) hoses (1,2) are seated properly. 4 Unscrew bolts (4, 5, 6) Replace screws (4, 5, 6). Screws (4, 5, 6) vary in length. 5 Remove charge air cooler (3) Installation:

When replacing the charge air cooler (3) the rubber mount (7) and the air and air ducting (8) must be modified. 6 Install in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.41-p-6817ff, Removing/installing the charge air cooler ENGINES 122.950, 639.939 in MODEL 454.0

AR09.41-P-1310FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 996 · Applies to: 453 · AR: AR09.41-P-1310FG, AR09.20-P-1330FG, AR20.00-P-1142FG

Removing/installing the charge air distribution pipe 29.9.04 ENGINE 639.939 in MODEL 454.0 P09.41-2356-09 1 Vacuum line 4 Charge air distribution pipe B11/4 Coolant temperature sensor 2 Bolts 5 Coolant hose M16/6 Throttle valve actuator 3 Bolts Y27 EGR [ARF] switchover valve Removing/installing

1 Remove mixing housing with exhaust gas AR09.20-P-1330FG recirculation 2 Detach vacuum line (1) 3 Detach connector (arrows) 4 Drain coolant AR20.00-P-1142FG 5 Unscrew bolts (2) *BA20.10-P-1003-01R

6 Remove screws (3) *BA14.20-P-1002-01H

*BA14.20-P-1003-01H

7 Unscrew lower bolts on charge air manifold Installation:

Screw on lower bolts for (4) charge air manifold (4) from below and tighten from above. *BA09.41-P-1004-01K

8 Lower vehicle 9 Detach coolant hose (5) on charge air distribution pipe (4) 10 Unscrew upper bolts on charge air manifold *BA09.41-P-1004-01K

(4) 11 Take out charge air distribution pipe (4) Installation:

When replacing the charge air manifold (4) the coolant temperature sensor (B11/4), the EGR [ARF] switchover valve (Y27) and the throttle valve actuator (M16/6) must be modified. 12 Install in reverse order 13 Read out fault memory If necessary, correct faults in control units. Connect up STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Charge air pipe/charge air cooling Number Designation Engine 639.939 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.41-p-1310fg, Removing/installing the charge air distribution pipe ENGINE 639.939 in MODEL 454.0

AR09.50-P-8680FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 998 · Applies to: 453 · AR: AR09.50-P-8680FG, AR82.10-P-4725FF

Removing/installing charge air duct downstream of charge air cooler 3.11.04 ENGINE 639.939 in MODEL 454.0 P09.50-2095-09 1 Clip 4 Bolt 7 Charge air duct 2 Charge air hose 5 Bolt 8 Charge air hose 3 Intake-air duct 6 Clip Removing/installing

1 Remove left turn signal lamp AR82.10-P-4725FF 2 Loosen clamp (1) and detach charge air hose (2) 3 Remove intake air guide (3) The intake air guide (3) is fixed in place with two clips. 4 Unscrew bolts (4, 5) 5 Loosen clip (arrow) 6 Loosen clamp (6) and detach charge air duct (7) on charge air hose (8) 7 Remove charge air hose (2) with charge air duct (7) 8.1 Remove charge air duct (7) on charge air Only if the charge air duct (7) has been hose (2) replaced. 9 Install in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar09.50-p-8680fg, Removing/installing charge air duct downstream of charge air cooler ENGINE 639.939 in MODEL 454.0

BE13.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1001 · Applies to: 453 · AR: BE13.00-Z-9999CZ

Test and adjustment values: Smart: Air compressor, belt drives 18.09.2019 MODEL all Single-belt drive ENGINE 160 ... BE13.22-P-1000-01I Single-belt drive ENGINE 660.940 BE13.22-P-1000-01J Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be13.00-z-9999cz, Test and adjustment values: Smart: Air compressor, belt drives MODEL all

AR13.21-P-3350SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1003 · Applies to: 453 · AR: AR13.21-P-3350SR, AR13.22-P-1202SR

Remove/install poly-V belt guide pulley 21.10.2014 ENGINE 281 in MODEL 453 P13.21-2161-09 1 Guide pulley 3 Cover 2 Poly-V belt 4 Screw/bolt Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Remove

1 Remove poly-V belt (2)
AR13.22-P-1202SR 2 Remove cover (3)
3 Remove screw/bolt (4) and guide pulley (1) from alternator carrier Check

4 Check guide pulley (1) for wear and damage If there are problems: Replace guide pulley (1). Install

5 Attach guide pulley (1) with screw/bolt (4) at *BA13.25-P-1006-01K Bolt, guide pulley to alternator carrier alternator carrier 6 Fit on cover (3) 7 Install poly-V belt (2) AR13.22-P-1202SR Belt tensioning device Number Designation ENGINE 281 BA13.25-P-1006-01K Bolt, guide pulley to alternator carrier Nm 50 Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar13.21-p-3350sr, Remove/install poly-V belt guide pulley ENGINE 281 in MODEL 453

AR13.21-P-3350FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1004 · Applies to: 453 · AR: AR13.21-P-3350FF, AR13.22-P-1202FG

Remove/install the poly V-belt guide pulley 21.6.04 ENGINE 639.939 in MODEL 454.0 1 Poly-V-belt 2 Guide pulley for poly V-belt 3 Screw 4 Washer P13.21-2038-05 Remove/Install

1 Remove poly V-belt (1) AR13.22-P-1202FG 2 Unscrew bolt (3). *BA13.22-P-1001-01B

3 Remove guide pulley of poly V-belt (2) with washer (4) 4 Install in the reverse order Single-belt drive

Number Designation Engine 639.939 BA13.22-P-1001-01B Screw for guide pulley on crankcase Nm 55 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar13.21-p-3350ff, Remove/install the poly V-belt guide pulley ENGINE 639.939 in MODEL 454.0

AP13.22-P-1351FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1006 · Applies to: 453 · AR: AP13.22-P-1351FF, AR13.22-P-1202FC, AR13.22-P-1202FF, AR13.22-P-1202FG

Inspect poly V-belt for wear and damage 1.10.03 ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0 Damage patterns A New poly-V B Wear to flanks: Poly-V are pointed (new: trapezoidal) C Cords are visible at the base of the poly-V-belts (lighter points) D Transverse cracks across the back E Poly-V released from base of the poly-V-belt (arrow) F Fraying of outer cords G Cord torn out at the side P13.22-0004-06 H Transverse cracks in several poly-V L Dirt or stones embedded in ribs J Poly-V-belt chippings M Rubber lumps in base of poly-V K Single poly-V transverse cracks. Check

Risk of injury caused by moving parts that Keep all body parts and limbs away from AS00.00-Z-0009-01A Danger!

can pinch, crush or, in extreme cases even moving mechanical components. sever extremities. 1 Withdraw ignition key 2 Open engine hood 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 Check the splines for wear and damage by Make a chalk mark as a reference point at rotating the engine at the center bolt of the poly-V-belt. crankshaft in the engine's direction of rotation. If necessary: Replace poly V-belt - subject to separate repair order. Remove/install poly V-belt

Engine 122.9 AR13.22-P-1202FC Engine 134.9, 135.9 AR13.22-P-1202FF Engine 639.9 AR13.22-P-1202FG Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap13.22-p-1351ff, Inspect poly V-belt for wear and damage ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0

AR13.22-P-1202FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1007 · Applies to: 453 · AR: AR13.22-P-1202FF, AR61.20-P-1105FF, AP13.22-P-1351FF

Remove/install poly-V belt 15.1.10 ENGINES 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 and code (I01) Air conditioning Plus (with outside temperature indicator) (FFO) 1 Nut 2 Screw 3 Nut 4 Poly-V-belt 5 Gauge (V-belt tension)

P15.40-2257-06 Removing

1 Open engine hood 2 Loosen nut (1) on alternator Do not remove poly-V belt (4) when engine is hot 3 Loosen bolt (2) on alternator 4 Detach lower engine compartment paneling AR61.20-P-1105FF 5 Loosen nut (3) on alternator 6 Remove poly-V belt (4) Install

7 Check poly-V belt (4) for damage and wear; replace if necessary Check poly-V belt for wear and damage AP13.22-P-1351FF

8 Fit on poly-V belt (4) 9 Lower vehicle 10 Tighten poly-V belt (4) by twisting the bolt (2) Only use gauge (V-belt tension) (5) on and check tension using gauge (V-belt area shown. tension) (5) Reference value for first assembly of poly-V belt (4): approx. 784 N to 980 N. Reference value for reassembly of poly-V belt (4): approx. 441 N to 539 N. *450589002100

11 Tighten nut (3) on alternator *BA15.40-P-1002-01J

12 Tighten nut (1) on alternator *BA13.25-P-1001-01O

13 Tighten bolt (2) on alternator *BA13.25-P-1003-01O

Checking

Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not touch hot or rotating parts. engine as it is running 14 Carry out engine test run 15 Raise vehicle 16 Check tension of poly-V belt (4) Only use gauge (V-belt tension) (5) on area shown. Reference value for first assembly of poly-V belt (4): approx. 784 N to 980 N. Reference value for reassembly of poly-V belt (4): approx. 441 N to 539 N. Retension limit: 392 N to 588 N. *450589002100

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar13.22-p-1202ff, Remove/install poly-V belt ENGINES 134.9, 135.9 in MODEL 454.0

AR13.22-P-1202SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1009 · Applies to: 453 · AR: AR13.22-P-1202SR

Remove/install poly-V belt 02.05.2019 Engine 281 in model 453 Modification notes 25.04.2019 Remove/install cover over the poly-V-belt, added. Operation steps 2 and 7 Shown with CODE I01 (AAC) 7 Cover 8 Bolts P13.22-A005-06 P13.22-2196-09 Shown with CODE I01 (AAC) 1 Poly-V-belt 2 Tensioning device 3 Support Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar13.22-p-1202sr, Remove/install poly-V belt Engine 281 in model 453

AR13.22-P-1202FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1011 · Applies to: 453 · AR: AR13.22-P-1202FG, AR61.20-P-1105FF, AP13.22-P-1351FF

Remove/install poly-V-belt 24.5.04 ENGINE 639.939 in MODEL 454.0 P13.22-2097-07 Shown on vehicles with CODE (I01) air 1 Tensioning device 2 Poly-V-belt conditioning system Plus (with outside temperature indicator) (FFO) Remove/Install

1 Remove lower engine compartment paneling AR61.20-P-1105FF 2 Tension the tensioning device (1) against the spring force and block with a suitable Allen wrench (arrowed) 3 Remove poly-V-belt (2) Installation:

Check the poly-V-belt (2) for wear and damage, and replace if necessary. Refer to: Inspect poly-V-belt for wear and damage AP13.22-P-1351FF

4 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off when engine is running. Risk of injury Wear closed and snug-fitting work clothes.

caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 5 Carry out an engine test run and check that poly-V-belt (2) runs correctly Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar13.22-p-1202fg, Remove/install poly-V-belt ENGINE 639.939 in MODEL 454.0

AR13.25-P-3216FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1012 · Applies to: 453 · AR: AR13.25-P-3216FF, AR15.40-P-5032FG

Remove/install V-belt tensioning device 10.5.04 ENGINE 639.939 in MODEL 454.0 1 Tensioning device 2 Spring 3 Allen wrench 4 Bolts P13.25-2030-04 Remove/Install

1 Remove alternator AR15.40-P-5032FG 2.1 Twist the tensioning device (1) against the Only if replacing tensioning device (1). spring force (2) and remove Allen wrench (3) 3 Remove bolts (4) Installation: Replace bolts (4). *BA13.25-P-1001-01S

4 Remove tensioning device (1) 5 Install in the reverse order Belt tensioning device

Number Designation Engine 639.939 BA13.25-P-1001-01S Torx bolt of belt tensioning device to timing case Nm 30 cover Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar13.25-p-3216ff, Remove/install V-belt tensioning device ENGINE 639.939 in MODEL 454.0

AR13.25-P-3200SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1013 · Applies to: 453 · AR: AR13.25-P-3200SR, AR13.22-P-1202SR, AR13.25-P-3250SR

Remove/install poly-V belt tensioning device 05.08.2014 ENGINE 281 in MODEL 453 P13.25-2077-09 1 Tensioning device 3 Tensioner pulley 2 Screw/bolt 4 Poly-V belt Risk of injury. Moving parts can pinch, crush No parts of the body or limbs should be within AS00.00-Z-0009-01A Danger !

or, in extreme cases even sever extremities. the operating range of the mechanism when moving components. Remove/install

1 Remove poly-V belt (4), release and relieve AR13.22-P-1202SR clamping device (1) 2 Remove tensioner pulley (3) for clamping When replacing the clamping device (1). device (1) AR13.25-P-3250SR 3 Unclip engine wiring harness from clamping device (1) 4 Remove screw/bolt (2) and take off clamping device (1) from carrier
5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar13.25-p-3200sr, Remove/install poly-V belt tensioning device ENGINE 281 in MODEL 453

AR13.25-P-3250SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1014 · Applies to: 453 · AR: AR13.25-P-3250SR, AR13.22-P-1202SR

Remove/install tensioner pulley for poly-V belt tensioning device 21.10.2014 ENGINE 281 in MODEL 453 P13.25-2078-09 1 Tensioner pulley 3 Cover 2 Poly-V belt 4 Screw/bolt Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Remove

1 Remove poly-V belt (2)
AR13.22-P-1202SR 2 Remove cover (3) 3 Remove screw/bolt (4) and take off tensioner pulley (1) from the clamping device Check

4 Check tensioner pulley (1) for wear and If there are problems: damage Replace tensioner pulley (1). Install

5 Attach tensioner pulley (1) with screw/bolt (4) *BA13.25-P-1007-01K Bolt, tensioner pulley to tensioning device to the clamping device 6 Fit on cover (3) 7 Install poly-V belt (2) AR13.22-P-1202SR Belt tensioning device Number Designation ENGINE 281 BA13.25-P-1007-01K Bolt, tensioner pulley to tensioning device Nm 50 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar13.25-p-3250sr, Remove/install tensioner pulley for poly-V belt tensioning device ENGINE 281 in MODEL 453

PE14.00-P-2051BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1019 · Applies to: 453 · AR: PE14.00-P-2051BBA

Electrical function schematic for exhaust treatment 17.11.15 Engine 281.910 in model 453.0/3/4 Electrical function schematic for exhaust PE14.00-P-2051-97BBA treatment Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe14.00-p-2051bba, Electrical function schematic for exhaust treatment Engine 281.910 in model 453.0/3/4

AR14.00-P-5303FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1020 · Applies to: 453 · AR: AR14.00-P-5303FH, AR01.20-P-5015FF

Remove/install oxygen sensor 9.3.10 ENGINE 639.939 in MODEL 454.0 1 Trim panel to cylinder head cover G3/2 O2 sensor upstream of TWC [KAT] G3/2x1 O2 sensor connector upstream of TWC P14.00-2089-04 Remove/Install

1 Remove trim panel of cylinder head cover (1) AR01.20-P-5015FF 2 Loosen the connector of O2 sensor upstream of TWC (G3/2x1) from the bracket and disconnect 3 Unscrew the O2 sensor upstream of TWC (G3/2) *BA14.00-P-1001-01D

*450589040900

*BR00.45-Z-1005-06A 4 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off when engine is running. Risk of injury Wear closed and snug-fitting work clothes.

caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 5 Carry out an engine test run and check the exhaust system around the O2 sensor upstream of TWC (G3/2) for leaks 6 Read out fault memory Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system O2 sensor Number Designation Engine 639.939 BA14.00-P-1001-01D O2 sensor to catalytic converter Nm 40 450 589 04 09 00 Socket wrench bit Repair materials Number Designation Order number BR00.45-Z-1005-06A Paste, hot lubrication 1 kg, DB supply specification 6879.20 A 000 989 76 51 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar14.00-p-5303fh, Remove/install oxygen sensor ENGINE 639.939 in MODEL 454.0

AR14.00-P-5303SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1021 · Applies to: 453 · AR: AR14.00-P-5303SR

Remove/install oxygen sensor 08.06.2017 Engine 281 in model 453 Modification notes 21.04.2017 Method for oxygen sensor upstream of catalytic converter adapted. Shown on ENGINE 281.920 1 Electrical wiring harness 2 Electrical wiring harness 3 Heat shield G3/1 Oxygen sensor downstream of catalytic converter G3/1x1 Electrical connector for oxygen sensor downstream of catalytic converter G3/2 Oxygen sensor upstream of catalytic converter G3/2x1 Electrical connector for oxygen sensor upstream of catalytic converter P14.00-2151-05 4 Rear muffler 4.1 Flexible pipe G3/2 Oxygen sensor upstream of catalytic converter P07.04-2948-12 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. Remove/install

Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar14.00-p-5303sr, Remove/install oxygen sensor Engine 281 in model 453

AR14.00-P-5303FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1024 · Applies to: 453 · AR: AR14.00-P-5303FF, AR91.10-P-1000FF, AR68.30-P-4010FF, AR68.30-P-4100FF, AR82.62-P-7839FF

Remove/install the oxygen sensor 9.3.10 ENGINE 134.9, 135.9 in MODEL 454.0 O2 sensor downstream of catalytic converter P14.00-2076-09 1 Footwell paneling 5 Electrical line (for code (C22) Sound G3/1x1 O2 sensor connector package (FFO)) downstream of TWC [KAT] 2 Door sill molding 6 Sealing 3 Wiring harness 4 Front floor covering G3/1 O2 sensor downstream of TWC [KAT] P14.00-2077-01 Remove/install

1 Remove left front seat AR91.10-P-1000FF 2 Remove left paneling in footwell (1) AR68.30-P-4010FF 3 Loosen left door sill molding (2) AR68.30-P-4100FF 4.1 Remove subwoofer On vehicles with code (C22) Sound package AR82.62-P-7839FF (FFO) 5 Lead electrical wiring harness (3) through the opening in front floor covering (4) 6.1 Lead electrical line (5) of subwoofer through On vehicles with code (C22) Sound package the opening in front floor covering (4) (FFO) 7 Lift front floor covering (4) until the O2 sensor connector downstream of TWC [KAT] (G3/1x1) is accessible 8 Unclip O2 sensor connector downstream of Installation:

Ensure correct connection of TWC [KAT] (G3/1x1) from bracket and O2 sensor connector downstream of TWC separate [KAT] (G3/1x1). 9 Release catch hook of sealing (6) and lead electrical line of O2 sensor downstream of TWC [KAT] (G3/1) through the opening in the vehicle floor Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar14.00-p-5303ff, Remove/install the oxygen sensor ENGINE 134.9, 135.9 in MODEL 454.0 O2 sensor downstream of catalytic converter

AR14.00-P-5303FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1026 · Applies to: 453 · AR: AR14.00-P-5303FG, AR68.30-P-4010FF

Remove/install the oxygen sensor 9.3.10 ENGINE 134.9, 135.9 in MODEL 454.0 O2 sensor upstream of catalytic converter P14.00-2070-07 1 Front floor covering 3 Retaining clip G3/2x1 O2 sensor connector upstream of TWC [KAT] 2 Sealing 4 Catch hook G3/2 O2 sensor upstream of TWC [KAT] P14.00-2069-11 Remove/install

1 Remove right floor covering in footwell AR68.30-P-4010FF 2 Fold forward right front floor covering (1) under the instrument panel until the O2 sensor connector upstream of TWC [KAT] (G3/2x1) is accessible 3 Unclip retaining clip (3) of O2 sensor connector upstream of TWC [KAT] (G3/2x1) 4 Detach connector of O2 sensor upstream Installation:

Ensure correct connection of TWC (G3/2x1) O2 sensor connector upstream of TWC [KAT] (G3/2x1). 5 Release catch hook (4) of sealing (2) and lead electrical line of O2 sensor upstream of TWC [KAT] (G3/2) through the opening in the vehicle floor 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. 6 Raise vehicle. 7 Unscrew O2 sensor upstream of TWC [KAT] Installation: Coat the thread of the O2

(G3/2) and remove sensor upstream of TWC [KAT] (G3/2) with heat-resistant lubricant. *BA14.00-P-1001-01D

*450589040900

Paste *BR00.45-Z-1005-06A 8 Install in the reverse order 9 Read fault memory, erase if necessary 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, ar14.00-p-5303fg, Remove/install the oxygen sensor ENGINE 134.9, 135.9 in MODEL 454.0 O2 sensor upstream of catalytic converter

AR14.00-P-5303FI

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1028 · Applies to: 453 · AR: AR14.00-P-5303FI

Remove/install the oxygen sensor 9.3.10 ENGINE 134.9, 135.9 in MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle O2 sensor upstream of catalytic converter 1 Floor mat 2 Sealing G3/2x1 O2 sensor connector upstream of TWC [KAT] P14.00-2094-04 2 Sealing G3/2 O2 sensor upstream of TWC [KAT] P14.00-2093-04 Remove/Install

1 Fold down floor covering (1) in driver-side Fold down floor covering (1) carefully as footwell until the O2 sensor connector otherwise the floor covering (1) can be upstream of TWC [KAT] (G3/2x1) is damaged. accessible 2 Unclip O2 sensor connector upstream of TWC [KAT] (G3/2x1) from the bracket 3 Detach connector of O2 sensor upstream Installation: Ensure correct connection of TWC (G3/2x1) O2 sensor connector upstream of TWC [KAT] (G3/2x1). 4 Guide the sealing (2) and O2 sensor electrical line upstream of TWC [KAT] (G3/2) through the opening in the firewall 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. 5 Raise vehicle. 6 Unscrew O2 sensor upstream of TWC [KAT] Installation: Coat the thread of the O2 (G3/2) and remove sensor upstream of TWC [KAT] (G3/2) with heat-resistant lubricant. *BA14.00-P-1001-01D

*450589040900

Paste *BR00.45-Z-1005-06A 7 Install in the reverse order 8 Read fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns during Do not grasp hot or rotating parts. starting procedure or when working near engine 9 Carry out engine test run and in doing so, check exhaust system in the area of the O2 sensor upstream of TWC [KAT] (G3/2) for leaks O2 sensor Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar14.00-p-5303fi, Remove/install the oxygen sensor ENGINE 134.9, 135.9 in MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle O2 sensor upstream of catalytic converter

AR14.10-P-3915FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1032 · Applies to: 453 · AR: AR14.10-P-3915FH, AR61.20-P-1105FF, AR49.10-P-5500FG, AR49.10-P-5501FF, AR09.10-P-1150FG

Remove, install exhaust manifold 20.3.06 ENGINE 639.9 in MODEL 454.0 1 Shield 2 Hose 3 Bolt 4 Exhaust manifold 5 Bracket 6 Oil return line 7 Air hose 8 Turbocharger 9 Air hose 10 Charge air pipe 11 Air hose 12 Vacuum line 13 Vacuum reservoir 14 Nut 15 Banjo bolt P14.10-2063-06 16 Bolt 18 Cylinder head 17 Oil feed line 19 Bolts Remove/install

1 Remove lower engine compartment paneling AR61.20-P-1105FF 2.1 Remove catalytic converter On vehicles without Code (K13) Diesel AR49.10-P-5500FG particulate filter 2.2 Remove catalytic converter diesel particulate On vehicles with Code (K13) Diesel AR49.10-P-5501FF filter unit particulate filter 3 Unscrew bolt (3). 4 Detach hose (2) at cylinder head (18) 5 Remove shield (1) 6 Remove bolts (19) on bracket (5) and bracket (5) 7 Detach oil return line (6) at turbocharger (8) AR09.40-P-6020-06FG *BA09.40-P-1001-01I

8 Detach air hose (7) at turbocharger (8) 9 Remove air filter housing AR09.10-P-1150FG 10 Detach air hose (11) at turbocharger (8) 11 Detach air hose (9) at charge air pipe (10) 12 Detach vacuum line (12) at vacuum unit (13) 13 If the nut (14) of the exhaust manifold (4) used Installation:

Replace self-locking nut to secure the oil return line (6) is fastened, (14). unscrew. *BA14.10-P-1001-01K

14 Unscrew the banjo bolt (15) Installation: Replace sealing rings of

banjo bolt (15). *BA09.40-P-1002-01I

15 Unscrew bolt (16) on oil feed line (17) from Installation:

Install new self-locking bolt cylinder head (18) (16) *BA09.40-P-1003-01I

16 Pull the oil feed line (17) out of the cylinder Installation:

replace sealing ring of oil head (18) feed line (17). 17 Unscrew nuts of exhaust manifold (4) The exhaust manifold (4) is secured with a further seven nuts. Installation: Install new self-locking nuts. *BA14.10-P-1001-01K

18 Remove exhaust manifold (4) together with Installation:

Clean sealing surfaces, turbocharger (8) replace gasket of exhaust manifold (4) 19 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar14.10-p-3915fh, Remove, install exhaust manifold ENGINE 639.9 in MODEL 454.0

AR14.10-P-3006SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1034 · Applies to: 453 · AR: AR14.10-P-3006SR, AR49.10-P-5500SRA

Remove/install exhaust manifold 15.07.2016 Engine 281.910 in model 453 (except 453.062/362/462) 1 Exhaust manifold 2 Securing clamp 3 Control rod 4 Clamp 5 Nuts 6 ATL 7 Seal P14.10-2147-05 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. Notes on self-locking nuts and bolts AH00.00-N-0001-01A

Remove

1 Remove catalytic converter AR49.10-P-5500SRA 2 Remove securing clamp (2) 3 Remove control rod (3) from exhaust manifold (1) 4 Unfasten clamp (4) and take off 5 Unscrew nuts (5) 6 Remove exhaust manifold (1) Hold ATL (6) somewhat to the side.

7 Remove seal (7) Replace seal (7).

Clean

8 Clean sealing surface on exhaust manifold (1) When reusing the exhaust manifold (1). 9 Clean sealing surface on cylinder head Install

10 Lay new seal (7) on cylinder head 11 Hold ATL (6) somewhat to the side and Screw on nuts (5) evenly up to the stop.

attach exhaust manifold (1) with nuts (5) to the cylinder head 12 Tighten nuts (5) *BA49.10-P-1002-02C Nut, exhaust manifold to cylinder head 13 Install clamp (4) and tighten down 14 Attach control rod (3) to exhaust manifold (1) 15 Install new safety clip (2) 16 Install catalytic converter AR49.10-P-5500SRA Only install covering over engine after the

leak test. Check

Risk of accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 17 Perform an engine test run and check exhaust system in the area of the exhaust manifold (1) for leaktightness Exhaust system Number Designation Engine 281.910 BA49.10-P-1002-02C Nut, exhaust manifold to cylinder head Nm 35 Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar14.10-p-3006sr, Remove/install exhaust manifold Engine 281.910 in model 453 (except 453.062/362/462)

AR14.10-P-3915FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1035 · Applies to: 453 · AR: AR14.10-P-3915FF, AR49.10-P-5500FF

Removing/installing the exhaust manifold 6.10.03 ENGINE 135.9 in MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle 1 Exhaust manifold 2 Heat shield 3 Bolts 4 Exhaust manifold support 5 Heat shield 6 Nuts P14.10-2043-06 Removing/installing

1 Remove upper bolts on heat shield (5) The heat shield (5) is fastened at the top

with two screws. 2 Remove catalytic converter AR49.10-P-5500FF 3 Unscrew screws (3) and remove heat shield (2) 4 Remove exhaust manifold support (4) *BA14.10-P-1003-01H

*BA14.10-P-1004-01H

5 Remove lower bolt on heat shield (5) The heat shield (5) is fastened at the

bottom with one screw. 6 Lower vehicle 7 Take out heat shield (5) 8 Raise vehicle. 9 Unscrew nuts (6) on exhaust manifold (1) Replace nuts (6). Installation:

Tighten the nuts (6) from inside to outside on the exhaust manifold (1). *BA14.10-P-1001-01H

10 Remove exhaust manifold (1) with gasket Installation: Clean sealing surfaces and replace gasket. 11 Install in reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns during Do not grasp hot or rotating parts. starting procedure or when working near engine 12 Conduct engine test run and check exhaust system in the area of the exhaust manifold (1) for leaks Exhaust manifold

Number Designation Engine Engine 135.930 135.950 BA14.10-P-1001-01H Nut for exhaust manifold on cylinder head Nm 35 35 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar14.10-p-3915ff, Removing/installing the exhaust manifold ENGINE 135.9 in MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle

AR14.20-P-3106FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1037 · Applies to: 453 · AR: AR14.20-P-3106FG, AR83.25-P-1402FF, AP20.00-P-2010FG

Remove, install the vacuum transducer 20.3.06 ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter 1 Fuse 2 Electrical connector 3 Bolt 4 Hose clamps 5 Coolant hoses 6 Sealing ring Y31/2 Pressure control flap vacuum transducer P14.20-2229-06 Remove/install

Risk of injury Do not open cooling system unless coolant Danger! to skin and eyes caused by AS20.00-Z-0001-01A

scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

1 Remove water collector AR83.25-P-1402FF 2 Loosen fuse (1) at electrical connector (2) and disconnect electrical connector (2) 3 Unscrew bolts (3) at pressure control flap *BA14.20-P-1005-01H

vacuum transducer (Y31/2) 4 Loosen hose clamps (4) and detach coolant Collect coolant which flows out in a hoses (5) at pressure control flap vacuum suitable vessel. transducer (Y31/2) Seal off openings on coolant hoses (5) and at pressure control flap vacuum transducer (Y31/2) using suitable plugs. 5 Remove pressure control flap vacuum Installation: Clean sealing surfaces.

transducer (Y31/2) from engine compartment Replace compression ring (6). 6 Install in the reverse order 7 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 Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 8 Conduct engine test run and check cooling system around the pressure control flap vacuum transducer (Y31/2) for leaks 9 Check coolant level, adjust to correct level if necessary. Engine cooling system - check fluid level, AP20.00-P-2010FG

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration Exhaust gas recirculation

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar14.20-p-3106fg, Remove, install the vacuum transducer ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter

AR14.20-P-7000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1039 · Applies to: 453 · AR: AR14.20-P-7000FF, AR83.25-P-1402FF

Remove, install vacuum control valve exhaust gas recirculation 11.5.04 ENGINE 639.939 in MODEL 454.0 1 Connector 2 Screw 3 Screw 4 Vacuum hoses Y27 EGR [ARF] switchover valve P09.41-2311-06 Remove/Install

1 Remove water collector AR83.25-P-1402FF 2 Unplug connector (1) 3 Detach screw (2). 4 Unscrew bolt (3). 5 Pull EGR switchover valve (Y27) upwards and out and pull out vacuum hoses (4) 6 Install in the reverse order 7 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 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, ar14.20-p-7000ff, Remove, install vacuum control valve exhaust gas recirculation ENGINE 639.939 in MODEL 454.0

AR14.20-P-7665FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1040 · Applies to: 453 · AR: AR14.20-P-7665FG, AR83.25-P-1402FF, AP20.00-P-2010FG

Remove/install exhaust gas recirculation cooler 11.10.04 ENGINE 639.939 in MODEL 454.0 1 Bolts 2 Connection 3 Exhaust gas recirculation cooler 4 Clip 5 Coolant hose 6 Screw 7 Clip 8 Coolant hose P14.20-2176-04 Remove/Install

Risk of injury Do not open cooling system unless coolant Danger! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolant spray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage bottles. Wear protective gloves, protective clothing and eye protection. 1 Remove water collector AR83.25-P-1402FF 2 Remove bolts (1) *BA14.20-P-1001-01H

3 Pull connection pipes (2) out of exhaust gas Installation:

Replace the gaskets. recirculation cooler (3) Risk of death Danger! cased by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A toppling off of the lifting platform. hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. 4 Raise vehicle. 5 Pinch off coolant hoses (5, 8) using suitable hose clamps 6 Loosen clamps (4, 7), remove coolant hoses Collect coolant which flows out in a (5, 8) from exhaust gas recirculation cooler (3) suitable vessel. 7 Unscrew bolt (6) *BA14.20-P-1002-01H

8 Undo bolts (arrows) and remove exhaust gas Installation:

Install new gasket recirculation cooler (3) with its associated seal *BA14.20-P-1003-01H

9 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 10 Perform engine test run and check coolant system around exhaust gas recirculation cooler (3) for leaks 11 Check coolant level, adjust to correct level if necessary. Engine cooling system - inspect fluid level, AP20.00-P-2010FG

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration Exhaust gas recirculation

Number Designation Engine 639.939 BA14.20-P-1001-01H Bolt connecting pipe to mixing chamber Nm 8 BA14.20-P-1002-01H Bolt of exhaust gas recirculation cooler to Nm 12 charge air distribution housing BA14.20-P-1003-01H Bolt of exhaust gas recirculation cooler to Nm 12 crankcase Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar14.20-p-7665fg, Remove/install exhaust gas recirculation cooler ENGINE 639.939 in MODEL 454.0

AR14.20-P-7662FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1041 · Applies to: 453 · AR: AR14.20-P-7662FG, AR88.00-P-2792FF

Remove/install exhaust gas recirculation valve 13.4.06 ENGINE 639.9 in MODEL 454.0 except CODE (K13) Diesel particulate filter 1 Vacuum hose 2 Bolts 3 Exhaust gas recirculation valve P14.20-2177-04 Remove/install

1 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 2 Detach vacuum hose (1) 3 Remove bolts (2) *BA14.20-P-1004-01H

4 Remove exhaust gas recirculation valve (3) Installation:

Replace exhaust gas recirculation valve sealing ring (3). 5 Install in the reverse order Exhaust gas recirculation

Number Designation Engine 639.939 BA14.20-P-1004-01H Bolt, exhaust gas recirculation valve to Nm 12 mixing chamber Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar14.20-p-7662fg, Remove/install exhaust gas recirculation valve ENGINE 639.9 in MODEL 454.0 except CODE (K13) Diesel particulate filter

GF14.40-P-9998FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1042 · Applies to: 453 · AR: GF14.40-P-9998FF, GF14.40-P-2010FF, GF07.04-P-6111FF, GF07.04-P-6109FF, GF07.04-P-6121FF (+4 more)

Overview of system components Exhaust aftertreatment 18.4.06 ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter Diesel particulate filter, component description GF14.40-P-2010FF Component description for the temperature B19/9 GF07.04-P-6111FF sensor on diesel particulate filter Component description for the temperature B19/11 GF07.04-P-6109FF sensor upstream of turbocharger Component description for the diesel B28/8 GF07.04-P-6121FF particulate filter pressure differential sensor Component description for the exhaust back B60 GF07.04-P-6130FF pressure sensor Component description for the pressure Y31/2 GF14.20-P-4011FF control flap pressure transducer Component description for the boost pressure Y31/5 GF09.40-P-4015FF control pressure transducer Table of contents for function description GF14.40-P-0998FF Exhaust aftertreatment Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf14.40-p-9998ff, Overview of system components Exhaust aftertreatment ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter

GF14.40-P-9998FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1043 · Applies to: 453 · AR: GF14.40-P-9998FG, GF14.40-P-2010FG, GF14.40-P-0998FG

Overview of system components Exhaust aftertreatment 13.4.06 ENGINE 639.9 in MODEL 454.0 with CODE (40Z) Diesel particulate filter (accessory) Component description for the diesel GF14.40-P-2010FG particulate filter Table of contents for function description GF14.40-P-0998FG Exhaust aftertreatment Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf14.40-p-9998fg, Overview of system components Exhaust aftertreatment ENGINE 639.9 in MODEL 454.0 with CODE (40Z) Diesel particulate filter (accessory)

GF14.40-P-0998FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1045 · Applies to: 453 · AR: GF14.40-P-0998FF, GF14.40-P-0002FF, GF14.40-P-9998FF

Table of contents for function description Exhaust aftertreatment 18.4.06 ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter Exhaust aftertreatment, function GF14.40-P-0002FF Exhaust aftertreatment, block diagram GF14.40-P-0002-01FF Exhaust aftertreatment, location of GF14.40-P-0002-02FF components Overview of system components Exhaust GF14.40-P-9998FF aftertreatment Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf14.40-p-0998ff, Table of contents for function description Exhaust aftertreatment ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter

GF14.40-P-0998FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1046 · Applies to: 453 · AR: GF14.40-P-0998FG, GF14.40-P-0002FG, GF14.40-P-9998FG

Table of contents for function description Exhaust aftertreatment 13.4.06 ENGINE 639.9 in MODEL 454.0 with CODE (40Z) Diesel particulate filter (accessory) Exhaust aftertreatment, function GF14.40-P-0002FG Overview of system components Exhaust GF14.40-P-9998FG aftertreatment Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf14.40-p-0998fg, Table of contents for function description Exhaust aftertreatment ENGINE 639.9 in MODEL 454.0 with CODE (40Z) Diesel particulate filter (accessory)

PE15.00-P-2001ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1054 · Applies to: 453 · AR: PE15.00-P-2001ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+5 more)

Block diagram for starter, alternator, battery 16.12.03 ENGINE 639.939, 134.910, 135.930 /950 in MODEL 454 PE15.00-P-2001-99ZA Block diagram for starter, alternator, battery PE15.00-P-2001-99ZA PE15.00-P-2001-60ZA Legend for block diagram of starter, PE15.00-P-2001-60ZA alternator, battery 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 PE15.00-P-1100ZA Further wiring diagrams PE15.00-P-1100ZA PE46.00-P-1100ZA Further wiring diagrams PE46.00-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE83.00-P-1100ZA Further wiring diagrams PE83.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe15.00-p-2001za, Block diagram for starter, alternator, battery ENGINE 639.939, 134.910, 135.930 /950 in MODEL 454

BE15.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1056 · Applies to: 453 · AR: BE15.00-Z-9999CZ

Test and adjustment values: Smart: Electrical system - engine 18.09.2019 MODEL all Check values for alternator ENGINE 660.940 BE15.40-P-1000-01G Test values for alternator ENGINE 160.910 BE15.40-P-1000-01F Governor ENGINE 122, 134, 135, 639 in MODEL 454 BE15.40-P-1000-02G Starter-alternator bearing play check values ENGINE 132.910 in MODEL 451.334/380/480 BE15.40-P-1000-03A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be15.00-z-9999cz, Test and adjustment values: Smart: Electrical system - engine MODEL all

PE15.00-P-2103BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1060 · Applies to: 453 · AR: PE15.00-P-2103BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram for engine start/stop 09.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Wiring diagram for engine Start/Stop PE15.00-P-2103-97BBA 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, pe15.00-p-2103bba, Wiring diagram for engine start/stop Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020

PE15.00-P-2000ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1061 · Applies to: 453 · AR: PE15.00-P-2000ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram for starter, alternator 16.12.03 ENGINE 639.939, 134.910, 135.930 /950, 122 in MODEL 454 up to 2.4.06 PE15.00-P-2000-99ZA Wiring diagram for starter, alternator PE15.00-P-2000-99ZA PE15.00-P-2000-60ZA Legend for wiring diagram for starter, PE15.00-P-2000-60ZA alternator 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 for 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 PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe15.00-p-2000za, Wiring diagram for starter, alternator ENGINE 639.939, 134.910, 135.930 /950, 122 in MODEL 454 up to 2.4.06

PE15.00-P-2000ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1062 · Applies to: 453 · AR: PE15.00-P-2000ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+5 more)

Wiring diagram for starter, alternator 8.3.06 ENGINE 639.939, 134.910, 135.930 /950, 122 in MODEL 454 as of 3.4.06 PE15.00-P-2000-99ZB Wiring diagram for starter, alternator PE15.00-P-2000-99ZB PE15.00-P-2000-60ZB Legend of wiring diagram for starter, PE15.00-P-2000-60ZB alternator 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 PE83.00-P-1100ZA Further wiring diagrams PE83.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe15.00-p-2000zb, Wiring diagram for starter, alternator ENGINE 639.939, 134.910, 135.930 /950, 122 in MODEL 454 as of 3.4.06

PE15.00-P-2101BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1084 · Applies to: 453 · AR: PE15.00-P-2101BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of starter, alternator, battery 09.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Wiring diagram for starter, alternator, battery PE15.00-P-2101-97BBA 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, pe15.00-p-2101bba, Wiring diagram of starter, alternator, battery Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020

AP15.10-P-1580FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1085 · Applies to: 453 · AR: AP15.10-P-1580FF, AR15.12-P-2003FF

Replace spark plugs 19.11.2019 Engine 134.9, 135.9 in model 454.0 Shown on engine 135.9 R4 Spark plugs P15.10-2114-11 Remove/install

Risk of death Danger when working on component Do not touch damaged or defective live AS00.00-Z-0035-01A

parts and systems with U >= 30 V alternating component parts and lines or non-insulated voltage (AC) or U >= 60 V direct voltage (DC) electrical connections and lines. 1 Remove ignition coils AR15.12-P-2003FF

2 Remove spark plugs (R4) *BA15.10-P-1001-01D Spark plugs 3 Install in the reverse order Spark plugs Number Designation Engine 134.910 Engine 134.911 BA15.10-P-1001-01D Spark plugs Nm 25 25 Spark plugs Number Designation Engine 135.930 Engine 135.950 BA15.10-P-1001-01D Spark plugs Nm 25 25 Page 1 of 1 © Mercedes-Benz AG, 5/20/18, L/07/20, ap15.10-p-1580ff, Replace spark plugs Engine 134.9, 135.9 in model 454.0

AP15.10-P-1580S

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1086 · Applies to: 453 · AR: AR15.12-P-2003SR, AR15.12-P-1010SR

Replace spark plugs 19.11.2019 Engine 281 in model 453 1 Spark plugs P15.10-2550-06 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 death Danger when working on component Do not touch damaged or defective live AS00.00-Z-0035-01A

parts and systems with U >= 30 V alternating component parts and lines or non-insulated voltage (AC) or U >= 60 V direct voltage (DC) electrical connections and lines. Topical note Notes on avoiding damage through AH00.00-P-5000-01A contamination and foreign objects Remove

1 Remove ignition coils AR15.12-P-2003SR

Clean

2 Blow out spark plug stems using compressed

air and remove any dirt residue Openings through which contamination or foreign objects can be carried into the engine, its ancillary equipment or detachable parts must be immediately sealed off using suitable caps, stop plugs or a clean, lint-free rag. Otherwise, damage may occur! Remove

3 Remove spark plugs AR15.12-P-1010SR

Install

4 Install new spark plugs AR15.12-P-1010SR

Check

5 Check spark plug connector, ignition coil If there are complaints: connectors and electrical lines for damage, deformation and crack formation Rectify problem subject to separate repair order. Install

6 Install ignition coils AR15.12-P-2003SR

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap15.10-p-1580s, Replace spark plugs Engine 281 in model 453

AR15.12-P-2133FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1087 · Applies to: 453 · AR: AR15.12-P-2133FG

Remove, install crankshaft position sensor 28.2.06 ENGINE 639.939 in MODEL 454.0 P15.12-2077-07 1 Connector 2 Bolt L5 Crankshaft position sensor Remove/install

Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A toppling off of the lifting platform. lifting platform and position the four support plates below the lifting platform support points specified by the vehicle manufacturer. 1 Raise vehicle 2 Unplug connector (1) 3 Unscrew bolt (2) Installation:

Install new bolt (2). *BA07.04-P-1001-01J

4 Pull out crankshaft position sensor (L5) 5 Install in the reverse order 6 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 Sensors

Number Designation Engine 639.9 BA07.04-P-1001-01J Bolt connecting crankshaft position sensor Nm 7 to crankcase 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, ar15.12-p-2133fg, Remove, install crankshaft position sensor ENGINE 639.939 in MODEL 454.0

AR15.12-P-2133FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1088 · Applies to: 453 · AR: AR15.12-P-2133FF, AR13.22-P-1202FF, AR61.20-P-1105FF

Remove/install crankshaft position sensor 11.5.06 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 with code (I01) Air conditioning Plus 1 Electrical connector 2 Bolt L5 Crankshaft position sensor P15.12-2062-04 Remove/install

1.1 Remove poly-V-belt Only for vehicles with Code (I01) Air AR13.22-P-1202FF conditioning Plus or Code (I77) Manual AC 1.2 Detach lower engine compartment paneling Only on vehicles without code (I01) Air AR61.20-P-1105FF conditioning Plus or Code (I77) Manual AC 2.1 Remove refrigerant compressor Only for vehicles with Code (I01) Air AR83.55-P-5300-04FF conditioning Plus or Code (I77) Manual AC *BA83.55-P-1001-01L

*BA83.55-P-1002-01L

3 Disconnect electrical connector (1) 4 Unscrew bolt (2) *BA15.12-P-1002-01I

5 Pull out crankshaft position sensor (L5) Installation: Replace sealing ring at crankshaft position sensor (L5). 6 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 7 Conduct engine test run and check engine around crankshaft position sensor (L5) for leaks 8 Read fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A ECI ignition system

Number Designation Engine Engine 134.910 134.911 BA15.12-P-1002-01I Bolt, crankshaft position sensor to crankcase Nm 9 9 ECI ignition system

Number Designation Engine Engine 135.930 135.950 BA15.12-P-1002-01I Bolt, crankshaft position sensor to crankcase Nm 9 9 Refrigerant compressor

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.12-p-2133ff, Remove/install crankshaft position sensor ENGINE 134.9, 135.9 in MODEL 454.0

AR15.12-P-2133SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1090 · Applies to: 453 · AR: AR15.12-P-2133SR

Remove/install crankshaft position sensor 27.11.2017 Engine 281 in model 453 Shown on vehicle with transmission 700.12 1 Electrical connection 2 Screw/bolt 3 Transmission housing L5 Crankshaft position sensor P15.12-2174-04 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 Raise vehicle with vehicle lift
2 Disconnect electrical connection (1)
3 Remove screw/bolt (2) *BA15.12-P-1005-01G Screw/bolt, crankshaft position sensor to transmission housing 4 Pull crankshaft position sensor (L5) out of the transmission housing (3)
5 Install in the reverse order 6 Connect diagnostic unit, read out fault memory When replacing the crankshaft position sensor (L5). AD00.00-P-2000-06SR

Electronic ignition with variable characteristics Number Designation Engine 281 BA15.12-P-1005-01G Screw/bolt, crankshaft position sensor to transmission housing Nm 8 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.12-p-2133sr, Remove/install crankshaft position sensor Engine 281 in model 453

AR15.12-P-2003FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1091 · Applies to: 453 · AR: AR15.12-P-2003FF

Remove/install ignition coils 15.11.2019 Engine 134.9, 135.9 in model 454.0 Shown on engine 135.9 1 Bolts 2 Connector T1/1 Cylinder 1 ignition coil T1/2 Cylinder 2 ignition coil T1/3 Cylinder 3 ignition coil T1/4 Cylinder 4 ignition coil (only for engine 135.9) P15.12-2060-06 Remove/install

Risk of death Danger when working on component Do not touch damaged or defective live AS00.00-Z-0035-01A

parts and systems with U >= 30 V alternating component parts and lines or non-insulated voltage (AC) or U >= 60 V direct voltage (DC) electrical connections and lines. 1 Withdraw ignition key 2 Open hood 3 Release connector (2) and disconnect 4 Remove screw/bolts (1) *BA15.12-P-1004-01I Bolt, ignition coil module to cylinder head cover 5 Remove ignition coils (T1/1, T1/2, T1/3, T1/4). Cylinder 4 ignition coil (T1/4) only for

engine 135.9. 6 Install in the reverse order 7 Read out fault memory AD00.00-P-2000-04FF

Commercially available devices/tools

STAR DIAGNOSIS diagnosis system Electronic ignition with variable characteristics Number Designation Engine 134.910 Engine 134.911 BA15.12-P-1004-01I Bolt, ignition coil module to cylinder head cover Nm 9 9 Electronic ignition with variable characteristics Number Designation Engine 135.930 Engine 135.950 BA15.12-P-1004-01I Bolt, ignition coil module to cylinder head cover Nm 9 9 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.12-p-2003ff, Remove/install ignition coils Engine 134.9, 135.9 in model 454.0

AR15.12-P-2003SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1092 · Applies to: 453 · AR: AR15.12-P-2003SR

Remove/install ignition coils 18.11.2019 Engine 281 in model 453 1 Vent hose 2 Vent housing T1/1 Cylinder 1 ignition coil T1/2 Cylinder 2 ignition coil T1/3 Cylinder 3 ignition coil P01.00-3535-06 Risk of death Danger when working on component Do not touch damaged or defective live AS00.00-Z-0035-01A

parts and systems with U >= 30 V alternating component parts and lines or non-insulated voltage (AC) or U >= 60 V direct voltage (DC) electrical connections and lines. Remove/install

1 Switch off ignition and remove transmitter key 2 Remove cover over engine
3 Remove bleed hose (1) on ventilation housing (2) and place to one side
4 Release and disconnect electrical connection on cylinder 1 ignition coil (T1/1), cylinder 2 ignition coil (T1/2) and cylinder 3 ignition coil (T1/3)
5 Remove screw/bolts for cylinder 1 ignition coil *BA15.12-P-1003-01G Screw/bolt, ignition coil to cylinder head (T1/1), cylinder 2 ignition coil (T1/2) and cylinder 3 ignition coil (T1/3)
6 Remove cylinder 1 ignition coil (T1/1), cylinder 2 ignition coil (T1/2) and cylinder 3 ignition coil (T1/3) from the timing case cover 7 Install in the reverse order Electronic ignition with variable characteristics Number Designation Engine 281 BA15.12-P-1003-01G Screw/bolt, ignition coil to cylinder head Nm 10 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.12-p-2003sr, Remove/install ignition coils Engine 281 in model 453

AR15.12-P-2185FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1093 · Applies to: 453 · AR: AR15.12-P-2185FF

Remove/install knock sensor 12.9.03 ENGINE 134.9, 135.9 in MODEL 454.0 1 Bolt 2 Connector A16 Knock sensor P15.12-2061-04 Remove/Install

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

toppling off of the lifting platform. lifting platform and position the four support plates below the hoist support points specified by the vehicle manufacturer. 1 Raise vehicle. 2 Unscrew bolt (1) *BA15.12-P-1001-01I

3 Unlock the plug (2) at the knock sensor (A16) Installation: Make sure the plug (2) is and pull it out correctly engaged with the knock sensor (A16). 4 Remove the knock sensor (A16) from the crankcase 5 Install in the reverse order 6 Read fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A ECI ignition system

Number Designation Engine Engine 134.910 134.911 BA15.12-P-1001-01I Bolt of knock sensor to crankcase Nm 20 20 ECI ignition system

Number Designation Engine Engine 135.930 135.950 BA15.12-P-1001-01I Bolt of knock sensor to crankcase Nm 20 20 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, ar15.12-p-2185ff, Remove/install knock sensor ENGINE 134.9, 135.9 in MODEL 454.0

AR15.12-P-2185SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1094 · Applies to: 453 · AR: AR15.12-P-2185SRA, AR20.00-P-1142SR, AR09.41-P-1310SR

Remove/install knock sensor 19.08.2014 ENGINE 281.910 in MODEL 453 1 Coolant line 2 Screw/bolts 3 Electrical connection 4 Screw/bolt A16 Knock sensor P15.12-2178-06 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove

1 Drain coolant AR20.00-P-1142SR 2 Remove charge air distributor AR09.41-P-1310SR 3 Remove screw/bolts (2) 4 Remove coolant line (1) from crankcase and remove from working area 5 Disconnect electrical connection (3)
6 Mark installation position of knock sensor (A16) 7 Remove screw/bolt (4) and remove knock sensor (A16) from crankcase Install

8 Transfer marking of the installation position to When installing new a knock sensor (A16). the new part 9 The contact surface between the Lay knock sensor (A16) on the crankcase

and tighten with screw/bolt (4) crankcase and the knock sensor (A16) must be clean and flat. Observe the marking for the installation position. BA15.12-P-1001-01G Screw/bolt, knock sensor to crankcase 10 Connect Electrical connection (3) 11 Insert coolant line (1) in crankcase 12 Screw in screw/bolts (2) BA20.10-P-1012-01J Bolt, coolant line to crankcase 13 Install charge air distributor AR09.41-P-1310SR 14 Pour in coolant and bleed cooling system AR20.00-P-1142SR 15 Connect diagnostic unit, read out fault memory When installing new a knock sensor (A16). AD00.00-P-2000-06SR

Electronic ignition with variable characteristics Number Designation ENGINE 281 BA15.12-P-1001-01G Screw/bolt, knock sensor to crankcase Nm 20 Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar15.12-p-2185sra, Remove/install knock sensor ENGINE 281.910 in MODEL 453

AR15.12-P-1010SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1096 · Applies to: 453 · AR: AR15.12-P-1010SR, AR15.12-P-2003SR

Remove/install spark plugs 19.08.2014 ENGINE 281 in MODEL 453 R4 Spark plug P15.12-2173-06 Notes on avoiding damage through AH00.00-P-5000-01A

contamination and foreign objects Remove/install

1 Remove ignition coils AR15.12-P-2003SR 2 Unscrew spark plugs (R4) *BA15.10-P-1001-01B Spark plugs 3 Install in the reverse order Spark plugs Number Designation ENGINE 281 BA15.10-P-1001-01B Spark plugs Initial tightening Nm 24 torque Retightening torque Nm 24 Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar15.12-p-1010sr, Remove/install spark plugs ENGINE 281 in MODEL 453

AR15.20-P-4500FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1097 · Applies to: 453 · AR: AR15.20-P-4500FF, AR54.10-P-0003FF, AR83.25-P-1402FF

Remove/install glow output stage 11.6.04 ENGINE 639.939 in MODEL 454.0## 1# P15.20-2114-07 1 Clip 4 Plug N14/2 Glow output stage 2 Suspension strut tower 5 Plug 3 Bracket 6 Plug Remove/Install

1 Disconnect battery ground line AR54.10-P-0003FF 2 Remove water collector AR83.25-P-1402FF 3 Loosen clip (1) from suspension strut tower (2) 4 Remove screws from glow output stage Glow output stage (N14/2) is attached to (N14/2) bracket (3) by four screws. *BA15.20-P-1002-01D

5 Loosen glow output stage (N14/2) from the Installation:

Ensure that glow output guides in bracket (3) stage (N14/2) is correctly seated in bracket (3). 6 Pull out plugs (4, 5, 6) 7 Take out glow output stage (N14/2) 8 Install in the reverse order Preglow system

Number Designation Engine 639.939 BA15.20-P-1002-01D Torx bolt of glow output stage to bracket Nm 15 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.20-p-4500ff, Remove/install glow output stage ENGINE 639.939 in MODEL 454.0## 1#

AR15.20-P-4500FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1098 · Applies to: 453 · AR: AR15.20-P-4500FG, AR54.10-P-0003FF, AR83.25-P-1402FF

Remove/install glow output stage 17.6.04 ENGINE 639.939 in MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle 1 Screw 2 Bracket 3 Connector 4 Connector 5 Connector N14/2 Glow output stage P15.20-2115-04 Remove/Install

1 Disconnect battery ground cable AR54.10-P-0003FF 2 Remove water collector AR83.25-P-1402FF 3 Unscrew screws (1) for glow output stage *BA15.20-P-1002-01D

(N14/2) 4 Release glow output stage (N14/2) from Installation:

Ensure that glow output guides in mount (2) stage (N14/2) is seated correctly in mount (2) 5 Unplug plug (3, 4, 5) 6 Remove glow output stage (N14/2) 7 Install in the reverse order Preglow system

Number Designation Engine 639.939 BA15.20-P-1002-01D Torx bolt, glow output stage to bracket Nm 15 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.20-p-4500fg, Remove/install glow output stage ENGINE 639.939 in MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle

AR15.20-P-4111FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1099 · Applies to: 453 · AR: AR15.20-P-4111FF, AR07.03-P-1010FG

Remove/install glow plugs 8.1.09 ENGINE 639.939 in MODEL 454.0 P15.20-2112-08 1 Connector R9 Glow plugs Remove/install

1 Remove rail AR07.03-P-1010FG 2 Remove plug (1) for glow plugs (R9) 3 Unscrew glow plugs (R9) Installation:

Only replace glow plugs (R9) as a set. *454589020900

*BA15.20-P-1001-01D

4 Install in the reverse order Preglow system

Number Designation Engine 639.939 BA15.20-P-1001-01D Glow plug on cylinder head Nm 8.5 454 589 02 09 00 Glowplug wrench Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.20-p-4111ff, Remove/install glow plugs ENGINE 639.939 in MODEL 454.0

AR15.30-P-7100FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1100 · Applies to: 453 · AR: AR15.30-P-7100FG, AR54.10-P-0003FF, AR61.20-P-1105FF

Remove/install starter 17.1.06 ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0 1 Protective cap 2 Connector 3 Bolt M1 Starter P15.30-2169-05 Remove/install

1 Disconnect battery ground cable AR54.10-P-0003FF 2 Detach lower engine compartment paneling AR61.20-P-1105FF 3 Tilt protective cap (1) upwards and disconnect BA15.30-P-1002-01I the electrical line underneath it at the starter (M1) 4 Pull out the plug (2) on the starter (M1) 5 Unscrew bolts (3) and take starter (M1) down Replace bolts (3). and out On engine 122.9, a ground cable is secured to the bottom bolt (3). BA15.30-P-1001-01I 6 Install in the reverse order 7 Perform operational check of starter (M1) Starter

Number Designation Engine Engine Engine Engine 122.9 134.9 135.9 639.9 BA15.30-P-1001-01I Torx bolt connecting starter to transmission Nm 20 20 20 20 BA15.30-P-1002-01I Nut for circuit 30 connection to starter Nm 14 11 11 11 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.30-p-7100fg, Remove/install starter ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0

AR15.30-P-7100SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1101 · Applies to: 453 · AR: AR15.30-P-7100SR

Remove/install starter 09.08.2017 Engine 281 in model 453 Modification notes 23.08.2016 Electrical line on starter, circuit 50 Engine 281 BA15.30-P-1003-01E 09.08.2017 Electrical line on starter, circuit 30 Engine 281 BA15.30-P-1002-01E P15.12-2176-08 Shown on engine 281.920 1 Cap 5 Screw/bolt 2 Nut 6 Bracket 3 Electrical line 7 Screw/bolts 4 Electrical line M1 Starter P15.12-2177-08 ENGINE 281.910 8 Electrical wiring harness 10 Screw/bolt 9 Bracket M1 Starter Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.30-p-7100sr, Remove/install starter Engine 281 in model 453

Remove/install

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1102 · Applies to: 453 · AR: AR09.20-P-1310SR, AR09.41-P-1310SR

1.1 Remove intake manifold Engine 281.920 in model 453 AR09.20-P-1310SR 1.2 Remove charge air distributor Engine 281.910 in model 453 AR09.41-P-1310SR 2 Remove cap (1) 3 Unscrew nuts (2) and remove electrical line (3) BA15.30-P-1002-01E Electrical line on starter, circuit 30 from starter (M1) 4 Remove electrical line (4) from starter (M1). BA15.30-P-1003-01E Electrical line on starter, circuit 50 5 Remove screw/bolt (5) and remove bracket (6) 6 Unclip electrical wiring harness (8) from Engine 281.910 in model 453 bracket (9) 7 Remove screw/bolt (10) Engine 281.910 in model 453 8 Remove screw/bolts (7) and remove starter *BA15.30-P-1001-01E Bolt, starter to transmission (M1) from transmission
9 Install in the reverse order Starter Number Designation Engine 281 BA15.30-P-1001-01E Bolt, starter to transmission Nm 44 Starter Number Designation Engine 281 BA15.30-P-1002-01E Electrical line on starter, circuit 30 Nm 12 Starter Number Designation Engine 281 BA15.30-P-1003-01E Electrical line on starter, circuit 50 Nm 5 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.30-p-7100sr, Remove/install starter Engine 281 in model 453

AR15.40-P-5010FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1104 · Applies to: 453 · AR: AR15.40-P-5010FF, AR15.40-P-5009FF, AR54.10-P-1129FF, AR15.40-P-5032FB, AR15.40-P-5032FF (+1 more)

Check regulation voltage of alternator 19.11.04 ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0 1 Multimeter

F32 Front prefuse G1 Battery G2 Alternator M1 Starter W10 Ground (battery) P15.40-2294-06 Check

Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns during Do not grasp hot or rotating parts. starting procedure or when working near engine 1 Check whether the preconditions for the AR15.40-P-5009FF alternator test have been satisfied 2 Check condition of battery (G1) AR54.10-P-1129FF 3 Connect multimeter (1) according to *WH58.30-Z-1001-09A

connection diagram 4 Start engine 5 Check charge indictor when engine idling and In case of correct charging voltage, no when engine speed increased (up to 3000 fault message is shown in the display of the rpm) instrument cluster. 6 Check regulation voltage BE15.40-P-1001-02G Load battery (G1) by means of a permanent consumer. If the regulation voltage is > 14.7 V, the alternator (G2) should be replaced. Refer to: Remove and install alternator Engine 122 AR15.40-P-5032FB Engines 134, 135 AR15.40-P-5032FF Engine 639 AR15.40-P-5032FG If the regulation voltage is < 13.0 V: 1. Remove transition resistors at the electrical connections of the charging system and check regulation voltage again. 2. If the regulation voltage is still below < 13.0 V, the alternator (G2) must be replaced. See: Remove and install alternator Engine 122 AR15.40-P-5032FB Engines 134, 135 AR15.40-P-5032FF Engine 639 AR15.40-P-5032FG 7 Turn off engine 8 Disconnect multimeter (1) WH58.30-Z-1001-09A

9 Close engine hood Test values of regulator Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.40-p-5010ff, Check regulation voltage of alternator ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0

GF15.40-P-9999FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1106 · Applies to: 453 · AR: GF15.40-P-9999FF, GF15.40-P-2000FF, GF15.40-P-0999FF

Overview of system components, on-board electrical system power supply 22.2.06 ENGINE 122.9, 134.9, 135.9 in MODEL 454.0 Component description for the alternator GF15.40-P-2000FF Table of contents for the function description, GF15.40-P-0999FF on-board electrical system power supply Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf15.40-p-9999ff, Overview of system components, on-board electrical system power supply ENGINE 122.9, 134.9, 135.9 in MODEL 454.0

AR15.40-P-5009FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1107 · Applies to: 453 · AR: AR15.40-P-5009FF, AR15.40-P-5012FF, AP13.22-P-1351FF

Preconditions for alternator test 14.2.12 ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0 Check

Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by escaping AS54.10-Z-0001-01A

oxyhydrogen gas. Risk of injury Wear acid-resistant gloves and clothing and caused by caustic burns to eyes, skin and mucous safety glasses with side guards. membranes from battery electrolyte (contains Do not place any conductive objects on the diluted sulfuric acid) or metal spatter due to battery and avoid any short circuit from short circuit. Risk of burn injuries battery positive to ground. caused by short circuit. Risk of poisoning caused by Only fill liquid battery electrolyte (diluted swallowing battery electrolyte (contains sulfuric acid) into suitable and appropriately diluted sulfuric acid) or absorption of lead over marked containers. the skin or orifices Notes on battery AH54.10-P-0001-01A 1 Test alternator prefuse AR15.40-P-5012FF 2 Check ground strap between engine and body for tight seating and proper condition 3 Check that the electric leads of the battery are secured tightly and are in a proper condition 4.1 Check that the alternator electrical leads are On engines 134.9, 135.9, 639.9 fitted correctly and in proper condition 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. 5 Lift vehicle on lifting platform. 6.1 Check that the alternator electrical leads are Engine 122.9: fitted correctly and in proper condition 7 Check that the starter electrical leads are fitted correctly and in proper condition 8 Inspect poly V-belt Inspect poly V-belt for wear and damage AP13.22-P-1351FF

9 Lower vehicle Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.40-p-5009ff, Preconditions for alternator test ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0

AR15.40-P-5032FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1108 · Applies to: 453 · AR: AR15.40-P-5032FG, AR13.21-P-3350FF, AR54.10-P-0003FF, AR01.20-P-5015FF

Remove and install generator 11.6.04 ENGINE 639.939 in MODEL 454.0 P15.40-2278-07 1 Connector 4 Bracket 7 Screw 2 Protective cover 5 Fan shroud 3 Wiring harness 6 Screw G2 Alternator Remove/Install

1 Remove guide pulley of poly V-belt AR13.21-P-3350FF 2 Disconnect battery ground cable AR54.10-P-0003FF 3 Remove trim panel of cylinder head cover AR01.20-P-5015FF 4 Unplug connector (1) 5 Remove protective cover (2) and lock Replace nut. electrical wiring harness (3) to generator (G2) *BA15.40-P-1001-01L

6 Unscrew bolts (4), remove shift bracket and place to the side. 7 Disconnect wiring harness (3) at the fan shroud (5). 8 Unscrew bolt (6) Replace bolt (6). *BA15.40-P-1002-01L

9 Remove bolt (7) Replace bolt (7). *BA15.40-P-1002-01L

10 Take out generator (G2) 11 Install in the reverse order Alternator

Number Designation Engine 639.939 BA15.40-P-1001-01L Cable to generator circuit B+ Nm 15 BA15.40-P-1002-01L Bolt of generator to bracket Nm 40 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.40-p-5032fg, Remove and install generator ENGINE 639.939 in MODEL 454.0

AR15.40-P-5032SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1109 · Applies to: 453 · AR: AR15.40-P-5032SR, AR54.10-P-0003SR, AR13.22-P-1202SR, AR01.00-P-3050SR

Remove/install alternator 23.07.2014 ENGINE 281 in MODEL 453 P15.40-2642-09 1 Electrical connection 3 Screw/bolt 2 Nut G2 Alternator Remove/install

1 Disconnect ground line of battery AR54.10-P-0003SR 2 Remove poly-V belt AR13.22-P-1202SR 3 Lower rear drive module AR01.00-P-3050SR 4 Disconnect electrical connection (1) at the alternator (G2)
5 Unscrew nut (2) and remove electrical line *BA15.40-P-1002-01G Electrical line at alternator, terminal B+ from alternator (G2)
6 Remove screws/bolts (3)
7 Remove alternator (G2) 8 Install in the reverse order Alternator Number Designation ENGINE 281 BA15.40-P-1002-01G Electrical line at alternator, terminal B+ Nm 21 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.40-p-5032sr, Remove/install alternator ENGINE 281 in MODEL 453

GF15.40-P-0999FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1110 · Applies to: 453 · AR: GF15.40-P-0999FF, GF15.40-P-0001FF, GF15.40-P-9999FF

Table of contents for function description, on-board electrical system power 22.2.06 supply ENGINE 122.9, 134.9, 135.9 in MODEL 454.0 Power supply from the on-board electrical GF15.40-P-0001FF system, function Power supply from the on-board electrical GF15.40-P-0001-02FF system, location of components Overview of system components, on-board GF15.40-P-9999FF electrical system power supply Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf15.40-p-0999ff, Table of contents for function description, on-board electrical system power supply ENGINE 122.9, 134.9, 135.9 in MODEL 454.0

AR15.40-P-5012FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1111 · Applies to: 453 · AR: AR15.40-P-5012FF, AR15.40-P-5010FF

Test backup fuse of alternator 19.11.04 ENGINE 122, 134, 135, 639 in MODEL 454 Shown on engine 135 1 Cover F32fBatt1 Prefuse batt1 F32fBatt2 Prefuse batt2 G1 Battery P15.40-2292-11 Check

1 Fold open cover (1) 2 Check prefuse batt1 (F32fBatt1) and prefuse Replace faulty prefuse for batt1 batt2 (F32fbatt2) by visual inspection (F32fbatt1) or faulty prefuse for batt2 (F32fbatt2). 3 Close cover (1) 4.1 Test regulating voltage of alternator Only with prefuse batt1 (F32fbatt1) or prefuse AR15.40-P-5010FF batt2 (F32fbatt2) replaced. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.40-p-5012ff, Test backup fuse of alternator ENGINE 122, 134, 135, 639 in MODEL 454

AR15.60-P-2711FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1112 · Applies to: 453 · AR: AR15.60-P-2711FF, AR09.10-P-1150FF, AP20.00-P-2010FF

Remove/install coolant temperature sensor 4.6.03 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Connector 2 Connector B11/4 Coolant temperature sensor P15.60-2015-04 Remove/Install

Risk of injury Do not open cooling system unless coolant Danger! to skin and eyes caused by AS20.00-Z-0001-01A

scalding from contact with hot coolant spray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage bottles. Wear protective gloves, protective clothing and eye protection. Notes on coolant AH20.00-N-2080-01A

1 Remove air filter housing AR09.10-P-1150FF 2 Disconnect connector (1, 2) 3 Unscrew coolant temperature sensor (B11/4) Collect exuded coolant in a suitable vessel. Installation:

Coat the thread of the coolant temperature sensor (B11/4) with sealing compound. *454589050900

Loctite 262 *BR00.45-Z-1059-02A 4 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns during Do not grasp hot or rotating parts. starting procedure or when working near engine 5 Conduct an engine test run and check the cooling system in the area of the coolant temperature sensor (B11/4) for leaks 6 Check coolant level, adjust to correct level if necessary. Engine cooling system - check fluid level, AP20.00-P-2010FF

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration 7 Read fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A 454 589 05 09 00 Socket Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.60-p-2711ff, Remove/install coolant temperature sensor ENGINE 134.9, 135.9 in MODEL 454.0

AR15.60-P-2711SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1114 · Applies to: 453 · AR: AR15.60-P-2711SR, AR20.00-P-1142SR

Remove/install coolant temperature sensor 11.08.2014 ENGINE 281 in MODEL 453 P15.60-2050-09 Shown on engine 281.920 1 Electrical connector 3 Connection fitting B11/4 Coolant temperature sensor 2 Retaining clamp 4 Air intake hose Risk of injury Do not open cooling system unless coolant Danger ! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

Remove/install

1 Remove maintenance flap 2 Screw cap onto expansion reservoir by half a turn, relieve overpressure then unscrew cap 3 Remove covering over engine Installation: Only install covering over

engine after the leak test. 4 Remove air intake hose (4) 5 Disconnect electrical connection (1) on coolant temperature sensor (B11/4) 6 Pull out retaining clamp (2) 7 Pull coolant temperature sensor (B11/4) out Catch coolant with suitable container. of the connection fitting (3) Installation: Replace seal.

8 Install in the reverse order 9 Pour in coolant and bleed cooling system AR20.00-P-1142SR 10 Connect diagnostic unit, read out fault memory When replacing the coolant temperature sensor (B11/4). AD00.00-P-2000-06SR

Check

Risk of accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar15.60-p-2711sr, Remove/install coolant temperature sensor ENGINE 281 in MODEL 453

AP18.00-P-1811MS

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1122 · Applies to: 453 · AR: AP18.00-P-1811MS

Check engine oil level using on-board oil dipstick 04.06.2019 Engine 132, 281, 660 Shown on model 453 4 Oil dipstick 4a max. 4b min. 5 Oil measuring pipe P18.00-2402-01 Risk of accident Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. Risk of injury Wear protective gloves, protective clothing Caution to skin and eyes due to AS18.00-Z-0001-01A

handling of engine oil. Risk of poisoning and safety glasses.

caused by swallowing engine oil Do not fill engine oil into beverage containers. Preparatory activity 1 Run engine to warm it up. Coolant temperature at least 80 °C.

2 Switch off engine. 3 Remove interior flap above engine. Model 451, 453 Model 451 AR88.40-P-1100-03MCC

Check

4 Remove oil dipstick (4) from oil dipstick tube (5) and wipe off with lint-free cloth. 5 Check engine oil level using oil dipstick (4).

Always insert oil dipstick (4) into oil dipstick tube (5) up to end stop. Damage can otherwise occur. Insert oil dipstick (4) into oil dipstick

tube (5) up to end stop and hold in for a duration of at least 3 s. The level must at least be in the center

between the Min. (4b) and Max. (4a) marking on the oil dipstick (4). Engine 132, 660 The oil filling capacity between Min. (4b) and Max. (4a) is approx. 0.7 l. Engine 281.910 The oil filling capacity between Min. (4b) and Max. (4a) is approx. 1.1 l. Engine 281.920 The oil filling capacity between Min. (4b) and Max. (4a) is approx. 0.9 l. If the engine oil level is too high or too low, correct it 6 Correct engine oil level. Authorized engine oils (service) BB00.40-P-0226A

Service Information: Engine oil change Engine 132, 660 in model 451 SI18.00-P-0011A

Engine 281 in model 453 Service Information: Engine oil change Engine 660 in model 450 SI18.00-P-0011B

Check engine oil level again after

correcting it. To do so, repeat operation steps_4_and_5. If the engine oil level is too low, Refill engine oil until the level is at least in the center between the Min. (4b) and Max. (4a) marking on the oil dipstick (4). If the engine oil level is too high, Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap18.00-p-1811ms, Check engine oil level using on-board oil dipstick Engine 132, 281, 660

AR18.00-P-1250SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1124 · Applies to: 453 · AR: AR18.00-P-1250SR, AR18.40-P-4132SR, AR15.40-P-5032SR

Check oil pressure 29.11.2016 Engine 281 in model 453 Modification notes 24.11.2016 Check values integrated. Operation step 7 P18.00-2400-09 S41/2 Oil pressure switch Risk of accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. Check

1 Remove oil pressure switch (S41/2) AR18.40-P-4132SR 2 Screw adapter into threaded hole for oil 450589132100 Oil pressure tester pressure switch (S412)
3 Attach oil pressure testing device to adapter 450589132100 Oil pressure tester 4 Check engine oil level In case of a complaint Correct engine oil level. Multigrade engine oils (specification 229.5) BB00.40-P-0229-05A

Low SPAsh multigrade service engine oils BB00.40-P-0229-31A

(specification 229.31) 5 Install alternator AR15.40-P-5032SR Allow the engine to be lowered.

6 Warm-up the engine until a coolant temperature of about 80 °C is reached 7 Check oil pressure Check values for oil pressure *BE18.00-P-1001-01SR 8 Turn off engine
9 Remove alternator AR15.40-P-5032SR Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.00-p-1250sr, Check oil pressure Engine 281 in model 453

Detach oil pressure testing device from

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1125 · Applies to: 453 · AR: AR18.40-P-4132SR

10 Detach oil pressure testing device from adapter 11 Remove adapter from the threaded hole for the oil pressure switch (S41/2) 12 Install oil pressure switch (S41/2) AR18.40-P-4132SR Check values for oil pressure Number Designation Engine 281 BE18.00-P-1001-01SR Check values for oil pressure Test temperature °C 80 (coolant) Rpm for oil 1/min 1000...3900 pressure 1 Oil pressure 1 bar 1,7...2,5 Rpm for oil 1/min

4000 pressure 2 Oil pressure 2 bar 3,5...4,5 450 589 13 21 00 Oil pressure tester Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.00-p-1250sr, Check oil pressure Engine 281 in model 453

AR18.00-P-1250FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1126 · Applies to: 453 · AR: AR18.00-P-1250FF, AR18.40-P-4132FF, AR18.40-P-4132FB

Checking oil pressure 21.11.05 ENGINES 122.9, 134.9, 135.9, 639.9 in MODEL 454.0 Illustrated on removed engine 135.9 1 Oil pressure checking device S41/1 Oil pressure switch P18.00-2194-06 Checking

Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A

toppling off the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 1 Raise vehicle. 2 Remove the oil pressure switch (S41/1) Engines 134.9, 135.9 AR18.40-P-4132FF Engine 122.9 AR18.40-P-4132FB Engine 639.9 AR18.40-P-4132-01FF *452589020900

3 Attach oil pressure testing device (1) with Screw on the oil pressure checking device adapter instead of the oil pressure switch (S41/1). The adapter for connecting up the oil pressure testing device (1) is contained in the oil pressure testing device (1) case. *450589132100

4 Route oil pressure testing device (1) upwards Route oil pressure testing device (1) in into the engine compartment such a way that on lowering the vehicle and on starting the engine the oil pressure testing device (1) will not be damaged. *450589132100

5 Lower vehicle 6 Start the engine and bring to the operating temperature of about 80°C then switch off engine 7 Check engine oil level approx. 5 minutes after The vehicle must be positioned switching off the engine; adjust to correct level horizontally on the wheels, otherwise incorrect if required measurements occur. Multigrade engine oils (Sheet 229.1) Sheet 229.1 BB00.40-P-0229-01A

8 Pull out oil dipstick and introduce temperature Set length of the temperature sensor sensor for temperature measuring device according to the length of the oil dipstick. through the oil dipstick guide tube *450589082100

9 Start engine and allow to idle 10 Raise vehicle. Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.00-p-1250ff, Checking oil pressure ENGINES 122.9, 134.9, 135.9, 639.9 in MODEL 454.0

Read off oil pressure of the engine at

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1127 · Applies to: 453 · AR: AR18.30-P-6840FG, AR18.30-P-6840FF, AR18.40-P-4132FF, AR18.40-P-4132FB, AR18.40-P-4132FH (+1 more)

11 Read off oil pressure of the engine at *BE18.00-P-1002-01E operating temperature when idling at the oil pressure testing device (1)

BE18.00-P-1002-01F 450589082100

*450589132100

12.1 Increase engine speed to 3500 rpm and read On engines 122.9 and 639.9 BE18.00-P-1003-01E off oil pressure of the engine at operating temperature at the oil pressure testing device (1) BE18.00-P-1003-01F *450589082100

*450589132100

13 Pull temperature sensor for temperature measuring device out of the oil dipstick guide tube and introduce oil dipstick through the oil dipstick guide tube *450589082100

14 Raise vehicle. 15 Lead oil pressure testing device downwards 450589132100 out of the engine compartment 16 Disconnect oil pressure testing device (1) and 450589132100

remove adapter 17.1 Remove oil-water heat exchanger Engine 639.9: It is only through removing the oil-water heat exchanger that correct tightening down of the oil pressure switch (S41/1) is possible. Engine 639.9 with code (LHD) for left-hand AR18.30-P-6840FG drive vehicle Engine 639.9 with code (LHD) for right-hand AR18.30-P-6840FF drive vehicle 18 Install oil pressure switch (S41/1) Engines 134.9, 135.9 AR18.40-P-4132FF Engine 122.9 AR18.40-P-4132FB Engine 639.9 with code (LHD) for left-hand AR18.40-P-4132FH drive vehicle Engine 639.9 with code (LHD) for right-hand AR18.40-P-4132FG drive vehicle Check values for oil pressure Number Designation Engine Engine Engine 122 134 135 0.29 1.65 1.5 BE18.00-P-1002-01E Oil pressure engine at operating temperature and bar idling BE18.00-P-1003-01E Oil pressure at engine operating temperature and bar 2.94 to - - 3500 rpm 6.86 Check values for oil pressure Number Designation Engine 639 BE18.00-P-1002-01F Oil pressure engine at operating temperature and bar 0.4 to 0.8 idling BE18.00-P-1003-01F Oil pressure at engine operating temperature and bar 5.5 to 6.5 3500 rpm Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.00-p-1250ff, Checking oil pressure ENGINES 122.9, 134.9, 135.9, 639.9 in MODEL 454.0

AP18.00-P-0101FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1129 · Applies to: 453 · AR: AP18.00-P-0101FF

Engine oil and filter change 10.5.12 ENGINES 134, 135 in MODEL 454.0 P18.00-2129-08 Shown on engine 135.9 1 Oil filler neck cap 2 Drain screw 3 Oil filter Remove 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. Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not touch hot or rotating parts. engine as it is running Risk of injury Danger! to skin and eyes caused by Wear safety gloves, protective clothing and AS00.00-Z-0002-01A

handling hot or glowing objects. safety glasses, if necessary. Notes on avoiding damage through AH00.00-P-5000-01A

contamination and foreign objects 1 Allow engine to warm up until coolant and engine oil have reached operating temperature 2 Open engine hood 3 Raise vehicle with vehicle lift 4 Unscrew the oil filter (3) Collect engine oil in a suitable container. 454589060900 Socket wrench bit 5 Remove drain screw (2) and drain engine oil In order to drain all of the engine oil, the vehicle must be horizontal and the drain bore must be left open for at least 5 min. Any quantity of oil remaining in the engine will result in an excess amount of oil being recorded after filling with the specified oil change quantity, which in turn may result in damage to the engine and the catalytic converter. Collect engine oil in a suitable container. Install 6 Screw in drain plug (2). Replace sealing ring. BA01.45-P-1003-01L 7 Install oil filter (3) Wet sealing ring of oil filter (3) with engine oil. BF18.00-P-1001-01P 454589060900 Socket wrench bit 8 Pour in engine oil Use only approved engine oils. Service Information: Engine oil change * Not for USA, Japan SI18.00-P-0011B

*BF18.00-P-1001-01P

9 Conduct engine test run and check engine for Do not increase engine rpm until 10 leaks seconds after starting the engine. Engine damage may occur otherwise. Page 1 of 3 © Mercedes-Benz AG, 5/20/18, L/07/20, ap18.00-p-0101ff, Engine oil and filter change ENGINES 134, 135 in MODEL 454.0

Turn off engine

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1130 · Applies to: 453 · AR: AP00.20-P-0042FF

10 Turn off engine 11 Check engine oil level with the oil dipstick Insert oil dipstick up to the end stop in the approx. 5 minutes after switching off the guide tube and maintain length of stay of a engine which is at operating temperature, least 3 s. correct if necessary 12 Close engine hood 13 Reset service indicator AP00.20-P-0042FF Oil pan

Number Designation Engine Engine Engine Engine 134.910 134.911 135.930 135.950 BA01.45-P-1003-01L Oil drain screw to oil pan Nm 39 39 39 39 Filling capacities of engine lubrication system

Number Designation Engine 134.910/911 BF18.00-P-1001-01P Engine oil Capacity Liters 3.2 (oil and filter change) Filling capacity Liters - (following removal of oil pan) Filling capacity Liters - (initial filling) Specifications for Operating Sheet BB00.40-P-0229-01A Fluids Sheet - Sheet - Sheet - Sheet - Sheet - Sheet - Filling capacities of engine lubrication system

Number Designation Engine 135.930/950 BF18.00-P-1001-01P Engine oil Capacity Liters 4.2 (oil and filter change) Filling capacity Liters - (following removal of oil pan) Filling capacity Liters - (initial filling) Specifications for Operating Sheet BB00.40-P-0229-01A Fluids Sheet - Page 2 of 3 © Mercedes-Benz AG, 5/20/18, L/07/20, ap18.00-p-0101ff, Engine oil and filter change ENGINES 134, 135 in MODEL 454.0

AP18.00-P-0101FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1132 · Applies to: 453 · AR: AP18.00-P-0101FG, AP00.20-P-0042FF

Engine oil and filter change 10.5.12 ENGINES 639.9 in MODEL 454.0 1 Oil filler neck cap 2 Drain screw 3 Oil filter P18.00-2149-04 Remove 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. Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not touch hot or rotating parts. engine as it is running Risk of injury Danger! to skin and eyes caused by Wear safety gloves, protective clothing and AS00.00-Z-0002-01A

handling hot or glowing objects. safety glasses, if necessary. Notes on avoiding damage through AH00.00-P-5000-01A

contamination and foreign objects 1 Allow engine to warm up until coolant and engine oil have reached operating temperature 2 Open engine hood 3 Raise vehicle with vehicle lift 4 Unscrew the oil filter (3) Collect engine oil in a suitable container. 454589100900 Socket wrench bit 5 Remove drain screw (2) and drain engine oil In order to drain all of the engine oil, the vehicle must be horizontal and the drain bore must be left open for at least 5 min. Any quantity of oil remaining in the engine will result in an excess amount of oil being recorded after filling with the specified oil change quantity, which in turn may result in damage to the engine and the catalytic converter. Collect engine oil in a suitable container. Install 6 Screw in drain plug (2). Replace sealing ring. BA01.45-P-1004-01P 7 Install oil filter (3) Wet sealing ring of oil filter (3) with engine oil. *BA18.20-P-1001-01S

*454589100900 Socket wrench bit 8 Pour in engine oil Use only approved engine oils. Service Information: Engine oil change * Not for USA, Japan SI18.00-P-0011B

*BF18.00-P-1001-01P

9 Conduct engine test run and check engine for Do not increase engine rpm until leaks 10 seconds after starting the engine. Engine damage may occur otherwise. 10 Turn off engine 11 Check engine oil level with the oil dipstick Insert oil dipstick up to the end stop in the approx. 5 minutes after switching off the guide tube and maintain length of stay of a engine which is at operating temperature, least 3 s. correct if necessary 12 Close engine hood 13 Reset service indicator AP00.20-P-0042FF Oil pan

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap18.00-p-0101fg, Engine oil and filter change ENGINES 639.9 in MODEL 454.0

Risk of accident

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1135 · Applies to: 453 · AR: AP18.00-P-1811MS

Warning from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Topical note Notes on engine oil and filter changes AH18.00-P-0104-01A Remove

1 Run engine to warm it up. Coolant temperature at least 80 °C.

2 Remove interior flap above engine. 3 Lift vehicle with lifting platform. 4 Unscrew drain screw (15) and drain engine oil. 5 Loosen oil filter screw cap (1). Loosen the oil filter screw cap (1) far

enough to enable the engine oil to drain out of the oil filter and oil filter housing. 6 Unscrew oil filter screw cap (1) and remove. Install

7 Engage new oil filter element (2) directly into

oil filter housing. Make sure that the new oil filter element (2) directly engages in the oil filter housing and not in the oil filter screw cap (1). Damage can otherwise occur. Arresting noise is audible.

8 Replace sealing ring (3) and moisten with engine oil. 9 Screw in oil filter screw cap (1). BA18.20-P-1001-01SN Threaded cap to oil filter housing 10 Replace sealing ring of drain screw (15). 11 Screw in drain screw (15). BA01.45-P-1003-01J Oil drain screw to oil pan 12 Lower vehicle with vehicle lift. 13 Add engine oil.

Use only approved engine oils. Engine damage can occur otherwise. *BF18.00-P-1001-01SN Engine oil Check

14 Run engine until warm and check for leak Coolant temperature at least 80 °C.

tightness. If fluid loss is detected, determine cause and correct. After obtaining special order.

15 Switch off engine. 16 Pull oil dipstick (4) out of oil dipstick tube (5) and wipe using a lint-free cloth. 17 Check engine oil level using oil dipstick (4); AP18.00-P-1811MS correct if necessary. Insert oil dipstick (4) into the oil-dipstick

guide tube (5) until the end stop and hold in for a duration of at least 3 seconds. The engine oil level must at least be in the

center between the Min. and Max. markings on the oil dipstick (4). The oil filling capacity between Min. and Max. is approx. 1.1 l. Install

18 Install interior flap above engine. Oil pan Number Designation Engine 281 BA01.45-P-1003-01J Oil drain screw to oil pan Nm 50 Oil filter Number Designation Engine 281.910 BA18.20-P-1001-01SN Threaded cap to oil filter housing Seal oiled Nm 25 Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ap18.00-p-0101s, Engine oil and oil filter change Engine 281.910 in model 453

AR18.00-P-0025MCC

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1137 · Applies to: 453 · AR: AR18.00-P-0025MCC

Measure oil consumption 18.2.09 ENGINE 160, 660 in MODEL 450 ENGINE 132, 660 in MODEL 451 ENGINE 160 in MODEL 452 ENGINE 122, 134, 135, 639 in MODEL 454 Checking

1 Check engine for oil loss, rectify oil loss if required 2 Check part-load vent lines for signs of leaks, rectify leak if required 3 Check air lines for signs of leaks, rectify leak if necessary 4 Park vehicle horizontally For example on wheel alignment system. 5 Start engine 6 Switch off engine after reaching coolant temperature of 80 °C and wait for 5 minutes 7 Clean oil dipstick and insert into oil dipstick guide tube 8 Pull oil dipstick after approx. 1 min. out of oil The engine oil level must not exceed the dipstick guide tube max. mark on the oil dipstick. 9 Use a suitable scriber to mark the oil dipstick This serves to record the current engine oil level with the engine at operating temperature. 10 After a driven distance of roughly 1000 km, Steps 1 to 9. check the engine oil level again To correctly measure the oil consumption, a driven distance of roughly 1000 km should lie between the individual measurements. 11 Top up engine oil in steps of 100 ml to the The measurement and refilling of the mark made on the oil dipstick engine oil should be done in the presence of the customer. 12 Calculate oil consumption Calculate actual oil consumption: V 1000 S V = Differential quantity in liters s = measured distance covered in km The oil consumption limit for smart engines over 1000 km is 0.8 liters. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.00-p-0025mcc, Measure oil consumption ENGINE 160, 660 in MODEL 450 ENGINE 132, 660 in MODEL 451 ENGINE 160 in MODEL 452 ENGINE 122, 134, 135, 639 in MODEL 454

AR18.00-P-0025SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1138 · Applies to: 453 · AR: AR18.00-P-0025SR

Measure oil consumption 21.11.2014 ENGINE 281 in MODEL 453 4 Oil dipstick 5 Guide tube P18.00-2396-06 Risk of death Danger ! caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. Risk of injury. 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 accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. Check

1 Remove covering over engine 2 Raise vehicle with vehicle lift 3 Check engine externally from above and If there are problems: below for oil loss Eliminate leaks prior to oil consumption measurement. 4 Lower vehicle with vehicle lift and place horizontally
5 Start engine and bring to operating temperature 6 Stop engine after reaching a coolant temperature of 80°C and wait for 5 minutes
7 Pull oil dipstick (4) out of guide tube (5) and clean it. 8 Insert oil dipstick (4) into guide tube (5) 9 Pull oil dipstick (4) after about 1 minute out of The engine oil level must not exceed the

the guide tube (5)
MAX mark on the oil dipstick (4). 10 Mark the oil level on the oil dipstick (4) with a suitable scriber
11 Install covering over engine 12 Determine the engine oil level again after a Repeat operation steps 1 to 9. driving distance of about 1000 km
13 Pour in engine oil in steps of 100 ml up to the Perform measurement and top up with

applied marking on the oil dipstick (4)
engine oil in the presence of the customer. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.00-p-0025sr, Measure oil consumption ENGINE 281 in MODEL 453

AP18.00-P-1849UB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1140 · Applies to: 453 · AR: AP18.00-P-1849UB

Overview of service intervals for gasoline engines depending on engine oil 01.02.2016 specification Engine 111, 112, 113, 132, 133, 137, 152, 156, 157, 159, 177, 178, 266, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 281, 285 Engine 112, 113, 157, 273, 279 in model 463 Service Information: Engine oil change Model 117, 156, model 164.1## #A as of SI18.00-P-0011A 193232, model 164.8## #A as of 192868, model 166, model 169.### #J as of 386540, model 171.### #F as of 149734, model 172, 176, 190, 197, model 203.### #R as of 251655, model 203.0## #A as of 938312, model 203.2## #F as of 885750, model 203.7## #A as of 944805, model 204, 205, 207, model 209.3## #F as of 216791, model 209.4## #T as of 078925, model 211.### #B as of 081230, model 212, 213, model 216.###

A as of 002778, model 217, 218, model

219.### #A as of 097557, model 221.### #A as of 104927, model 222, model 230.### #F as of 129725, model 231, model 240.### #A as of 001837, model 242, model 245.### #J as of 169768, model 246, model 251.0## #A as of 046500, model 251.1## #A as of 046570, model 253, 292, model 451, 453, model 463 with engine 113, 157, 273, 279 Service Information: Engine oil change Model 129, model 163, model 164.1## #A up SI18.00-P-0011B to 193231, model 164.8## #A up to 192867, model 169.### #J up to 386539, model 170, model 171.### #F up to 149733, model 203.### #R up to 251654, model 203.0## #A up to 938311, model 203.2## #F up to 885749, model 203.7## #A up to 944804, model 208, model 209.3## #F up to 216790, model 209.4## #T up to 078924, model 210, model 211.### #A, model 215, model 216.###

A up to 002777, model 219.### #A up to

097556, model 220, model 221.### #A up to 104926, model 230.### #F up to 129724, model 240.### #A up to 001836, model 245.### #J up to 169767, model 251.0## #A up to 046499, model 251.1## #A up to 046569, model 463 with engine 112 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap18.00-p-1849ub, Overview of service intervals for gasoline engines depending on engine oil specification Engine 111, 112, 113, 132, 133, 137, 152, 156, 157, 159, 177, 178, 266, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 281, 285 Engine 112, 113, 157, 273, 279 in model 463

AP18.00-P-1849UBU

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1141 · Applies to: 453 · AR: AP18.00-P-1849UBU

Overview of service intervals for gasoline engines depending on engine oil 01.02.2016 specification Engine 111, 112, 113, 132, 133, 137, 152, 156, 157, 159, 177, 178, 266, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 281, 285 Engine 112, 113, 157, 273, 279 in model 463 Service Information: Engine oil change Model 117, 156, model 164.1## #A as of SI18.00-P-0011A 193232, model 164.8## #A as of 192868, model 166, model 169.### #J as of 386540, model 171.### #F as of 149734, model 172, 176, 190, 197, model 203.### #R as of 251655, model 203.0## #A as of 938312, model 203.2## #F as of 885750, model 203.7## #A as of 944805, model 204, 205, 207, model 209.3## #F as of 216791, model 209.4## #T as of 078925, model 211.### #B as of 081230, model 212, 213, model 216.###

A as of 002778, model 217, 218, model

219.### #A as of 097557, model 221.### #A as of 104927, model 222, model 230.### #F as of 129725, model 231, model 240.### #A as of 001837, model 242, model 245.### #J as of 169768, model 246, model 251.0## #A as of 046500, model 251.1## #A as of 046570, model 253, 292, model 451, 453, model 463 with engine 113, 157, 273, 279 Service Information: Engine oil change Model 129, model 163, model 164.1## #A up SI18.00-P-0011B to 193231, model 164.8## #A up to 192867, model 169.### #J up to 386539, model 170, model 171.### #F up to 149733, model 203.### #R up to 251654, model 203.0## #A up to 938311, model 203.2## #F up to 885749, model 203.7## #A up to 944804, model 208, model 209.3## #F up to 216790, model 209.4## #T up to 078924, model 210, model 211.### #A, model 215, model 216.###

A up to 002777, model 219.### #A up to

097556, model 220, model 221.### #A up to 104926, model 230.### #F up to 129724, model 240.### #A up to 001836, model 245.### #J up to 169767, model 251.0## #A up to 046499, model 251.1## #A up to 046569, model 463 with engine 112
Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap18.00-p-1849ubu, Overview of service intervals for gasoline engines depending on engine oil specification Engine 111, 112, 113, 132, 133, 137, 152, 156, 157, 159, 177, 178, 266, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 281, 285 Engine 112, 113, 157, 273, 279 in model 463

AR18.00-P-4000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1142 · Applies to: 453 · AR: AR18.00-P-4000SR, AR01.40-P-8410SR

Remove/install oil spray nozzles (pistons) 19.08.2014 ENGINE 281 in MODEL 453 P18.00-2383-09 Shown on cylinder 2 1 Oil spray nozzle 3 Crankshaft 2 Screw/bolt 4 Crankcase upper part Remove

1 Remove crankcase lower section AR01.40-P-8410SR 2 Turn crankshaft (3) until the respective oil spray nozzle (1) is accessible. 3 Remove screw/bolts (2) 4 Detach oil spray nozzle (1) from the crankcase upper section (4) Check

5 Check oil spray nozzles (1) for passage,

deformation and other damage The respective oil spray nozzle (1) must not be damaged, bent or clogged. The piston crown will not be adequately cooled from below otherwise which can lead to heat damage on the piston or a piston clamp. If there are problems: Replace affected oil spray nozzle (1). Install

6 Push oil spray nozzles (1) into the bores of the crankcase upper part (4) 7 Screw in screw/bolts (2) *BA18.00-P-1001-01J Bolt, oil spray nozzle to crankcase 8 Install crankcase lower section AR01.40-P-8410SR Oil spray nozzle Number Designation ENGINE 281 BA18.00-P-1001-01J Bolt, oil spray nozzle to crankcase Nm 10 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.00-p-4000sr, Remove/install oil spray nozzles (pistons) ENGINE 281 in MODEL 453

BE18.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1160 · Applies to: 453 · AR: BE18.00-Z-9999CZ

Test and adjustment values: Smart: Engine lubrication, engine oil cooling 18.09.2019 MODEL all Oil pressure ENGINE 122, 132, 134, 135, 160 BE18.00-P-1000-01E Oil pressure ENGINE 639, 660 BE18.00-P-1000-01F Oil pressure Engine 281 in model 453 BE18.00-P-1000-01SR Engine oil change MODEL 452 BE18.00-P-1000-06AA Engine oil change ENGINE 122.950, 134, 135, 639.939 in BE18.00-P-1000-06AB MODEL 454 Engine oil change MODEL 451 ... BE18.00-P-1000-06P Engine oil change ENGINE 660 in MODEL 450 DPF ENGINE BE18.00-P-1000-06Z 160 in MODEL 450 except diesel particulate filter Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be18.00-z-9999cz, Test and adjustment values: Smart: Engine lubrication, engine oil cooling MODEL all

AR18.10-P-2000FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1162 · Applies to: 453 · AR: AR18.10-P-2000FG, AR05.10-P-8127FG, AR05.10-P-8484FG

Remove, install the tensioning device of the oil pump chain 4.10.04 ENGINE 639.939 in MODEL 454.0 P18.10-2129-07 1 Chain tensioner of oil pump chain 2 Bolts 3 Belt pulley Remove/install

1 Remove the tensioning rail AR05.10-P-8127FG When removing the tensioning rail, the TDC marking on the belt pulley (3) is adjusted with respect to the positioning edge of the timing case cover (arrow A). The crankshaft must not be twisted any more. 2 Remove sliding rail from timing case cover AR05.10-P-8484FG 3 Press the chain tensioner of the oil pump chain (1) all the way to the stop and secure with a drift having Ø 3.5 mm through the bore (arrow B) 4 Unscrew bolts (2) and remove the chain *BA05.10-P-1001-01M

tensioner of the oil pump chain (1) 5 Install in the reverse order Timing chain drive

Number Designation Engine 639.939 BA05.10-P-1001-01M Bolt of the chain tensioner of the oil pump Nm 8.4 chain to the crankcase Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.10-p-2000fg, Remove, install the tensioning device of the oil pump chain ENGINE 639.939 in MODEL 454.0

AR18.10-P-6021SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1163 · Applies to: 453 · AR: AR18.10-P-6021SR, AR01.45-P-7500SR

Remove/install oil pressure control valve on oil pump 23.07.2014 ENGINE 281 in MODEL 453 P18.10-2219-09 1 Clamp 3 Seal 6 Oil pump 2.1 Electrical connector 4 Crankcase lower section Y130 Engine oil pump valve 2.2 Electrical connector 5 Screw/bolt Remove/install

1 Remove oil pan AR01.45-P-7500SR 2 Disconnect electrical connector (2.1) from electrical connector (2.2) 3 Unclip clamp (1) from electrical connector (2.2) 4 Remove electrical clutch (2.2) from the lower Installation: Install new seal (3).

part crankcase (4) 5 Remove screw/bolt (5) 6 Pull engine oil pump valve (Y130) out of the oil pump (6) 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar18.10-p-6021sr, Remove/install oil pressure control valve on oil pump ENGINE 281 in MODEL 453

AR18.10-P-6020SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1164 · Applies to: 453 · AR: AR18.10-P-6020SR, AR18.10-P-4020SR, AR18.10-P-6021SR

Remove/install oil pump 23.07.2014 ENGINE 281 in MODEL 453 P18.10-2214-09 Shown on engine 281.910 1 Oil pump 4 Screw/bolt 7 Oil pump chain 2 Oil suction pipe 5 Screw/bolt Y130 Engine oil pump valve 3 Screw/bolt 6 Bracket Remove/install

1 Remove oil suction pipe (2) AR18.10-P-4020SR 2 Disconnect electrical connection for engine AR18.10-P-6021SR oil pump valve (Y130) and remove from crankcase 3 Remove screw/bolt (3) 4 Unfasten screw/bolt (4) and turn holder (6) to the side 5 Remove screw/bolts (5) *BA18.10-P-1003-01G Bolt, oil pump to crankcase 6 Remove oil pump chain (7) from oil pump gear and remove oil pump (1) 7 Install in the reverse order Oil pump Number Designation ENGINE 281 BA18.10-P-1003-01G Bolt, oil pump to crankcase Initial tightening Nm 25 torque Retightening torque Nm 25 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.10-p-6020sr, Remove/install oil pump ENGINE 281 in MODEL 453

AR18.10-P-4020SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1165 · Applies to: 453 · AR: AR18.10-P-4020SR, AR01.45-P-7500SR

Remove/install oil suction pipe 23.07.2014 ENGINE 281 in MODEL 453 P18.10-2220-09 Shown on engine 281.920 1 Oil suction pipe 3 Screw/bolt 5 Screw/bolt 2 Screw/bolt 4 Oil strainer 6 Seal Remove

1 Remove oil pan AR01.45-P-7500SR 2 Remove screw/bolt (2) 3 Remove screws/bolts (3) 4 Remove oil suction pipe (1) from oil pump Clean

5 Clean oil strainer (4) on oil suction pipe (1) When reusing the oil suction pipe (1). Install

6 Replace seal (6). When reusing the oil suction pipe (1). 7 Loosen screw/bolts (5) 8 Lay oil suction pipe (1) on oil pump and *BA18.10-P-1005-01G Bolt, oil suction pipe to oil pump tighten down with screw/bolts (3) 9 Screw in screw/bolt (2) to stop 10 Tighten screws/bolts (2, 5) 11 Install oil pan AR01.45-P-7500SR Oil pump Number Designation ENGINE 281 BA18.10-P-1005-01G Bolt, oil suction pipe to oil pump Nm 25 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.10-p-4020sr, Remove/install oil suction pipe ENGINE 281 in MODEL 453

AR18.10-P-2141SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1166 · Applies to: 453 · AR: AR18.10-P-2141SR, AR05.10-P-7602SR, AR18.10-P-6020SR

Remove/install the oil pump drive 23.07.2014 ENGINE 281 in MODEL 453 P18.10-2215-09 1 Oil pump chain 3 Tensioning rail 5 Oil pump 2 Crankshaft gear 4 Compression spring Remove/install

1 Remove timing chain AR05.10-P-7602SR 2 Remove oil pump (5) AR18.10-P-6020SR 3 Installation: Pay attention to the correct Remove tensioning rail (3) with compression

spring (4) from crankcase seat of the compression spring (4) in tensioning rail (3) and crankcase. Check tensioning rail (3) for wear, galling and damage. If there are problems: Replace tensioning rail (3). 4 Remove oil pump chain (1) from crankshaft Installation: Check oil pump chain (1) for

gear (2) wear and damage. If there are problems: Replace oil pump chain (1), oil pump (5) and crankshaft gear (2). 5 Remove crankshaft gear (2) from crankshaft
Installation: Check crankshaft gear (2) for

wear and damage. If there are problems: Replace oil pump chain (1), oil pump (5) and crankshaft gear (2). 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.10-p-2141sr, Remove/install the oil pump drive ENGINE 281 in MODEL 453

AR18.10-P-6020FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1167 · Applies to: 453 · AR: AR18.10-P-6020FG, AR03.30-P-1700FG, AR01.45-P-7500FH

Removing/installing the oil pump 4.2.09 ENGINE 639.939 in MODEL 454.0 P18.10-2131-09 1 Transmission oil pump 4 Chain tensioner for oil pump chain 7 Bolt 2 Belt pulley 5 Bolts 8 Bolts 3 Screw plug 6 Cover 9 Bracket Remove

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

toppling off the lifting platform. hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. 1 Raise vehicle. 2 Position the piston of cylinder 1 to TDC by The belt pulley (2) is accessible over the rotating at the belt pulley (2). service flap in the right fender liner. The TDC marking on the belt pulley (2) must be aligned with the positioning edge on the timing case cover (arrow A). 3 Remove belt pulley (2) AR03.30-P-1700FG 4 Remove oil pan AR01.45-P-7500FH 5 Unscrew screw plug (3) on timing case cover 6 Press the chain tensioner for the oil pump chain (4) all the way to the stop and secure with a drift having a diameter of 3.5 mm through the bore (arrow B) 7 Unscrew screws (5) and remove cover (6) 8 Remove bolts (7) 9 Unscrew bolts (8), take off the oil pump (1) Do not turn the crankshaft. with the bracket (9) from the oil pump chain and remove 10.1 Remove bracket (9) from the oil pump (1) Only when replacing the oil pump (1). Installing

11.1 Clean strainer of oil pump (1) Only when reusing the old oil pump (1). 12.1 Mount bracket (9) on the oil pump (1) Only when replacing the oil pump (1). *BA18.10-P-1006-01L

13 Engage drive wheel for oil pump (1) in the oil Fill the oil pump (1) with engine oil before

pump chain installing so that it pumps engine oil immediately when the engine is started for the first time. Replace sealing ring on oil pump (1). 14 Firmly mount oil pump (1) on bracket (9) using *BA18.10-P-1001-01L

bolts (7, 8) *BA18.10-P-1004-01L

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.10-p-6020fg, Removing/installing the oil pump ENGINE 639.939 in MODEL 454.0

Pull drift of 3.5 mm diameter out of the bore

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1168 · Applies to: 453 · AR: AR03.20-P-3637FG, AR01.45-P-7500FH, AR03.30-P-1700FG

15 Pull drift of 3.5 mm diameter out of the bore (arrow B) and activate chain tensioner for oil pump chain (4) 16 Inspect basic position of the balancing shaft AR03.20-P-3637FG 17 Firmly mount cover (6) with bolts (5) *BA18.10-P-1002-01L

18 Firmly tighten screw plug (3) on timing case Replace screw plug (3). cover *BA01.30-P-1004-01R

19 Installing oil pan AR01.45-P-7500FH 20 Install belt pulley (2) AR03.30-P-1700FG 21 Lower vehicle Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 22 Conduct engine test run and check the engine for leaks Cylinder head Number Designation Engine 639.939 BA01.30-P-1004-01R Screw plug, large on timing case cover Nm 70 Oil pump Number Designation Engine 639.939 BA18.10-P-1001-01L Bolt for oil pump on crankcase Nm 14 BA18.10-P-1002-01L Bolt for cover to oil pump Nm 11 BA18.10-P-1004-01L Bolt for oil pump bracket on crankcase Nm 8 BA18.10-P-1006-01L Bolt for bracket on oil pump Nm 10 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.10-p-6020fg, Removing/installing the oil pump ENGINE 639.939 in MODEL 454.0

AR18.10-P-2140FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1169 · Applies to: 453 · AR: AR18.10-P-2140FG, AR05.10-P-8484FG, AR18.10-P-6020FG, AR03.20-P-3638FG

Replace oil pump chain 9.9.04 ENGINE 639.939 in MODEL 454.0 1 Oil pump chain 2 Chain tensioner of oil pump chain 3 Belt pulley 4 Balance shaft P18.10-2128-06 Remove/install

1 Remove sliding rail from timing case cover AR05.10-P-8484FG When removing the slide rail, the TDC marking on the belt pulley (3) is adjusted with respect to the positioning edge of the timing case cover (arrow A). The crankshaft must not be twisted any more. 2 Press the chain tensioner of the oil pump chain (2) all the way to the stop and secure with a drift having Ø 3.5 mm through the bore (arrow B) 3 Remove oil pump AR18.10-P-6020FG 4 Remove the oil pump chain (1) Do not twist the crankshaft. Installation: When placing the oil pump

chain (1), pay attention to the basic position of the balance shaft (4). Refer to: Set the basic position of the balance shaft AR03.20-P-3638FG 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.10-p-2140fg, Replace oil pump chain ENGINE 639.939 in MODEL 454.0

AR18.10-P-2130FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1170 · Applies to: 453 · AR: AR18.10-P-2130FG, AR05.10-P-8484FG, AR05.10-P-8127FG, AR18.10-P-6020FG

Replace tensioning rail and slide rails for oil pump chain 4.10.04 ENGINE 639.939 in MODEL 454.0 1 Slide rail 2 Tensioning rail 3 Slide rail 4 Belt pulley 5 Chain tensioner of oil pump chain 6 Timing case cover P18.10-2130-06 Remove/install

1 Remove sliding rail from timing case cover AR05.10-P-8484FG When removing the slide rail, the TDC marking on the belt pulley (4) is adjusted with respect to the positioning edge of the timing case cover (arrow A). The crankshaft must not be twisted any more. 2 Remove the tensioning rail AR05.10-P-8127FG 3 Remove the slide rail (1) in the timing case Installation: Note the installation position

cover (6) from the bearing pins of the slide rail (1). 4 Press the chain tensioner of the oil pump chain (5) all the way to the stop and secure with a drift having Ø 3.5 mm through the bore (arrow B) 5 Remove oil pump AR18.10-P-6020FG 6 Remove the tensioning rail (2) from the Twist the balance shaft if necessary. bearing pins 7 Remove the slide rail (3) from the bearing pins Twist the balance shaft if necessary. 8 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.10-p-2130fg, Replace tensioning rail and slide rails for oil pump chain ENGINE 639.939 in MODEL 454.0

AR18.30-P-6840FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1171 · Applies to: 453 · AR: AR18.30-P-6840FF, AP20.00-P-2010FG

Remove/install oil-water heat exchanger 29.6.04 ENGINE 639.939 in MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle 1 Oil-water heat exchanger 2 Oil filter 3 Coolant hose 4 Screw P18.30-2077-06 Remove/Install

Risk of death Danger! cased by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A toppling off of the lifting platform. hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. 1 Raise vehicle. 2 Unscrew oil filter (2) Collect oil which flows out in a suitable vessel. Installation:

replace oil filter (2) and cover oil filter seal (2) with engine oil. *BA18.20-P-1001-01S

3 Unclamp coolant hoses (3) using appropriate Collect coolant which flows out in a hose clamps and dismantle at oil-water heat suitable vessel. exchanger (1) 4 Remove bolts (4) *BA18.30-P-1001-02B

5 Remove oil-water heat exchanger (1) Installation:

replace seal for oil-water heat exchanger (1). 6 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 7 Perform engine test run and check for leaks at oil water heat exchanger (1) 8 Check engine oil level by means of oil dipstick Fill level must be between "Min" and "Max", otherwise engine damage could occur. Let engine run for approx. 1 minute, then switch off and wait approx. 5 minutes. Test fill level again and correct if required. 9 Check coolant level, correct if necessary Engine cooling system - inspect fluid level, AP20.00-P-2010FG

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration Oil filter

Number Designation Motor 639.939 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.30-p-6840ff, Remove/install oil-water heat exchanger ENGINE 639.939 in MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle

AR18.30-P-6840FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1173 · Applies to: 453 · AR: AR18.30-P-6840FG, AP20.00-P-2010FG

Remove/install oil-water heat exchanger 20.9.04 ENGINE 639.939 in MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle 1 Oil/water heat exchanger 2 Oil filter 3 Coolant hose 4 Bolts P18.30-2082-06 Remove/Install

Risk of injury Do not open cooling system unless coolant Danger! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolant spray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage bottles. Wear protective gloves, protective clothing and eye protection. Risk of death Danger! cased by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A toppling off of the lifting platform. hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. 1 Raise vehicle. 2 Unscrew oil filter (2) Collect oil which flows out in a suitable vessel. Installation:

Replace the oil filter (2) and cover the oil filter seal (2) with engine oil. *BA18.20-P-1001-01S

3 Unclamp coolant hoses (3) using appropriate Collect coolant which flows out in a hose clamps and dismantle at oil-water heat suitable vessel. exchanger (1) 4 Remove bolts (4) *BA18.30-P-1001-02B

5 Remove oil-water heat exchanger (1) Installation:

replace seal for oil-water heat exchanger (1). 6 Install in the reverse order 7 Check engine oil level by means of oil dipstick Fill level must lie between the markings, 'Min' and 'Max'; otherwise, engine damage may occur. Let engine run for approx. 1 minute, then switch off and wait approx. 5 minutes. Test fill level again and correct if required. Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 8 Perform engine test run and check for leaks at oil water heat exchanger (1) 9 Check coolant level, adjust to correct level if necessary. Engine cooling system - inspect fluid level, AP20.00-P-2010FG

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.30-p-6840fg, Remove/install oil-water heat exchanger ENGINE 639.939 in MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle

AR18.30-P-6840SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1175 · Applies to: 453 · AR: AR18.30-P-6840SR, AR01.00-P-3050SR, AR20.00-P-1142SR

Remove/install oil-water heat exchanger 23.07.2014 ENGINE 281.910 in MODEL 453 1 Screw/bolt 2 Screw/bolt 3 Screw/bolt 4 Screw/bolt 5 Engine oil heat exchanger 6 Coolant hoses 7 Crankcase 8 Seal P18.30-2172-06 Risk of injury Do not open cooling system unless coolant Danger ! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

Remove/install

1 Lower engine AR01.00-P-3050SR 2 Drain coolant AR20.00-P-1142SR 3 Remove coolant hoses (6) on engine oil heat Installation: Replace clamps.

exchanger (5) *003589033700 Hose clamp pliers 4 Remove screw/bolts (1 to 4) on engine oil Installation: Lay engine oil heat

heat exchanger (5) exchanger (5) with screw/bolts (1 to 4) evenly on the crankcase (7) then tighten down screw/ bolts (1 to 4) according to the numerical sequence. *BA18.30-P-1001-02B Engine oil heat exchanger at crankcase 5 Remove engine oil heat exchanger (5) from Catch coolant with suitable container.

crankcase (7) Installation: Replace seals (8) on

crankcase (7). 6 Install in the reverse order Check

Risk of accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. 7 Perform an engine test run and check engine around the engine oil heat exchanger (5) for leaktightness
8 Check engine oil level AP18.00-P-0101S

Engine oil heat exchanger Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar18.30-p-6840sr, Remove/install oil-water heat exchanger ENGINE 281.910 in MODEL 453

AR18.40-P-3510FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1177 · Applies to: 453 · AR: AR18.40-P-3510FF

Remove/install dipstick guide tube 19.11.03 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Bolt 2 Oil dipstick guide tube 3 Dipstick P18.40-2131-05 Remove/Install

1 Pull out oil dipstick (3) 2 Unscrew bolt (1) *BA01.45-P-1002-01L

3 Pull out oil dipstick guide tube (2) upward Installation: Replace sealing ring at oil dipstick guide tube (2). 4 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns during Do not grasp hot or rotating parts. starting procedure or when working near engine 5 Conduct engine test run and engine around the oil dipstick guide tube (2) for leaks 6 Check engine oil level, correct if necessary Oil pan

Number Designation Engine Engine 134.910 134.911 BA01.45-P-1002-01L Torx bolt of oil dipstick guide tube to cylinder Nm 8 8 head Oil pan

Number Designation Engine Engine 135.930 135.950 BA01.45-P-1002-01L Torx bolt of oil dipstick guide tube to cylinder Nm 8 8 head Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.40-p-3510ff, Remove/install dipstick guide tube ENGINE 134.9, 135.9 in MODEL 454.0

AR18.40-P-3510FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1178 · Applies to: 453 · AR: AR18.40-P-3510FG, AR01.45-P-7500FH

Remove/install oil dipstick guide tube 17.1.06 ENGINE 639.9 in MODEL 454.0 P18.40-2249-09 1 Dipstick 4 Bolt 7 Hose 5 Cover 8 Clip 2 Drift punch

6 Clip 9 Hose clamp 3 Oil dipstick guide tube

Remove

1 Open engine hood 2 Remove oil dipstick (1). 3 Remove cover (5) at oil dipstick guide tube (3) The cover (5) consists of two parts, which are interconnected by five clip connections. 4 Unscrew bolt (4) and remove clamp (6) 5 Loosen clamp (8) and pull out hose (7) at oil dipstick guide tube (3) 6 Remove oil pan AR01.45-P-7500FH 7 Knock oil dipstick guide tube (3) up and out of the crankcase using a suitable block and hammer 8 Lower the vehicle and remove the oil dipstick guide tube (3) from the top of the engine compartment Install

9 Insert the oil dipstick guide tube (3) into the crankcase and align so that the clamp (6) and the hose (7) can be installed without tension 10 Attach the drift punch (2) to the oil dipstick *454589051500

guide tube (3) and secure with a hose clamp (9) to the lower area of the oil dipstick guide tube (3) 11 Carefully knock in the oil dipstick guide tube *454589051500

(3) 12 Loosen the hose clamp (9) and remove the *454589051500

drift punch (2) 13 Push hose (7) onto oil dipstick guide tube (3) Replace clamp (8). and secure with a clamp (8) 14 Install cover (5) at oil dipstick guide tube (3) The cover (5) consists of two parts, which are interconnected by five clip connections. 15 Position the hose (6) at the oil dipstick guide tube (3), insert the bolt (4) and tighten 16 Raise vehicle. 17 Installing oil pan AR01.45-P-7500FH Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.40-p-3510fg, Remove/install oil dipstick guide tube ENGINE 639.9 in MODEL 454.0

AR18.40-P-4132FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1180 · Applies to: 453 · AR: AR18.40-P-4132FF, AR61.20-P-1105FF

Remove/install oil pressure switch 5.12.03 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.950 1 Connector S41/1 Oil pressure switch P18.40-2127-04 Remove/Install

1 Detach lower engine compartment paneling AR61.20-P-1105FF 2 Release plug (1) with suitable tool and unplug 3 Unscrew oil pressure switch (S41/1) and Do not tilt the socket, otherwise the oil remove pressure switch (S41/1) can be damaged. Installation:

Attach the oil pressure switch (S41/1) by hand, screw in and then carefully tighten with the socket, otherwise the oil pressure switch (S41/1) can be damaged. *452589020900

*BA18.40-P-1001-01K

4 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns during Do not grasp hot or rotating parts. starting procedure or when working near engine 5 Carry out engine test run and check oil pressure (S41/1) switch for leaks 6 Check engine oil level, correct as required. 7 Read fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system *WH58.30-Z-1048-13A Oil level/oil pressure sensor

Number Designation Engine Engine Engine Engine 134.911 134.910 135.930 135.950 BA18.40-P-1001-01K Oil pressure switch to crankcase Nm 10 10 10 10 452 589 02 09 00 Socket 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, 5/20/18, L/07/20, ar18.40-p-4132ff, Remove/install oil pressure switch ENGINE 134.9, 135.9 in MODEL 454.0

AR18.40-P-4132FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1181 · Applies to: 453 · AR: AR18.40-P-4132FG, AR18.30-P-6840FF

Remove/install oil pressure switch 1.7.04 ENGINE 639.939 in MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle 1 Oil-water heat exchanger 2 Connector S41/1 Engine oil pressure switch P18.40-2171-06 Remove/Install

1 Remove oil-water heat exchanger (1) AR18.30-P-6840FF 2 Unlock plug (2) and disconnect. 3 Unscrew oil pressure switch (S41/1) Installation:

Install new gasket *452589020900

*BA18.40-P-1001-01K

4 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 5 S41/1Carry out engine test run and check oil pressure switch for leaks 6 Read out fault memory and erase Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory Diagnosis system STAR DIAGNOSIS Oil level/oil pressure sensor

Number Designation Engine 639.939 BA18.40-P-1001-01K Oil pressure switch to crankcase Nm 15 452 589 02 09 00 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.40-p-4132fg, Remove/install oil pressure switch ENGINE 639.939 in MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle

AR18.40-P-4132FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1183 · Applies to: 453 · AR: AR18.40-P-4132FH, AR18.30-P-6840FG

Remove/install oil pressure switch 20.9.04 ENGINE 639.939 in MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle 1 Oil/water heat exchanger 2 Connector S41/1 Oil pressure switch P18.40-2184-06 Remove/Install

1 Remove oil/water heat exchanger (1) AR18.30-P-6840FG 2 Unlock plug (2) and unplug 3 Unscrew oil pressure switch (S41/1) Installation:

Install new gasket *452589020900

*BA18.40-P-1001-01K

4 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 5 S41/1rry out engine test run and check oil pressure switch for leaks 6 Read out fault memory and erase Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Oil level/oil pressure sensor

Number Designation Engine 639.939 BA18.40-P-1001-01K Oil pressure switch to crankcase Nm 15 452 589 02 09 00 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.40-p-4132fh, Remove/install oil pressure switch ENGINE 639.939 in MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle

AR18.40-P-4132SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1185 · Applies to: 453 · AR: AR18.40-P-4132SR, AR15.40-P-5032SR

Remove/install oil pressure switch 19.08.2014 ENGINE 281 in MODEL 453 P18.40-2450-09 1 Electrical connection 2 Seal S41/2 Oil pressure switch Remove/install

1 Remove alternator AR15.40-P-5032SR 2 Disconnect electrical connection (1) at oil pressure switch (S41/2) 3 Remove oil pressure switch (S41/2) from the Installation: Install new seal (2).

crankcase *BA18.40-P-1003-01G Oil pressure switch to crankcase 4 Install in the reverse order Oil level sensor, oil pressure switch Number Designation ENGINE 281 BA18.40-P-1003-01G Oil pressure switch to crankcase Nm 21 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.40-p-4132sr, Remove/install oil pressure switch ENGINE 281 in MODEL 453

SI18.40-P-0002A

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1186 · Applies to: 453 · AR: AP18.00-P-1811MP, AP18.00-P-1811MS

Service Information: Oil dipstick 25.07.2019 Engine 111, 112, 113, 132, 133, 152, 156, 157, 177, 178, 266, 270, 271, 272, 273, 274, 276.8/9, 278, 279, 281, 607, 611, 612, 626, 628, 629, 640, 642, 646, 651, 660 We would hereby like to inform you that the document contents in Always insert oil dipstick into oil dipstick tube up to end stop. documents AP18.00-P-1811MP and AP18.00-P-1811MS have been Damage can otherwise occur. adapted with regard to handling the oil dipstick. Check engine oil level using on-board oil Engine 111, 112, 113, 133, 152, 156, 157, AP18.00-P-1811MP dipstick 177, 178, 266, 270, 271, 272, 273, 274, 276.8/9, 278, 279, 607, 611, 612, 626, 628, 629, 640, 642, 646, 651 Engine 132, 281, 660 AP18.00-P-1811MS Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, si18.40-p-0002a, Service Information: Oil dipstick Engine 111, 112, 113, 132, 133, 152, 156, 157, 177, 178, 266, 270, 271, 272, 273, 274, 276.8/9, 278, 279, 281, 607, 611, 612, 626, 628, 629, 640, 642, 646, 651, 660

AR20.00-P-1142FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1192 · Applies to: 453 · AR: AR20.00-P-1142FF, AR61.20-P-1105FF

Drain/fill in coolant 5.8.11 ENGINES 122.9, 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Cooling system cap 2 Radiator 3 Drain plug on radiator 4 Expansion reservoir 5 Engine drain plug 6 Filling device

7 Adapter

P20.00-2219-06 Drain Risk of injury to skin and eyes caused by Do not open cooling system unless coolant AS20.00-Z-0001-01A Danger!

scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant caused by swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A 1 Turn the cooling system cap (1) on the radiator (2) half a revolution in counterclockwise direction, release pressure relief, then unscrew cooling system cap (1). 2 Remove lower engine compartment paneling AR61.20-P-1105FF 3 Unscrew radiator drain plug (3) on radiator (2) Catch coolant in a suitable vessel. and drain coolant 4 Unscrew engine drain plug (5) on the Catch coolant in a suitable vessel. crankcase and drain coolant Filling 5.1 Tighten engine drain plug (5) with new gasket On engines 134.9 and 135.9 on crankcase *BA01.40-P-1001-01O

5.2 Coat engine drain plug (5) with sealing On engine 122.9 compound and screw onto crankcase *BA01.40-P-1001-01U

*454589050900

Loctite 262 BR00.45-Z-1059-02A 6 Tighten radiator drain plug (3) on radiator (2) 7 Install lower engine compartment paneling. AR61.20-P-1105FF 8 Connect filling device (6) with adapter (7) to Observe instruction manual from filling the radiator (2), evacuate and then fill the device (6) manufacturer. cooling system BF20.00-P-1001-02T

*450589206300

*454589009100

9 Screw cooling system cap (1) onto the radiator (2) Checking

Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.00-p-1142ff, Drain/fill in coolant ENGINES 122.9, 134.9, 135.9 in MODEL 454.0

Risk of accident

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1193 · Applies to: 453 · AR: AP20.00-P-2010FF

Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not touch hot or rotating parts. engine as it is running 10 Carry out engine test run 11 Check coolant level in radiator (2) and in the expansion reservoir (4) and correct if necessary Engine cooling system - check fluid level, AP20.00-P-2010FF

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration Cylinder crankcase, timing case cover, end cover

Number Designation Engine Engine 134.911 134.910 BA01.40-P-1001-01O Coolant drain plug to crankcase Nm 25 25 Cylinder crankcase, timing case cover, end cover

Number Designation Engine Engine 135.930 135.950 BA01.40-P-1001-01O Coolant drain plug to crankcase Nm 25 25 Cylinder crankcase, timing case cover, end cover

Number Designation Engine 122.9 BA01.40-P-1001-01U Coolant drain plug to crankcase Nm 40 Cooling system

Number Designation Engine Engine Engine 122.950 134.910/911 135.930/950 BF20.00-P-1001-02T Cooling system Total filling capacity Liters 6.0 4,2 4.6 Filling capacity of anticorrosion/ Liters 3,0 2,1 2,3 antifreeze down to -37 °C Filling capacity of anticorrosion/ Liters 3,3 2,3 2,5 antifreeze down to -45°C Sheet BB00.40-P-0325-00A BB00.40-P-0325-00A BB00.40-P-0325-00A Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.00-p-1142ff, Drain/fill in coolant ENGINES 122.9, 134.9, 135.9 in MODEL 454.0

AR20.00-P-1142SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1195 · Applies to: 453 · AR: AR20.00-P-1142SR

Drain/pour in coolant 11.04.2017 Engine 281 in model 453 Modification notes 27.03.2017 Basic date for filling capacity incorporated. Operation steps 14, 19 1 Expansion reservoir 2 Cap 3 Cap 4 Breather hose P20.00-2516-06 Shown with engine 281.910 12 Coolant hose 13 Coolant line 14 Coolant hose 15 Coolant line P20.00-2532-11 Page 1 of 5 © Mercedes-Benz AG, 5/22/18, L/07/20, ar20.00-p-1142sr, Drain/pour in coolant Engine 281 in model 453

Hose clamp pliers

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1198 · Applies to: 453 · AR: AR20.00-P-1010SR

*003589033700 Hose clamp pliers 12 Attach coolant hose (12) to coolant line (13) Engine 281.910 in model 453 Replace clamp.

*003589033700 Hose clamp pliers 13 Unscrew cap (3) from breather hose (4) 14 Fill cooling system via expansion reservoir (1)
The coolant level in the expansion

reservoir (1) must be at the upper marking. *BF20.00-P-1001-06SR Cooling system 15 Remove vent screw (10) by approx. 2 Wait until the coolant flows out from the

revolutions connection fitting (11). 16 Unscrew cap (17) from breather connection Engine 281.910 in model 453 (16) Wait until the coolant flows out from the

breather connection (16). 17 Tighten vent screw (10). 18 Screw on cap (17) Engine 281.910 in model 453 19 Correct coolant level in expansion reservoir (1) The coolant level in the expansion

reservoir (1) must be at the upper marking. *BF20.00-P-1001-06SR Cooling system 20 Seal expansion reservoir (1) with the cap (2)
21 Screw cap (3) onto breather hose (4) securely 22 Allow the engine to warm up until the cooler fan motor has switched on and then turn off 23.1 Repeat the venting process until there in no Engine 281.920 in model 453 further air coming out of the connection fitting (11)

The venting process (operation steps 3 and 13 to 22) must be repeated at least once. Otherwise it can lead to damage to the engine. 23.2 Repeat the venting process until there in no Engine 281.910 in model 453 further air coming out of the connection fitting (11) and the breather connection (16)

The venting process (operation steps 3 and 13 to 22) must be repeated at least once. Otherwise it can lead to damage to the engine. Check

24 Check cooling system for leak tightness AR20.00-P-1010SR Install

25 Install underfloor paneling 26 Install cover over engine 27 Install maintenance flap Cooling system Number Designation Engine 281 in Engine 281 in model model 453.041/042/043 453.341/342/343/44 2/443 7,2 6,9 BF20.00-P-1001-06SR Cooling system Filling capacity l Antifreeze/water to -37 °C % 50/50 50/50 as from -38 °C % 55/45 55/45 Specifications for service BB00.40-P-0310-01A BB00.40-P-0310-01 products A Sheet BB00.40-P-0325-00A BB00.40-P-0325-00 A Cooling system Number Designation Engine 281 in Engine 281 in model model 453.044/053/062 453.344/353/362/44 4/453/462 10,9 10,5 BF20.00-P-1001-06SR Cooling system Filling capacity l Antifreeze/water to -37 °C % 50/50 50/50 as from -38 °C % 55/45 55/45 Specifications for service BB00.40-P-0310-01A BB00.40-P-0310-01 products A Page 4 of 5 © Mercedes-Benz AG, 5/22/18, L/07/20, ar20.00-p-1142sr, Drain/pour in coolant Engine 281 in model 453

AR20.00-P-1142FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1200 · Applies to: 453 · AR: AR20.00-P-1142FG, AR61.20-P-1105FF, AP20.00-P-2010FG

Draining/filling with coolant 5.8.11 ENGINE 639.939 in MODEL 454.0 1 Cap 2 Expansion reservoir 3 Filling device

4 Adapter

5 Drain plug 6 Radiator P20.00-2236-06 Modification notes 3.2.05 Filling capacity for cooling system altered *BF20.00-P-1001-02T Draining Risk of injury Do not open cooling system unless coolant Danger! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage bottles. Wear protective gloves, protective clothing and eye protection. Notes on coolant AH20.00-N-2080-01A 1 Open engine hood See Operator's Manual 2 Unscrew the cap (1) on the expansion Rotate one revolution counterclockwise, reservoir (2) drain overpressure, then unscrew cap of cooling system (1). 3 Remove lower engine compartment paneling AR61.20-P-1105FF 4 Unscrew drain plug (5) at radiator (6) and Collect coolant drain coolant Filling 5 Screw tight drain plug (5) at radiator (6) 6 Install lower engine compartment paneling. AR61.20-P-1105FF 7 Connect filling device (3) with adapter (4) to Observe instruction manual from filling expansion reservoir (2), evacuate cooling device (3) manufacturer. system and then fill *BF20.00-P-1001-02T

*454589039100

*450589206300

8 Screw cap (1) onto expansion reservoir (2) Checking

Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 9 Carry out engine test run Until the cooling fan is switched on. 10 Check coolant level, adjust to correct level if necessary. Engine cooling system - inspect fluid level, AP20.00-P-2010FG

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.00-p-1142fg, Draining/filling with coolant ENGINE 639.939 in MODEL 454.0

AP20.00-P-2010FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1202 · Applies to: 453 · AR: AP20.00-P-2010FF, AP20.00-P-2080FF, AR20.00-P-1010FF

Engine cooling system - check fluid level, adjust to correct level. Inspect 5.8.11 anticorrosion/antifreeze protection, adjust to correct concentration ENGINE 122.9, 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Radiator system cap 2 Radiator 3 Expansion reservoir P20.30-2191-04 Modification notes 27.9.05 Note on leaktightness test added Step 4 Check

Risk of injury Do not open cooling system unless coolant Danger! to skin and eyes caused by AS20.00-Z-0001-01A

scalding from contact with hot coolant spray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

1 Open engine hood 2 Turn the cooling system cap (1) on the engine radiator (2) a half turn counterclockwise, relieve the pressure and then unscrew the cooling system cap (1) 3 Check anticorrosion/antifreeze in the coolant *450589012100

If the mixing ratio is incorrect, correct the coolant composition. Refer to: Correct the antifreeze - subject to separate repair order. Replace coolant AP20.00-P-2080FF 4 Check coolant level, adjust to correct level if *BF20.00-P-1001-02T

necessary. Only use approved anticorrosion/ antifreeze agents. The coolant in the radiator (2) must be up to

the overflow and be between the "LOW" and "FULL" marks in the expansion reservoir (3). If more than 0.4 l of coolant have to be added for reasons of coolant loss, the cooling system should be checked for leaks. Refer to: Inspect cooling system for leaks AR20.00-P-1010FF

5 Screw cooling system cap (1) onto the radiator (2) Cooling system

Number Designation Engine Engine 122.950 134.910/911 BF20.00-P-1001-02T Cooling system Total capacity Liters 6.0 4.2 Filling capacity of anticorrosion/ Liters 3,0 2,1 antifreeze down to -37 °C Filling capacity of anticorrosion/ Liters 3,3 2,3 antifreeze down to -45 °C Page 1 of 2 © Mercedes-Benz AG, 5/20/18, L/07/20, ap20.00-p-2010ff, Engine cooling system - check fluid level, adjust to correct level. Inspect anticorrosion/antifreeze protection, adjust to ... ENGINE 122.9, 134.9, 135.9 in MODEL 454.0

AP20.00-P-2010FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1204 · Applies to: 453 · AR: AP20.00-P-2010FG, AP20.00-P-2080FG, AR20.00-P-1010FG

Engine cooling system - check fluid level, adjust to correct level. Inspect 5.8.11 anticorrosion/antifreeze protection, adjust to correct concentration ENGINE 639.9 in MODEL 454.0 1 Cap 2 Expansion reservoir P20.00-2237-04 Modification notes 27.9.05 Note on leaktightness test added Step 4 Check

Risk of injury Do not open cooling system unless coolant Danger! to skin and eyes caused by AS20.00-Z-0001-01A

scalding from contact with hot coolant spray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

1 Open engine hood 2 Turn the cooling system cap (1) on the

engine radiator (2) a half turn counterclockwise, relieve the pressure and then unscrew the cooling system cap (1) 3 Check anticorrosion/antifreeze in the coolant *450589012100

If the mixing ratio is incorrect, correct the coolant composition. Refer to: Correct the antifreeze - subject to separate repair order. Replace coolant AP20.00-P-2080FG 4 Check coolant level, adjust to correct level if *BF20.00-P-1001-02T

necessary. Only use approved anticorrosion/ antifreeze agents. The coolant in the expansion reservoir (2) must be between the "LOW" and "FULL" markings. If more than 0.4 l of coolant have to be added for reasons of coolant loss, the cooling system should be checked for leaks. Refer to: Inspect cooling system for leaks AR20.00-P-1010FG

5 Screw the cap (1) onto the expansion reservoir (2) Cooling system

Number Designation Engine 639.939 BF20.00-P-1001-02T Cooling system Total capacity Liters 6,6 Filling capacity of anticorrosion/ Liters 3,3 antifreeze down to -37 °C Filling capacity of anticorrosion/ Liters 3,6 antifreeze down to -45 °C Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap20.00-p-2010fg, Engine cooling system - check fluid level, adjust to correct level. Inspect anticorrosion/antifreeze protection, adjust to ... ENGINE 639.9 in MODEL 454.0

AR20.00-P-1010FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1206 · Applies to: 453 · AR: AR20.00-P-1010FF

Inspect cooling system for leaks 5.8.11 ENGINE 122.9, 134.9, 135.9 in MODEL 454.0 Shown on engine 134.9 1 Cooling system cap 2 Adapter card

3 Pressure pump P20.00-2304-11 Checking

Risk of injury Do not open cooling system unless coolant Danger! to skin and eyes caused by AS20.00-Z-0001-01A

scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A 1 Open engine hood 2 Turn the cooling system cap (1) on the radiator half a revolution in counterclockwise direction, release pressure relief, then unscrew cooling system cap (1). 3 Check coolant level, adjust to correct level if The coolant in the radiator must be filled

necessary. up to the overflow and must lie between the markings "LOW" and "FULL" in the expansion tank . Only use approved anticorrosion/antifreeze agents. *BF20.00-P-1001-02T

4 Connect pressure pump (3) with adapter card *450589072100

(2) to radiator *454589009100

5 Pressurize cooling system The test pressure must not exceed 1.4 bar. If a new cylinder head gasket is fitted, first of all warm up engine to operating temperature before testing cooling system for leaks. 6 Check coolant hoses and heater hoses and If necessary, retighten the hose clamps or their connecting points for condition and replace the coolant and heater hoses or hose coolant loss clamps. 7 Disconnect the pressure pump (3) with *450589072100

adapter card (2) from the radiator *454589009100

8 Screw cooling system cap (1) onto the radiator Cooling system

Number Designation Engine Engine 122.950 134.910/911 BF20.00-P-1001-02T Cooling system Total filling capacity Liters 6.0 4.2 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.00-p-1010ff, Inspect cooling system for leaks ENGINE 122.9, 134.9, 135.9 in MODEL 454.0

AR20.00-P-1010FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1208 · Applies to: 453 · AR: AR20.00-P-1010FG, AP20.00-P-2010FG

Inspect cooling system for leaks 1.6.04 ENGINE 639.939 in MODEL 454.0 1 Cap 2 Expansion reservoir P20.00-2238-04 Check

Risk of injury to skin and eyes suffering Do not open cooling system unless coolant AS20.00-Z-0001-01A Danger!

scalding from contact with hot coolant spray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage bottles. Wear protective gloves, protective clothing and eye protection. Notes on coolant AH20.00-N-2080-01A 1 Open engine hood See Operating Instructions 2 Unscrew the cap (1) of the expansion Turn once in the anti-clockwise direction, reservoir (2) release the excess pressure and then unscrew the cap (1). 3 Check coolant level, adjust to correct level if necessary. Engine cooling system - inspect fluid level, AP20.00-P-2010FG

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration 4 Connect a pressure pump with an adapter at Use the adapter from the brake fluid the expansion reservoir (2) replacement unit. *450589072100

WE58.40-Z-1001-07A 5 Pressurize cooling system The test overpressure must not be greater than 1.4 bar. If new cylinder head gasket fitted, first of all warm up engine to operating temperature before testing cooling system for leaks. 6 Inspect condition and connection of hose clamps, retighten or replace, if necessary 7 Check cooling and heating hoses as well as their connection points for proper condition and loss of coolant; replace coolant hoses if necessary 8 Disconnect the pressure pump with the 450589072100

adapter at the expansion reservoir (2) *WE58.40-Z-1001-07A 9 Seal the expansion reservoir (2) with the cap (1) 450 589 07 21 00 Pressure pump Workshop equipment Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.00-p-1010fg, Inspect cooling system for leaks ENGINE 639.939 in MODEL 454.0

AR20.00-P-1010SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1210 · Applies to: 453 · AR: AR20.00-P-1010SR

Inspect cooling system for leaks 09.07.2019 Engine 281, 780 in model 453 1 Cap 2 Coolant expansion reservoir P20.00-2521-06 Risk of injury Do not open cooling system unless coolant Warning to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Topical note Notes on coolant AH20.00-N-2080-01A Check

1 Remove maintenance flap. 2 Turn the cap (1) on the coolant expansion reservoir (2) counter-clockwise by half a turn, bleed overpressure, and then unscrew the cap (1). 3 Check coolant level in the coolant expansion The coolant level in the coolant expansion

reservoir (2). reservoir (2) must be at the upper marking. If the coolant level is not at the top marking, Determine the cause or correct the coolant level. Coolant specifications BB00.40-P-0310-01A

Anticorrosion/antifreeze agent (specification BB00.40-P-0325-07A

325.7) Premixed coolant (specification 326.7) BB00.40-P-0326-07A

4 Attach pressure pump with adapter to the 454589019100 Adapter coolant expansion reservoir (2). 450589072100 Pressure pump 5 Check cooling system for leaks. Pressure drop in filled engine cooling system *BE20.00-P-1001-02SR If a pressure drop is detected, Determine the leakage and rectify it. 6 Remove pressure pump and adapter from coolant expansion reservoir (2). 7 Check coolant level in the coolant expansion The coolant level in the coolant expansion

reservoir (2). reservoir (2) must be at the upper marking. If the coolant level is not at the top marking, Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.00-p-1010sr, Inspect cooling system for leaks Engine 281, 780 in model 453

AP20.00-P-2080FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1212 · Applies to: 453 · AR: AP20.00-P-2080FF, AR61.20-P-1105FF

Replace coolant 5.8.11 ENGINE 122.9, 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Cooling system cap 2 Radiator 3 Drain plug on radiator 4 Expansion reservoir 5 Engine drain plug 6 Filling device

7 Adapter

P20.00-2219-06 Drain Risk of injury to skin and eyes caused by Do not open cooling system unless coolant AS20.00-Z-0001-01A Danger!

scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant caused by swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A 1 Turn the cooling system cap (1) on the radiator (2) half a revolution in counterclockwise direction, release pressure relief, then unscrew cooling system cap (1). 2 Detach lower engine compartment paneling Remove/install bottom engine compartment AR61.20-P-1105FF

paneling 3 Unscrew radiator drain plug (3) on radiator (2) Catch coolant in a suitable vessel. and drain coolant 4 Unscrew engine drain plug (5) on the Catch coolant in a suitable vessel. crankcase and drain coolant Filling 5.1 Tighten engine drain plug (5) with new gasket On engines 134.9 and 135.9 on crankcase *BA01.40-P-1001-01O

5.2 Coat engine drain plug (5) with sealing On engine 122.9 compound and screw onto crankcase *BA01.40-P-1001-01U

6 Tighten radiator drain plug (3) on radiator (2) 7 Install lower engine compartment paneling. Remove/install bottom engine compartment AR61.20-P-1105FF

paneling 8 Connect filling device (6) with adapter (7) to Observe instruction manual from filling the radiator (2), evacuate and then fill the device (6) manufacturer. cooling system *BF20.00-P-1001-02T

*450589206300

*454589009100

9 Screw cooling system cap (1) onto the radiator (2) Checking

Page 1 of 3 © Mercedes-Benz AG, 5/20/18, L/07/20, ap20.00-p-2080ff, Replace coolant ENGINE 122.9, 134.9, 135.9 in MODEL 454.0

Risk of accident

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1213 · Applies to: 453 · AR: AP20.00-P-2010FF

Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not touch hot or rotating parts. engine as it is running 10 Carry out engine test run Until the cooling fan is switched on. 11 Check coolant level in radiator (2) and in the AP20.00-P-2010FF expansion reservoir (4) and correct if necessary Cylinder crankcase, timing case cover, end cover

Number Designation Engine Engine 134.911 134.910 BA01.40-P-1001-01O Coolant drain plug to crankcase Nm 25 25 Cylinder crankcase, timing case cover, end cover

Number Designation Engine Engine 135.930 135.950 BA01.40-P-1001-01O Coolant drain plug to crankcase Nm 25 25 Cylinder crankcase, timing case cover, end cover

Number Designation Engine 122.9 BA01.40-P-1001-01U Coolant drain plug to crankcase Nm 40 Cooling system

Number Designation Engine Engine Engine 122.950 134.910/911 135.930/950 BF20.00-P-1001-02T Cooling system Total filling capacity Liters 6.0 4,2 4.6 Filling capacity of anticorrosion/ Liters 3,0 2,1 2,3 antifreeze down to -37 °C Filling capacity of anticorrosion/ Liters 3,3 2,3 2,5 antifreeze down to -45°C Sheet BB00.40-P-0325-00A BB00.40-P-0325-00A BB00.40-P-0325-00A Page 2 of 3 © Mercedes-Benz AG, 5/20/18, L/07/20, ap20.00-p-2080ff, Replace coolant ENGINE 122.9, 134.9, 135.9 in MODEL 454.0

AP20.00-P-2080FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1215 · Applies to: 453 · AR: AP20.00-P-2080FG, AR61.20-P-1105FF

Replace coolant 2.11.11 ENGINE 639.939 in MODEL 454.0 1 Cap 2 Expansion reservoir 3 Filling device

4 Adapter 5 Drain screw 6 Radiator P20.00-2236-06 Modification notes 3.2.05 Filling capacity of cooling system altered *BF20.00-P-1001-02T Drain Risk of injury to skin and eyes caused by Do not open cooling system unless coolant AS20.00-Z-0001-01A Danger!

scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant caused by swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A 1 Open engine hood See Operator's Manual 2 Unscrew the cap (1) on the expansion Turn the cap (1) counterclockwise one reservoir (2) half-turn, release the pressure, and then unscrew the cap (1). 3 Detach lower engine compartment paneling Remove/install bottom engine compartment AR61.20-P-1105FF

paneling 4 Unscrew drain plug (5) at radiator (6) and Collect coolant drain coolant Filling 5 Screw tight drain plug (5) at radiator (6) 6 Install lower engine compartment paneling. Remove/install bottom engine compartment AR61.20-P-1105FF

paneling 7 Connect filling device (3) with adapter (4) to Use the adapter (4) from the brake fluid expansion reservoir (2), evacuate cooling change device. system and then fill Observe instruction manual from filling device (3) manufacturer. *BF20.00-P-1001-02T

*450589206300

Brake fluid change unit gotis://B_42/43.2_01 8 Screw cap (1) onto expansion reservoir (2) Checking

Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not touch hot or rotating parts. engine as it is running 9 Carry out engine test run Until the cooling fan is switched on. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap20.00-p-2080fg, Replace coolant ENGINE 639.939 in MODEL 454.0

Check coolant level, adjust to correct level if

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1216 · Applies to: 453 · AR: AP20.00-P-2010FG

10 Check coolant level, adjust to correct level if AP20.00-P-2010FG necessary. Cooling system

Number Designation Engine 639.939 BF20.00-P-1001-02T Cooling system Total filling capacity Liters 6.6 Filling capacity of anticorrosion/ Liters 3.3 antifreeze down to -37 °C Filling capacity of anticorrosion/ Liters 3,6 antifreeze down to -45°C Specifications for Operating Sheet BB00.40-P-0325-00A Fluids 450 589 20 63 00 Filling device Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap20.00-p-2080fg, Replace coolant ENGINE 639.939 in MODEL 454.0

AP20.00-P-2080S

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1217 · Applies to: 453 · AR: AR20.00-P-1142SR

Replace coolant 09.06.2016 Engine 281 in model 453 Modification notes 26.09.2014 Mischungsverhältnis Kühlmittel BF20.00-P-1001-04A 1 Coolant expansion reservoir P20.00-2527-06 Risk of injury Do not open cooling system unless coolant Danger ! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

Check

1 Check coolant level in coolant expansion AP20.30-P-2050S reservoir (1) Lowering 2 Drain coolant AR20.00-P-1142SR

Filling 3 Pour in new coolant AR20.00-P-1142SR

Anticorrosion agent/antifreeze (specification BB00.40-P-0325-05A

325.5) Premixed coolant (specification 326.5) BB00.40-P-0326-05A

Ensure correct mixing ratio of the coolant.

*BF20.00-P-1001-04A Coolant mixing ratio Coolant mixing ratio Number Designation Engine all BF20.00-P-1001-04A Coolant mixing ratio Antifreeze/water Up to -37°C % 50/50 As of -38 °C % 55/45 Sheet BB00.40-P-0310-01 A Sheet BB00.40-P-0325-00 A Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ap20.00-p-2080s, Replace coolant Engine 281 in model 453

BE20.00-Z-9999CZ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1221 · Applies to: 453 · AR: BE20.00-Z-9999CZ

Test and adjustment values: Smart: Engine cooling system 17.01.2020 MODEL all Engine cooling system Engine 281, 780 in model 453 BE20.00-P-1000-02SR Check values for cooling system cap ENGINE 100, 102, 103, 104, 110, 111, 112, BE20.30-P-1000-01A 113, 114, 115, 116, 117, 119, 120, 121, 122, 123, 127, 129, 130, 132, 133, 134, 135, 137, 139, 152, 155, 156, 157, 159, 160, 166, 180, 254, 256, 260, 264, 266, 270, 271, 272, 273, 274, 275, 276, 277, 278, 279, 281, 282, 285, 601, 602, 603, 604, 605, 606, 607, 608, 611, 612, 613, 615, 616, 617, 621, 626, 628, 629, 639, 640, 642, 646, 648, 651, 654, 656, 660, 668, 780 ... Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, be20.00-z-9999cz, Test and adjustment values: Smart: Engine cooling system MODEL all

AR20.10-P-1275SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1223 · Applies to: 453 · AR: AR20.10-P-1275SR, AR13.22-P-1202SR

Remove/install belt pulley for the coolant pump 28.07.2014 ENGINE 281 in MODEL 453 1 Belt pulley 2 Screw/bolt 3 Poly-V belt P20.10-2402-12 Risk of injury. Moving parts can pinch, crush No parts of the body or limbs should be within AS00.00-Z-0009-01A Danger !

or, in extreme cases even sever extremities. the operating range of the mechanism when moving components. Remove

1 Remove covering over engine 2 Slacken screw/bolts (2) for belt pulley (1) 3 Remove poly-V belt (3) AR13.22-P-1202SR 4 Remove screw/bolts (2) for belt pulley (1) and take off belt pulley (1) from the coolant pump Install

5 Attach belt pulley (1) to with screw/bolts (2) at Screw in screw/bolts (2) up to the stop.

the coolant pump 6 Install poly-V belt (3) AR13.22-P-1202SR 7 Fasten screw/bolts (2) for belt pulley (1) *BA20.10-P-1001-01J Bolt, belt pulley to coolant pump 8 Install covering over engine Coolant pump, coolant thermostat Number Designation ENGINE 281 BA20.10-P-1001-01J Bolt, belt pulley to coolant pump Nm 8 Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar20.10-p-1275sr, Remove/install belt pulley for the coolant pump ENGINE 281 in MODEL 453

AR20.10-P-1271FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1224 · Applies to: 453 · AR: AR20.10-P-1271FF, AR20.00-P-1142FF, AR13.22-P-1202FF

Remove/install coolant pump 17.1.06 ENGINE 134.9, 135.9 in MODEL 454.0 P20.10-2141-09 Shown on engine 135.9 with code (I01) Air conditioning Plus (with outside temperature indicator) (FFO) 1 Coolant pump 3 Bolts 5 Poly-V-belt 2 Bolts 4 Belt pulley 6 Seal Remove/install

Risk of injury Do not open cooling system unless coolant Danger! to skin and eyes caused by AS20.00-Z-0001-01A

scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

1 Drain coolant AR20.00-P-1142FF 2 Slacken bolts (3) of belt pulley (4) *BA20.10-P-1002-01N

3 Remove poly-V belt (5) AR13.22-P-1202FF 4 Unscrew screws (3) of belt pulley (4) 5 Remove belt pulley (4) 6 Unscrew bolts (2) of coolant pump (1) *BA20.10-P-1001-01N

7 Take out coolant pump (1) toward bottom Installation: Clean the sealing surfaces on the crankcase and on the coolant pump (1). 8.1 Remove (6) gasket from coolant pump (1) and When reusing the removed coolant pump (1). check Clean sealing surfaces of the coolant pump (1). Installation: The gasket (6) is not available separately. If the gasket (6) is damaged, it must be replaced together with the coolant pump (1). 9 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 10 Conduct engine test run and check cooling system in the area of the coolant pump (1) for leaks Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.10-p-1271ff, Remove/install coolant pump ENGINE 134.9, 135.9 in MODEL 454.0

AR20.10-P-1271FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1226 · Applies to: 453 · AR: AR20.10-P-1271FG, AR20.10-P-1275FG, AR20.00-P-1142FG

Remove/install coolant pump 30.4.04 ENGINE 639.939 in MODEL 454.0 Shown on vehicles with code (I01) Air Conditioning Plus (with outside temperature indicator) (FFO) 1 Belt pulley 2 Bolts 3 Coolant pump P20.10-2161-06 Remove/Install

1 Remove the belt pulley (1) of the coolant AR20.10-P-1275FG pump (3) 2 Drain coolant AR20.00-P-1142FG 3 Unscrew bolts (2) Installation: Replace bolts (2). *BA20.10-P-1001-01R

4 Remove coolant pump (3) Installation:

Clean sealing surfaces and install new gasket. 5 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 6 Carry out an engine test run and check the coolant pump for leaks Coolant pump, coolant thermostat

Number Designation Engine 639.939 BA20.10-P-1001-01R Torx bolt of coolant pump to Nm 8 crankcase Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.10-p-1271fg, Remove/install coolant pump ENGINE 639.939 in MODEL 454.0

AR20.10-P-1271SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1227 · Applies to: 453 · AR: AR20.10-P-1271SR, AR20.00-P-1142SR, AR20.10-P-1275SR

Remove/install coolant pump 28.10.2014 ENGINE 281 in MODEL 453 P20.10-2401-09 1 Screw/bolt 3 Screw/bolt 5 Coolant pump 2 Screw/bolt 4 Screw/bolt 6 Seal Risk of injury Do not open cooling system unless coolant Danger ! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

Remove/install

1 Drain coolant AR20.00-P-1142SR 2 Remove belt pulley from coolant pump (5)
AR20.10-P-1275SR Installation: Only install covering over

engine after the leak test. 3 Remove screws/bolts (1 to 4)
Installation: Lay coolant pump (5) with

screw/bolts (1 to 4) evenly on the cylinder head then tighten screw/bolts (1 to 4) according to the numerical sequence. *BA20.10-P-1013-01J Bolt, coolant pump to cylinder head 4 Remove coolant pump (5) and catch running Installation:

Replace seal (6). off coolant with a suitable container
Clean

5 Clean sealing surface on crankcase 6 Clean sealing surface on coolant pump (5) When reusing the coolant pump (5). 7 Install in the reverse order Check

Risk of accident Danger ! from vehicle starting off by Secure vehicle to prevent it from starting off by AS00.00-Z-0005-01A

itself when engine running. Risk of injury itself. Wear closed and snug-fitting work

(bruises and burns) resulting from working on clothes. Do not touch hot or rotating parts. the engine while it is being started or when it is running. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.10-p-1271sr, Remove/install coolant pump ENGINE 281 in MODEL 453

AR20.10-P-2460FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1229 · Applies to: 453 · AR: AR20.10-P-2460FF, AR20.00-P-1142FF

Remove/install coolant thermostat 21.3.07 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.950 1 Coolant hose 2 Housing 3 Coolant thermostat 4 Sealing ring P20.10-2139-06 Remove/install

Risk of injury Do not open cooling system unless coolant Danger! to skin and eyes caused by AS20.00-Z-0001-01A

scalding from contact with hot coolant spray. temperature is below 90°C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant caused by swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

1 Drain coolant AR20.00-P-1142FF Installation: Inspect the cooling system

around the coolant thermostat (3) for leaks. 2 Detach coolant hose (1) at housing (2) 3 Detach housing (2) at crankcase Pay attention to the clip at the housing (2). *BA20.10-P-1003-01N

4 Remove coolant thermostat (3) with sealing Installation:

Clean the sealing surfaces at ring (4) from the crankcase the housing (2) and crankcase. 5 Install in the reverse order Coolant pump, coolant thermostat Number Designation Engine Engine Engine Engine 134.910 134.911 135.930 135.950 BA20.10-P-1003-01N Bolt of coolant thermostat housing to Nm 9 9 9 9 crankcase Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.10-p-2460ff, Remove/install coolant thermostat ENGINE 134.9, 135.9 in MODEL 454.0

AR20.10-P-2460FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1230 · Applies to: 453 · AR: AR20.10-P-2460FG, AR20.00-P-1142FG

Remove/install coolant thermostat 4.10.04 ENGINE 639.939 in MODEL 454.0 1 Coolant thermostat 2 Bolts 3 Crankcase P20.10-2169-06 Remove/Install

1 Drain coolant AR20.00-P-1142FG 2 Detach coolant hoses at coolant temperature Collect coolant which flows out in a controller (1) suitable vessel. 3 Unscrew bolts (2) *BA20.10-P-1003-01R

4 Remove the coolant thermostat (1) from Installation:

do not push coolant crankcase (3) temperature controller (1) too far into the crankcase (3), otherwise the coolant temperature controller (1) can jam in the crankcase (3) and damage can occur to the seal when the coolant temperature controller (1) is prised out. Installation:

Install new sealing ring. 5 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 6 Conduct engine test run and check cooling Until the cooling fan is switched on. system in the area of the coolant temperature controller (1) for leaks Coolant pump, coolant thermostat

Number Designation Engine 639.939 BA20.10-P-1003-01R Torx bolt coolant temperature controller to charge Nm 14 air duct housing Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.10-p-2460fg, Remove/install coolant thermostat ENGINE 639.939 in MODEL 454.0

AR20.10-P-2461SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1231 · Applies to: 453 · AR: AR20.10-P-2461SR, AR20.00-P-1142SR

Remove/install coolant thermostat 28.07.2014 ENGINE 281 in MODEL 453 P20.10-2411-09 Shown on engine 281.920 1 Coolant thermostat 3 Coolant hose 2 Coolant hose 4 Coolant hose Risk of injury Do not open cooling system unless coolant Danger ! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

Remove/install

1 Drain coolant AR20.00-P-1142SR Installation: Only attach underfloor

paneling after the leak test. 2 Remove coolant hose (2) from coolant Catch coolant in a suitable container.

thermostat (1) Observe installation position of coolant

hose (2). Installation: Replace clamp if necessary.

*003589033700 Hose clamp pliers 3 Remove coolant hose (3) from coolant Catch coolant in a suitable container.

thermostat (1) and take off coolant thermostat (1) together with coolant hose (4) Observe installation position of coolant

hose (3). Installation: Replace clamp if necessary.

*003589033700 Hose clamp pliers 4 Remove coolant hose (4) from coolant Observe installation position of coolant

thermostat (1) hose (4). Installation: Replace clamp if necessary.

*003589033700 Hose clamp pliers 5 Install in the reverse order Check

Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar20.10-p-2461sr, Remove/install coolant thermostat ENGINE 281 in MODEL 453

AR20.10-P-1281SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1233 · Applies to: 453 · AR: AR20.10-P-1281SR, AR20.00-P-1142SR

Remove/install electric coolant pump 10.3.15 ENGINE 281.910 in MODEL 453 P20.10-2434-08 1 Coolant pump 3 Coolant hose 5 Electrical connection 2 Coolant hose 4 Elastomer bearing Risk of injury Do not open cooling system unless coolant Danger ! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

Remove/install

1 Drain off coolant AR20.00-P-1142SR 2 Disconnect electrical connection (5) from coolant pump (1) 3 Remove coolant hoses (2, 3) from coolant Catch coolant in a suitable container.

pump (1) Pay attention to installation position.

Installation: Replace clamps.

4 Pull out coolant pump (1) upwards from the elastomer bearing (4) 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.10-p-1281sr, Remove/install electric coolant pump ENGINE 281.910 in MODEL 453

AR20.10-P-1275FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1234 · Applies to: 453 · AR: AR20.10-P-1275FG, AR61.20-P-1105FF, AR13.22-P-1202FG

Removing and installing the belt pulley for the coolant pump 26.5.04 ENGINE 639.939 in MODEL 454.0 Shown on vehicles with code (I01) Air Conditioning Plus (with outside temperature indicator) (FFO) 1 Bolts 2 Poly-V-belt 3 Belt pulley P20.10-2160-05 Remove/Install

Risk of death Danger! cased by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A toppling off of the lifting platform. hydraulic hoist and position the four support plates below the hoist support points specified by the vehicle manufacturer. 1 Raise vehicle. 2 Remove lower engine compartment paneling AR61.20-P-1105FF 3 Loosen screws (1) *BA20.10-P-1002-01R

4 Remove poly V-belt (2) AR13.22-P-1202FG 5 Unscrew the bolts (1) and remove the belt Installation: Install new bolts (1). pulley (3) 6 Install in the reverse order Coolant pump, coolant thermostat

Number Designation Engine 639.939 BA20.10-P-1002-01R Torx bolt of belt pulley to coolant pump Nm 10 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.10-p-1275fg, Removing and installing the belt pulley for the coolant pump ENGINE 639.939 in MODEL 454.0

AR20.20-P-7450FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1236 · Applies to: 453 · AR: AR20.20-P-7450FF, AR20.00-P-1142FF, AR09.20-P-1310FF

Remove, install coolant pipe 13.4.06 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 Coolant hose 2 Coolant hose 3 Coolant pipe 4 Bolt 5 Bolts P20.20-2212-06 Remove/install

1 Drain coolant AR20.00-P-1142FF 2 Remove intake manifold AR09.20-P-1310FF 3 Detach coolant hose (2) from coolant pipe (3) 4.1 Detach coolant hose (1) from coolant pipe (3) Only when replacing coolant pipe (3). 5 Unscrew bolt (4) 6 Remove bolts (5) *BA20.10-P-1004-01N

7 Remove coolant pipe (3) Installation: Install new gasket at coolant pipe (3). 8 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 9 Perform engine test run and check coolant system in the area of the coolant pipe (3) for leaks Coolant pump, coolant thermostat Number Designation Engine Engine Engine Engine 134.910 134.911 135.930 135.950 BA20.10-P-1004-01N Bolt connecting water pipe flange to Nm 8 8 8 8 crankcase Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.20-p-7450ff, Remove, install coolant pipe ENGINE 134.9, 135.9 in MODEL 454.0

AR20.20-P-3865FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1237 · Applies to: 453 · AR: AR20.20-P-3865FH, AR88.00-P-1010FF, AR20.00-P-1142FG, AR20.40-P-6800FG

Remove, install radiator 13.4.06 ENGINE 639.9 in MODEL 454.0 P20.20-2260-09 Shown on vehicle with code (I01) AC Plus 1 Coolant hose 2 Radiator 5 Bolt 9 Bolt (with Code (I01) AC Plus or with code (I77) Manual AC) 3 Bolt 6 Bolt 10 Condenser (with Code (I01) AC Plus 4 Coolant hose 7 Bracket or with code (I77) Manual AC) 8 Bracket Remove/install

1 Remove front CBS AR88.00-P-1010FF 2 Drain coolant AR20.00-P-1142FG 3 Remove fan shroud AR20.40-P-6800FG 4 Detach coolant hoses (1, 4) at radiator (2) 5 Unscrew bolt (3). 6 Unscrew bolts (5, 6) 7 Take out bracket (7, 8). 8.1 Remove bolts (9) Only on vehicles with Code (I01) Air conditioning Plus or Code (I77) Manual AC 9.1 Suspend condenser (10) at radiator (2) Only on vehicles with Code (I01) Air conditioning Plus or Code (I77) Manual AC 10 Pull radiator (2) out of mounts by lifting and Installation:

Pay attention to correct seat remove from the bottom of radiator (2). 11 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 12 Perform engine test run and check coolant system around radiator (2) for leaks Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.20-p-3865fh, Remove, install radiator ENGINE 639.9 in MODEL 454.0

AR20.20-P-7470SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1238 · Applies to: 453 · AR: AR20.20-P-7470SR, AR20.00-P-1142SR, AR09.20-P-1310SR, AR09.41-P-1311SR

Remove/install connection fittings for coolant hoses 28.07.2014 ENGINE 281 in MODEL 453 Shown on engine 281.910 1 Connection fitting 2 Electrical connection 3 Coolant hose 4 Coolant hose (with engine 281.910) 5 Coolant hose (with engine 281.910) 6 Screw/bolts P20.20-2499-06 Risk of injury Do not open cooling system unless coolant Danger ! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

Remove/install

1 Drain coolant AR20.00-P-1142SR 2.1 Remove intake manifold ENGINE 281.920 in MODEL 453 AR09.20-P-1310SR Installation: Only position rear drive

module after a leak test. 2.2 Remove charge air pipe ENGINE 281.910 in MODEL 453 AR09.41-P-1311SR 3 Disconnect electrical connection (2) 4 Remove coolant hose (3) from connection Installation: Replace clamp if necessary.

fitting (1) *003589033700 Hose clamp pliers 5 Remove coolant hose (4) from connection ENGINE 281.910 in MODEL 453 fitting (1) Installation: Replace clamp if necessary.

*003589033700 Hose clamp pliers 6 Remove coolant hose (5) from connection ENGINE 281.910 in MODEL 453 fitting (1) Installation: Replace clamp if necessary.

003589033700 Hose clamp pliers 7 Remove screw/bolts (6) BA20.10-P-1014-01J Bolt, connection fitting to cylinder head 8 Remove connection fitting (1) from cylinder Collect coolant in a suitable container.

head Installation: Replace seal.

9 Install in the reverse order Check

Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar20.20-p-7470sr, Remove/install connection fittings for coolant hoses ENGINE 281 in MODEL 453

AR20.20-P-3865SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1240 · Applies to: 453 · AR: AR20.20-P-3865SR

Remove/install radiator 07.09.2016 Engine 281 in model 453 Engine 780 in model 453 Shown on model 453 with engine 281 2 Condenser (with code I01 (A/C PLUS) or code I77 (manual A/C)) 3 Expansion reservoir 4 Crossmember 5 Refrigerant line (with code I01 (A/C PLUS) or code I77 (A/C manual)) 6 Hoses 7 Screw/bolts 8 Screw/bolts P20.20-2507-06 P20.20-2508-09 Shown on model 453 with engine 281 1 Radiator 11 Coolant hose (with engine 281.910) 14 Elastomer guide 9 Coolant hose 12 Coolant hose 10 Coolant hose (with engine 281.910) 13 Front axle Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar20.20-p-3865sr, Remove/install radiator Engine 281 in model 453 Engine 780 in model 453

AR20.20-P-3871FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1242 · Applies to: 453 · AR: AR20.20-P-3871FF

Remove/install radiator unit 17.1.06 ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0 with CODE (I01) Air conditioning Plus (with outside temperature indicator) (FFO) P20.20-2219-09 Shown on engine 135.9 1 Radiator unit 5 Coolant hose M4/2x1 Coolant fan motor connector 2 Refrigerant line 6 Coolant hose 3 Nut 7 Refrigerant line 4 Retaining clip 8 Bolt Shown on engine 639.9 1 Radiator unit 9 Alternator wiring harness 10 Bracket P20.20-2306-11 Remove/install

Risk of explosion from welding or soldering Never perform welding work on or near a AS83.00-Z-0001-01A Danger!

work on closed air conditioning system. Risk closed air conditioning system. No smoking or of poisoning from inhaling overheated open flames. Wear safety glasses and refrigerant vapors. Risk of injury to skin and protective gloves. Work only in well ventilated eyes caused by contact with liquid refrigerant. areas. Carry out repair work on the air conditioning system circuit only after the system has been discharged. Conduct if air conditioning system is damaged AH83.30-N-0004-01A

or leaking Protect air conditioning circuit and AH83.30-N-0005-01A

components from moisture when carrying out repair work Notes on handling refrigerant R134a AH83.30-N-0003-01A

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.20-p-3871ff, Remove/install radiator unit ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0 with CODE (I01) Air conditioning Plus (with outside temperature indicator) (FFO)

AR20.20-P-7450FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1244 · Applies to: 453 · AR: AR20.20-P-7450FG, AR20.00-P-1142FG, AR09.10-P-1150FG

Removing/installing the coolant pipe 7.10.04 ENGINE 639.939 in MODEL 454.0 1 Screw 2 Coolant hose 3 Coolant pipe 4 Bleed hose 5 Bolts 6 Charge air hose 7 Charge air pipe 8 Wiring harness 9 Bracket 10 Vacuum line 11 Bolt 12 Bolt 13 Clip 14 Coolant hose P20.20-2274-06 Removing/installing

1 Drain coolant AR20.00-P-1142FG 2 Unscrew bolt (1) 3 Remove coolant hose (2) on coolant pipe (3). Collect coolant which flows out in a suitable vessel. 4 Lower vehicle 5 Remove air cleaner housing AR09.10-P-1150FG 6 Pull bleed hose (4) upwards The bleed hose (4) is fixed at the lower end on the transmission with a fishplate. 7 Unscrew bolts (5) on charge air pipe (7) 8 Remove charge air hose (6) on charge air pipe (7) and place charge air pipe (7) aside 9 Remove electrical wiring harness (8) on bracket (9) 10 Detach vacuum line (10) 11 Unscrew bolts (11, 12) 12 Loosen clamp (13) from coolant hose (14) 13 Pull coolant pipe (3) out of coolant hose (14) and remove 14 Install in reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 15 Perform engine test run and check coolant Until the cooling fan is switched on. system around the coolant pipe (3) for leaks Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.20-p-7450fg, Removing/installing the coolant pipe ENGINE 639.939 in MODEL 454.0

AR20.20-P-3865FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1245 · Applies to: 453 · AR: AR20.20-P-3865FF, AR20.00-P-1142FF, AR88.00-P-1010FF, AR20.40-P-6800FF, AR20.40-P-6800FB

Removing/installing the radiator 13.8.03 ENGINES 122.9, 134.9, 135.9 in MODEL 454.0 Shown on vehicles with code (I01) Air conditioning Plus (with Outside temperature indicator) (FFO) 3 Radiator 7 Bolt P20.20-2304-11 Shown on vehicles with code (I01) Air conditioning Plus (with outside temperature indicator) (FFO) 1 Bolt (with code (I01) Air conditioning Plus (with outside temperature indicator) (FFO) 2 Condenser (with code (I01) Air conditioning Plus (with outside temperature indicator) (FFO) 3 Radiator 4 Coolant hose 5 Coolant hose 6 Refrigerant line (for code (I01) Air conditioning Plus (with outside temperature indicator) (FFO)) P20.20-2247-06 Removing/installing

1 Drain coolant AR20.00-P-1142FF 2 Remove front CBS AR88.00-P-1010FF 3 Remove fan shroud Engines 134.9, 135.9 AR20.40-P-6800FF Engine 122.9 AR20.40-P-6800FB 4.1 Remove bolts (7) on front module Only for engine 122.9 5.1 Remove bolts (1) and detach condenser (2) Only on vehicles with code (I01) Air on radiator (3) conditioning system Plus (with outside temperature indicator) (FFO) Detach condenser (2) carefully from radiator (3) otherwise refrigerant lines on the condenser (2) will be damaged. 6 Detach coolant hoses (4, 5) at radiator (3) Collect coolant which flows out in a suitable vessel. 7.1 Detach refrigerant line (6) from radiator (3) Only on vehicles with code (I01) Air bracket conditioning system Plus (with outside temperature indicator) (FFO) 8 Remove brackets (arrows) on radiator (3) 9 Remove radiator (3) 10 Install in reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.20-p-3865ff, Removing/installing the radiator ENGINES 122.9, 134.9, 135.9 in MODEL 454.0

AR20.20-P-0001SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1248 · Applies to: 453 · AR: AR20.20-P-0001SR, AR82.10-P-4730SR, AR82.10-P-4730SRA

Replace lock pin of engine radiator 21.12.15 Engine 281 in model 453 2 Air duct 5 Expansion reservoir 6 Refrigerant line (with code I01 (A/C PLUS) or code I77 (A/C manual)) 7 Bolts 8 Crossmember P20.20-2540-05 P20.20-2539-08 1 Radiator 3 Fan unit 2 Air duct 4 New lock pin Risk of injury Always wear protective gloves when working Danger ! caused by scraping or cutting AS00.00-Z-0017-01A

body parts on sharp vehicle parts on or near sharp and non-deburred vehicle parts. Deburr repair panels. Remove

1 Remove both lamp units at the front Engine 281 in model 453.0 AR82.10-P-4730SR Engine 281 in model 453.3/4 AR82.10-P-4730SRA 2 Unhook expansion reservoir (5) from crossmember (8) 3 Remove refrigerant line (6) from crossmember Engine 281 in model 453 with code I01 (Air conditioning Plus) (8) Engine 281 in model 453 with code I77 (Air conditioning, manual) 4 Remove screw/bolts (7) 5 Remove crossmember (8) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.20-p-0001sr, Replace lock pin of engine radiator Engine 281 in model 453

AR20.30-P-4950FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1254 · Applies to: 453 · AR: AR20.30-P-4950FG, AR88.00-P-2792FF, AR62.20-P-1300FG, AP20.00-P-2010FG

Remove/install expansion reservoir 30.4.04 ENGINE 639.939 in MODEL 454.0 P20.30-2209-07 1 Cap 4 Coolant pipe 7 Screw 2 Expansion reservoir 5 Coolant hose 8 Clamp 3 Coolant hose 6 Screw Remove/Install

Risk of injury Do not open cooling system unless coolant Danger! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolant spray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage bottles. Wear protective gloves, protective clothing and eye protection. Notes on coolant AH20.00-N-2080-01A

1 Remove paneling on center piece in front of AR88.00-P-2792FF the windshield 2 Remove the right headlamp support AR62.20-P-1300FG 3 Open the cap (1)

Turn 180º in the anti-clockwise direction, release the excess pressure and then unscrew the cap (1). 4 Pinch off the coolant hose (3) using suitable Collect the coolant that flows out in a pliers and detach at the coolant pipe (4) suitable container. 5 Detach the coolant hose (5) at the expansion reservoir (2) 6 Unscrew bolts (6, 7) 7 Take out the expansion reservoir (2) Installation:

When the expansion reservoir (2) is replaced, the clamps (8) and the coolant hose (3) must be adapted. 8 Install in the reverse order 9 Correct the coolant level Engine cooling system - inspect fluid level, AP20.00-P-2010FG

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 10 Carry out an engine test run and test the cooling system for leaks in the area of the expansion reservoir (2) Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.30-p-4950fg, Remove/install expansion reservoir ENGINE 639.939 in MODEL 454.0

AR20.30-P-4950SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1255 · Applies to: 453 · AR: AR20.30-P-4950SR

Remove/install expansion reservoir 07.09.2016 Engine 281 in model 453 Engine 780 in model 453 P20.30-2451-08 Shown on model 453 with engine 281 1 Expansion reservoir 6 Coolant hose 2 Bracket 7 Coolant hose 3 Retaining clip 8 Coolant hose (for engine 281.910) 4 Cap 9 Clamps 5 Bracket 10 Clamp Risk of injury Do not open cooling system unless coolant Danger ! to skin and eyes suffering AS20.00-Z-0001-01A

scalding from contact with hot coolantspray. temperature is below 90 °C. Open cap slowly Risk of poisoning and release the pressure. Do not pour coolant from swallowing coolant. into beverage containers. Wear protective gloves, protective clothing and safety glasses. Notes on coolant AH20.00-N-2080-01A

Remove/install

1 Remove maintenance flap 2 Turn cap (4) on expansion reservoir (1) half a revolution counterclockwise, relieve overpressure and then unscrew cap (4) 3 Suction coolant out of the expansion reservoir 210589007100 Hand pump (1) 4 Unclip retaining clip (3) 5 Remove coolant hose (6) from expansion 003589033700 Hose clamp pliers reservoir (1) 6 Pull expansion reservoir (1) upwards out of the brackets (2, 5) until the coolant hose (7) is accessible 7 Support the expansion reservoir (1) with a suitable object 8 Clamp off coolant hose (7) 000589543700 Clamp 9 Clamp off coolant hose (8) Engine 281.910 in model 453 000589543700 Clamp 10 Loosen clamp (9) of coolant hose (7) and 003589033700 Hose clamp pliers remove coolant hose (7) from expansion reservoir (1) 11 Loosen clamp (9) of coolant hose (8) and Engine 281.910 in model 453 remove coolant hose (8) from expansion reservoir (1) 003589033700 Hose clamp pliers 12 Remove expansion reservoir (1) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.30-p-4950sr, Remove/install expansion reservoir Engine 281 in model 453 Engine 780 in model 453

Install in the reverse order

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1256 · Applies to: 453 · AR: AR20.00-P-1147SRE, AR20.00-P-1142SR, AR20.00-P-1010SR

13 Install in the reverse order Check

14 Check and correct coolant level Engine 780.997 in model 453.091 AR20.00-P-1147SRE Engine 281 in model 453 AR20.00-P-1142SR 15 Check cooling system for leaktightness AR20.00-P-1010SR 003 589 03 37 00 000 589 54 37 00 210 589 00 71 00 Hose clamp pliers Hand pump Clamp Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.30-p-4950sr, Remove/install expansion reservoir Engine 281 in model 453 Engine 780 in model 453

AR20.40-P-6800FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1257 · Applies to: 453 · AR: AR20.40-P-6800FF, AR20.30-P-4950FF, AR20.40-P-5000FF

Remove fan shroud, install 21.10.03 ENGINE 134.9, 135.9 in MODEL 454.0 1 Fan shroud 2 Coolant hose 3 Bolt 4 Radiator P20.40-2076-11 Remove/install

1 Remove expansion reservoir AR20.30-P-4950FF 2 Loosen coolant hose (2) from brackets at fan shroud (1) 3 Unscrew screws (3) from fan shroud (1) 4 Raise the fan shroud (1) and remove from the guides at the radiator (4) 5 Remove fan shroud (1) from bottom 6.1 Remove coolant fan motor Only when replacing fan shroud (1). AR20.40-P-5000FF 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.40-p-6800ff, Remove fan shroud, install ENGINE 134.9, 135.9 in MODEL 454.0

AR20.40-P-6800FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1258 · Applies to: 453 · AR: AR20.40-P-6800FG

Remove fan shroud, install 13.6.04 ENGINE 639.939 in MODEL 454.0 1 Clip 2 Air ducting 3 Clip 4 Wiring harness 5 Fan shroud M4/2 Engine coolant fan motor M4/2x1 Coolant fan motor connector P20.40-2101-04 Remove/Install

1 Remove clips (1) and dismantle air ducting (2) 2 Unclip clip (3) using appropriate tool and separate coolant fan engine connector (M4/2x1) 3 Disconnect wiring harness (4) at the fan shroud (5). 4 Unscrew fan shroud bolts (5) at radiator The fan shroud (5) is fixed to the radiator using two bolts. 5 Suspend fan shroud (5) by raising and pull out from below 6.1 Remove coolant fan motor (M4/2) Only when replacing fan shroud(5). 7 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving. Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of Wear closed and snug-fitting work clothes. injury caused by contusions and burns when Do not grasp hot or rotating parts. working in engine during starting procedure 8 Carry out engine test run when coolant fan motor is switched on (M4/2). Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.40-p-6800fg, Remove fan shroud, install ENGINE 639.939 in MODEL 454.0

AR20.40-P-5000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1259 · Applies to: 453 · AR: AR20.40-P-5000FF, AR20.40-P-6800FB, AR20.40-P-6800FF, AR20.40-P-6800FG

Remove/install electric fan 21.10.03 ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0 1 Bolts 2 Fan shroud M4/2 Engine coolant fan motor M4/2x1 Coolant fan motor connector P20.40-2075-01 Remove/install

1 Remove fan shroud Engine 122.9 AR20.40-P-6800FB Engine 134.9, 135.9 AR20.40-P-6800FF Engine 639.9 AR20.40-P-6800FG 2 Unclip coolant fan motor connector (M4/2x1) from the fan shroud (2) 3 Remove bolts (1) 4 Remove coolant fan motor (M4/2) from the fan shroud (2) 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.40-p-5000ff, Remove/install electric fan ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0

AR20.40-P-5000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1260 · Applies to: 453 · AR: AR20.40-P-5000SR, AR82.10-P-4730SR, AR82.10-P-4730SRA, AR62.10-P-1020SR

Remove/install electric fan 21.12.15 Engine 281 in model 453 P20.40-2246-08 Shown on engine 281.920 1 Air duct segment 4 Refrigerant line (with code I01 (A/C 7 Screw/bolts PLUS) or code I77 (A/C manual)) 2 Expansion reservoir 5 Hoses 8 Radiator package 3 Crossmember 6 Screw/bolts P20.40-2247-08 Shown on engine 281.920 8 Radiator package 10 Electrical wiring harness M4/7 Fan motor 9 Electrical connections 11 Fan unit Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Remove both lamp units at the front Engine 281 in model 453.0 AR82.10-P-4730SR Engine 281 in model 453.3/4 AR82.10-P-4730SRA 2 Remove CMS front AR62.10-P-1020SR Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar20.40-p-5000sr, Remove/install electric fan Engine 281 in model 453

AR20.40-P-5614SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1262 · Applies to: 453 · AR: AR20.40-P-5614SR

Remove/install fan 02.12.2014 ENGINE 281 in MODEL 453 Shown on engine 281.920 1 Electrical connection 2 Electrical wiring harness 3 Screw/bolt 4 Nuts M4/4 Fan P20.40-2250-06 Remove/install

1 Remove covering over engine 2 Release and disconnect electrical connection Disconnect electrical connection (1) only

(1) when the fan has stopped (M4/4). 3 Unclip electrical wiring harness (2) and remove from working area 4 Remove screw/bolt (3) 5 Unscrew nuts (4) 6 Remove fan (M4/4) 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar20.40-p-5614sr, Remove/install fan ENGINE 281 in MODEL 453

AR22.10-P-1100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1267 · Applies to: 453 · AR: AR22.10-P-1100FF

Remove, install engine mount 13.4.06 ENGINE 134.9, 135.9 in MODEL 454.0 P22.10-2180-07 1 Windshield washer reservoir filler 3 Engine bracket 5 Nut neck 4 Bolt 6 Engine mount 2 Bracket Remove, install

1.1 Remove windshield washer reservoir filler Only for engine 135.9 neck (1) with mount (2) Installation: Inspect sealing ring at

windshield washer reservoir filler neck (1), replace if necessary. 2 Support engine with a suitable jack Use a suitable support of wood or rubber to prevent damage to the oil pan. Ensure that the jack is securely positioned to prevent it from slipping. 3 Dismantle engine bracket (3) Replace self-locking bolts and nuts. *454589040900

*BA22.10-P-1003-01Q

*BA22.10-P-1004-01Q

*BA22.10-P-1005-01Q

4 Remove bolts (4) and nut (5) Replacing self-locking nuts (5) and bolts (4). *BA22.10-P-1001-01Q

*BA22.10-P-1002-01Q

5 Take out engine mount (6) 6 Install in the reverse order Engine mounts, engine supports

Number Designation Engine Engine 134.9 135.9 BA22.10-P-1001-01Q Bolt connecting engine mount to longitudinal Nm 48 48 member BA22.10-P-1002-01Q Nut connecting engine mount to longitudinal Nm 48 48 member BA22.10-P-1003-01Q Nut connecting engine bracket to engine mount Nm 48 48 BA22.10-P-1004-01Q Nut connecting engine bracket to timing case cover Nm 48 48 BA22.10-P-1005-01Q Bolt connecting engine bracket to timing case Nm 48 48 cover Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar22.10-p-1100ff, Remove, install engine mount ENGINE 134.9, 135.9 in MODEL 454.0

AR22.10-P-1100FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1269 · Applies to: 453 · AR: AR22.10-P-1100FG

Remove/install engine mount 22.6.04 ENGINE 639.939 in MODEL 454.0 P22.10-2168-07 1 Windshield washer reservoir filler 3 Bolts 6 Bolt neck 4 Nut 7 Nut 2 Bracket 5 Nuts 8 Engine mount Remove/install

1 Remove Windshield washer reservoir filler Installation:

Replace the sealing ring of neck (1) with mount (2) the filler neck (1). 2 Remove bolts (3) 3 Use a suitable jack to support the Use a suitable support of wood or rubber transmission to prevent damage to the transmission. Ensure that the jack is securely positioned to prevent it from slipping. 4 Unscrew nut (4) Replace self-locking nut (4). *BA22.10-P-1003-01Q

5 Unscrew nuts (5). Replace self-locking nuts (5). *BA22.10-P-1006-01Q

6 Remove bolts (6) and nut (7) Replacing self-locking nuts (7) and bolts (6). *BA22.10-P-1001-01Q

*BA22.10-P-1002-01Q

7 Take out engine mount (8) 8 Install in the reverse order Engine mounts, engine supports

Number Designation Engine 639.9 BA22.10-P-1001-01Q Bolt, engine mount at longitudinal member Nm 48 BA22.10-P-1002-01Q Nut, engine mount at longitudinal member Nm 48 BA22.10-P-1003-01Q Nut, engine bracket at engine mount Nm 48 BA22.10-P-1006-01Q Nut, engine bracket at bracket Nm 45 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar22.10-p-1100fg, Remove/install engine mount ENGINE 639.939 in MODEL 454.0

AR22.10-P-4330SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1270 · Applies to: 453 · AR: AR22.10-P-4330SR, AR00.60-P-0100SR

Remove/install front engine mount 11.08.2017 Engine 281 in model 453 Modification notes 30.05.2017 Work procedure completely revised. 1 Engine mount 2 Support brace 3 Screw 4 Screw 5 Screw 6 Carrier 7 Transmission housing P22.10-2457-06 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. Topical note Notes on self-locking nuts and bolts AH00.00-N-0001-01A Remove

1 Secure vehicle on vehicle lift AR00.60-P-0100SR 2 Support engine 000 588 11 62 00 Major assembly mount WS01.00-P-0092B

3 Loosen screw/bolt (3) 4 Remove screw/bolt (5) 5 Swivel support (2) slightly to the side 6 Remove screw/bolt (4) and remove engine mount (1) from carriers (6) Check

7 Check engine mount (1) for wear and damage In case of a complaint Replace engine mount (1). Install

8 Position engine mount (1) in carriers (6) and Do not tighten the screw/bolt (4) yet.

screw screw/bolt (4) in all the way 9 Position support (2) on the engine mount (1) 10 Position engine mount (1) on transmission housing (7) and screw screw/bolt (5) all the way into the transmission housing 11 Raise vehicle using the vehicle lift and remove support 12 Tighten bolt (5) BA22.10-P-1005-01H Bolt, front engine mount to transmission housing 13 Tighten bolt (4) BA22.10-P-1006-01H Bolt, front engine mount to carrier 14 Tighten screw (3) *BA22.10-P-1007-01H Bolt, support to crankcase Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar22.10-p-4330sr, Remove/install front engine mount Engine 281 in model 453

Disconnect vehicle from vehicle lift

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1271 · Applies to: 453 · AR: AR00.60-P-0100SR

15 Disconnect vehicle from vehicle lift AR00.60-P-0100SR Engine mounts, engine supports Number Designation Engine 281 in model 453 BA22.10-P-1005-01H Bolt, front engine mount to transmission housing Nm 105 Engine mounts, engine supports Number Designation Engine 281 in model 453 BA22.10-P-1006-01H Bolt, front engine mount to carrier Nm 105 Engine mounts, engine supports Number Designation Engine 281 in model 453 BA22.10-P-1007-01H Bolt, support to crankcase Nm 105 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar22.10-p-4330sr, Remove/install front engine mount Engine 281 in model 453

AR22.10-P-1101SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1272 · Applies to: 453 · AR: AR22.10-P-1101SR, AR20.40-P-5614SR

Remove/install left engine mount 11.08.2017 Engine 281 in model 453 Shown on ENGINE 281.920 1 Engine mount 2 Bracket 3 Vent hose 4 Lifting eye 5 Screw 6 Engine hoist 7 Nut 8 Nuts P22.10-2454-06 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. Remove

1 Raise vehicle on vehicle lift to working height Align the turn plates so that the screws of

the rubber pads on the turn plates cannot come into contact with vehicle parts while jacking up. 2 Remove fan AR20.40-P-5614SR 3 Unclip bleed hose (3) from bracket (2) Engine 281.920 in model 453 4 Attach lifting eye (4) with screw/bolt (5) to 281589006100 Lifting eye bracket (2) 5 Position engine hoist (6), as shown using 639589006100 Engine lifting device support braces, over the engine and align *451589016200 Support braces 6 Mount engine hoist (6) using the associated screw/bolt onto the lifting eye (4) 7 Unscrew nut (7) 8 Unscrew nuts (8) 9 Lower the engine with engine hoist (6) until the engine mount (1) can be detached from the threaded pins of the engine carrier 10 Unfasten threaded pin for the engine carrier from the engine mount (1) using a suitable plastic mallet 11 Remove engine mount (1) upwards Check

12 Check engine mount (1) for wear and damage In case of a complaint Replace engine mount (1). Install

13 Position engine mount (1) on engine carrier 14 Tighten nuts (8) BA22.10-P-1003-01H Nut, engine mount to engine support 15 Raise engine using engine hoist (6) so high that the nuts (7) can be screwed onto the threaded pins of the engine carrier 16 Tighten nut (7) BA22.10-P-1004-01H Nut, engine mount to bearing pin Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar22.10-p-1101sr, Remove/install left engine mount Engine 281 in model 453

Support engine hoist (6), remove with the

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1273 · Applies to: 453 · AR: AR20.40-P-5614SR

17 Support engine hoist (6), remove with the support braces and guide out 18 Remove lifting eye (4) 19 Clip bleed hose (3) to holder (2) Engine 281.920 in model 453 20 Install fan AR20.40-P-5614SR 21 Lower vehicle with vehicle lift Engine mounts, engine supports Number Designation Engine 281 in model 453 BA22.10-P-1003-01H Nut, engine mount to engine support Nm 105 Engine mounts, engine supports Number Designation Engine 281 in model 453 BA22.10-P-1004-01H Nut, engine mount to bearing pin Nm 62 451 589 01 62 00 281 589 00 61 00 639 589 00 61 00 Support braces Lifting eye Engine lifting device Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar22.10-p-1101sr, Remove/install left engine mount Engine 281 in model 453

AR22.10-P-1102SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1274 · Applies to: 453 · AR: AR22.10-P-1102SR

Remove/install right engine mount 11.08.2017 Engine 281 in model 453 Shown on ENGINE 281.920 1 Engine mount 2 Mounting clip 3 Vent hose 4 Lifting eye 5 Screw 6 Engine hoist 7 Nut 8 Nuts P22.10-2453-06 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. Remove

1 Raise vehicle on vehicle lift to working height Align the turn plates so that the screws of

the rubber pads on the turn plates cannot come into contact with vehicle parts while jacking up. 2 Remove subwoofer Engine 281 in model 453 with code 556 (Radio 56A MM2012 with DAB and PREMIUM SOUND) Engine 281 in model 453 with code 557 (RADIO 57A MM2012 without DAB) Engine 281 in model 453 with code 561 (Radio 61C - PREMIUM without DAB with PREMIUM SOUND) Engine 281 in model 453 with code 562 (Radio 62C - R0 with DAB and PREMIUM SOUND) 3.1 Remove floor covering in trunk Engine 281 in model 453.0 3.2 Fold floor covering in trunk forwards Engine 281 in model 453.3/4 4 Remove covering over engine 5 Unclip retaining clip (2) for the bleed hose (3) Engine 281.920 in model 453 6 Screw lifting eye (4) with screw/bolt (5) into 281589006100 Lifting eye threaded hole of retaining clip (2) 7 Position engine hoist (6), as shown using 451589016200 Support braces support braces, over the engine and align *639589006100 Engine lifting device 8 Mount engine hoist (6) using corresponding screw/bolt onto the lifting eye (4) 9 Unscrew nut (7) 10 Unscrew nuts (8) 11 Lower the engine with engine hoist (6) until the engine mount (1) can be detached from the threaded pins of the carrier 12 Unfasten threaded pin for the carrier from the engine mount (1) using a suitable plastic mallet 13 Remove engine mount (1) upwards Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar22.10-p-1102sr, Remove/install right engine mount Engine 281 in model 453

AR22.10-P-4340FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1276 · Applies to: 453 · AR: AR22.10-P-4340FG

Remove/install right engine support 16.12.04 ENGINE 639.939 in MODEL 454.0 P22.10-2193-07 1 Windshield washer reservoir filler 3 Bolts 6 Coolant pipe neck 4 Nut 7 Engine supports 2 Bracket 5 Nuts Remove/install

1 Remove windshield washer reservoir filler Installation:

Replace the sealing ring of neck (1) with mount (2) the filler neck (1). 2 Remove bolts (3) 3 Use a suitable jack to support the engine Use a suitable support of wood or rubber to prevent risk of damage to the Motors. Ensure that the jack is securely positioned to prevent it from slipping. 4 Unscrew nut (4) Replace self-locking nut (4). *BA22.10-P-1003-01Q

5 Push coolant pipe (6) to the side and unscrew Replace self-locking nuts (5). nuts (5) *BA22.10-P-1006-01Q

6 Take out engine support (7) 7 Install in the reverse order Engine mounts, engine supports

Number Designation Engine 639.9 BA22.10-P-1003-01Q Nut, engine bracket at engine mount Nm 48 BA22.10-P-1006-01Q Nut, engine bracket at bracket Nm 45 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar22.10-p-4340fg, Remove/install right engine support ENGINE 639.939 in MODEL 454.0

AR25.20-P-3000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1303 · Applies to: 453 · AR: AR25.20-P-3000SR, AR09.41-P-1311SR, AR09.20-P-1310SR

Remove/install clutch actuator 20.03.2017 Model 453 (except 453.09/39/49) with transmission 700.41 Modification notes 14.07.2016 BA27.10-P-1009-06A added. Operation step 5 Shown on removed transmission M14 Clutch actuator 1 M15 Clutch actuator 2 N15/13 Double clutch transmission control unit P27.19-2716-76 Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Remove/install

1 Switch off ignition and remove transmitter key Risk of death Danger caused by vehicle slipping or Align vehicle between vehicle lift columns and AS00.00-Z-0010-01A

toppling off of the lifting platform. position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. 2 Raise vehicle When removing the clutch actuator 2 (M15). 3.1 Remove charge air pipe Model 453 with engine 281.910 with transmission 700.41 When removing the clutch actuator 1 (M14). AR09.41-P-1311SR 3.2 Remove intake manifold Model 453 with engine 281.920 with transmission 700.41 When removing the clutch actuator 1 (M14). AR09.20-P-1310SR 4 Release and disconnect electrical connector of clutch actuator 1 (M14) or clutch actuator 2 (M15) 5 Unscrew screws/bolts of clutch actuator 1 *BA27.10-P-1009-06A Bolt, clutch actuator to transmission (M14) or clutch actuator 2 (M15) 6 Pull out clutch actuator 1 (M14) or clutch actuator 2 (M15) 7 Install in the reverse order 8 Parameterize electronic transmission control again AD00.00-P-2000-06SR

N15/13 - Electronic transmission control

for dual-clutch transmission (DKG)
Adaptations Learning processes Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar25.20-p-3000sr, Remove/install clutch actuator Model 453 (except 453.09/39/49) with transmission 700.41

Unfasten nut (20) and remove threaded pin

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1418 · Applies to: 453 · AR: AR25.10-P-0002SR, AR03.30-P-8002SR

27 Unfasten nut (20) and remove threaded pin BA27.10-P-1005-06A Threaded pin to engine/transmission (21) BA27.10-P-1003-06A Nut, transmission to engine 28 Remove transmission (1) from below Installation: Before positioning the

transmission (1), turn damping ring (24) against flywheel (23) in the direction of the arrow and press notches (24.1) into the relevant opening of the flywheel (23) (arrow). Helper required.

Check

29 Check transmission (1) in the area of dual If there are problems clutch for leakage Remove dual clutch, identify cause and rectify. AR25.10-P-0002SR 30 Check gearing at flywheel (23) and dual clutch In the event of complaints for wear and damage Replace flywheel (23) and dual clutch. Replace flywheel (23) AR03.30-P-8002SR Replace dual clutch AR25.10-P-0002SR 31 Install in the reverse order 32 Reparameterize electronic transmission control AD00.00-P-2000-06SR

N15/13 - Electronic transmission control

for dual-clutch transmission (DKG) Adaptations Learning processes In the "Learning processes" menu, the

menu items must be processed in the following sequence: Resetting of learned values of component dual clutch Teach-in process of component B56/1 (transmission mode recognition sensor) Teach-in of reference positions of clutch Teach-in of clutch engagement points Engine mounts, engine supports Number Designation Engine 281 in model 453 BA22.10-P-1005-01H Bolt, front engine mount to transmission housing Nm 105 Engine mounts, engine supports Number Designation Engine 281 in model 453 BA22.10-P-1007-01H Bolt, support to crankcase Nm 105 Automatic transmission complete Number Designation Transmission 700.41 BA27.10-P-1001-06A Bolt, ground line to transmission Nm 24 Automatic transmission complete Number Designation Transmission 700.41 BA27.10-P-1002-06A Bolt, transmission to engine Nm 44 Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar27.10-p-0502sr, Remove/install automatic transmission Transmission 700.41 in model 453 (except 453.09/39/49)

SM27.60-P-0005A

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1442 · Applies to: 453 · AR: AR20.40-P-5614SR, AR27.60-P-6628SR

Check holder for wire of park pawl (code: 1507P27B68) 22.1.16 Model 453 with code 429 (twinamic) Operation no. of the operation texts or standard texts and flat rates Category Op. no. Operation text Time Acc. no. Code P 02-9245 Check bracket for wire of park pawl on vehicle with code 429 P 02-9246 Replace bracket for wire of park pawl (after check) for vehicle with code 429 1 Bracket 2 Cable 3 Bolt 4 Nuts 5 Lock P27.60-3966-04 Check

1 Check whether vehicle is affected by Model 453 as of 031634 up to 039986 SM27.60-P-0005-01AAA measure 2 Remove engine cover 3 Pull cable (2) at left and right of bracket (1) The scope of testing findings must be written upwards using two fingers and minimum force into the workshop order and filed in a tamperproof manner! To do so, pull lock (5) on cable (2) to rear.

If the cable (2) for the park pawl can be easily released from the bracket (1). End the measure. If the cable (2) for the park pawl can only be released from the bracket (1) with difficulty or not at all. Proceed with step 4. Remove

4 Remove fan (M4/4) Model 453 with engine 281 AR20.40-P-5614SR

with code 429 (twinamic) 5 Replace bracket (1) Bolt (3): 30 Nm

6 Expose bearing bracket and remove lock (5) for cable (2) from selector lever Model 453 with transmission 700.41 AR27.60-P-6628SR

with code 429 (twinamic) Installation:

The selector lever must be released to adjust the cable (2). Otherwise, selector lever shifting may be very sluggish. Conduct operation steps 1 - 4 and 6.

7 Release nuts (4) The bearing bracket must be capable of

being slid into the bolt holes. Install

8 Install cable (2) into new bracket (1) The transmission must be in park position "P". The cable (2) must latch into place in the

bracket (1) with a click. 9 Tighten nuts (4) Slide bearing bracket as far forward as

possible. 10 Install lock (5) Lock (5) must be correctly locked.

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, sm27.60-p-0005a, Check holder for wire of park pawl (code: 1507P27B68) Model 453 with code 429 (twinamic)

Install fan (M4/4)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1443 · Applies to: 453 · AR: AR20.40-P-5614SR

11 Install fan (M4/4) Model 453 with engine 281 AR20.40-P-5614SR

with code 429 (twinamic) 12 Reinstall engine cover Parts ordering note Part no. Designation Quantity A 453 274 00 41 Bracket 1 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, sm27.60-p-0005a, Check holder for wire of park pawl (code: 1507P27B68) Model 453 with code 429 (twinamic)

Clean inner spider (6) with bearing (7) and

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1586 · Applies to: 453 · AR: AP18.00-P-0101FB, AR40.10-P-1100FF

10 Clean inner spider (6) with bearing (7) and joint hub (9) Install

11 Push new clamps (3, 4) and rubber boot (2) onto the drive shaft (1) 12 Using a suitable tool, position the inner spider Do not damage, disassemble or drop the (6) on the axle shaft (1) and install new circlip internal spider (6) and bearing (7) when (8) installing because, if the internal spider (6) or bearing (7) is damaged, the drive shaft (1) must be replaced complete. 13 Pack joint hub (9) with the grease included in Use grease tubes marked in gray. the package 14 Press steering knuckle towards outside and The bearings (7) must be inserted into the carefully insert drive shaft (1) with inner spider notches of the joint hub (9), turn the drive (6) into joint hub (9) shaft (1) slightly if necessary. 15 Position rubber boot (2) on joint hub (9) and Ensure that the clamps (3, 4) are seated fasten clamps (3, 4) properly. *WH58.30-Z-1011-02A

16.1 Install oil filter On Engine 122.9 Engine oil and filter change AP18.00-P-0101FB

17 Install link rod on stabilizer bar Engine 122.9 AR32.35-P-2050-05FB *BA32.20-P-1002-01K

Engine 134.9, 135.9, 639.9 AR32.35-P-2050-05FF *BA32.20-P-1002-01K

18.1 Attach flange ball joint to upright On engines 134.9 and 135.9 AR33.20-P-0446-01FF *BA33.15-P-1002-01D

18.2 Attach upright to suspension strut On engines 122.9 and 639.9 AR33.25-P-0600-01FF *BA32.25-P-1002-04I

*BA42.10-P-1002-04G

19 Install left or right front wheel AR40.10-P-1100FF Front axle stabilizer bar

Number Designation Model 454.0 BA32.20-P-1002-01K Nut, link rod to stabilizer bar Nm 28 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

Number Designation Model Model 454.0 with 454.0 with engine engine 134.910/ 135.930/ 911 950 BA33.15-P-1002-01D Nut, flange joint to steering knuckle Nm 60 60 Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar33.30-p-0680ff, Remove/install rubber boot at input shaft on transmission side MODEL 454.0

AR18.40-P-3510SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1602 · Applies to: 453 · AR: AR18.40-P-3510SR, AR01.00-P-3050SR

Remove/install oil dipstick guide tube 23.07.2014 ENGINE 281 in MODEL 453 P18.40-2445-09 Shown on engine 281.920 1 Guide tube 2 Screw/bolt 3 Crankcase 1 Guide tube 5 Sealing ring P18.40-2446-11 Remove/install

1 Lower rear drive module AR01.00-P-3050SR Installation: Only position rear drive

module after a leak test. 2 Remove screw/bolt (2)
*BA01.45-P-1004-01J Bolt, oil dipstick guide tube to charge air distributor 3 Turn guide tube (1) somewhat Installation: Replace sealing ring (5).

counterclockwise and remove from the crankcase (3)
4 Install in the reverse order Check

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar18.40-p-3510sr, Remove/install oil dipstick guide tube ENGINE 281 in MODEL 453

SM42.00-P-0006A

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1705 · Applies to: 453 · AR: AR00.60-P-0100SR

Program Electronic Stability Program control unit and check parking brake (code: 10.03.2016 1512P42C63) Model 453 Operation no. of the operation texts or standard texts and flat rates Category Op. no. Operation text Time Acc. no. Code P 02-4762 Connect/disconnect diagnostic system (Xentry/DAS) P 02-5058 Connect/disconnect battery charger (with Xentry/DAS connected) P 02-9334 Update control unit software ......................... (with XENTRY/ DAS connected) P 02-9472 Check parking brake, correct if necessary Check

1 Check whether vehicle is affected by Model 453 as of 000195 up to 040296 SM42.00-P-0006-01AAA measure Model 453 as of 040297 up to 080547 SM42.00-P-0006-01AAB Model 453 as of 080548 up to 081354 SM42.00-P-0006-01AAC Programming 2 Connect diagnostic unit Use XENTRY Diagnostics version 12/2015 with all available add-ons or a newer version. The operation steps must be performed exactly as per Xentry Diagnostics! Make sure that the vehicle's on-board electrical system battery has sufficient voltage supply (more than 12.5 V) by using a battery charger. If Xentry Diagnostics is already connected to the vehicle, continue with operation step 3. AD00.00-P-2000-06SR

3 Program Electronic Stability Program control To do so, select menu item Control units

unit (N30/4) view Suspension ESP Electronic Stability Program Adaptations Control units update Update of control unit software. Then follow the user guidance in Xentry

Diagnostics. If two or more instances of control unit

programming or SCN coding are carried out during a workshop visit, the operation items 02-4762 and 02-5058 must only be charged once for each workshop order. 4 Disconnect diagnostic equipment AD00.00-P-2000-06SR

Check parking brake setting 5 Lift vehicle on vehicle lift Model 453 up to 034584 AR00.60-P-0100SR

Only raise far enough until the complete

wheels are off the ground. 6 Check free travel on parking brake lever Model 453 up to 034584 Release parking brake lever completely.

The parking brake lever when released must exhibit a free travel of 2 - 3 mm before the brake cable is pulled. The complete wheels on the rear axle must turn without any resistance. 7 Tighten parking brake up to third notch Model 453 up to 034584 A low braking effect must be noticeable

when turning the complete wheels on the rear axle. 8 Tighten parking brake up to fifth notch Model 453 up to 034584 The complete wheels on the rear axle

must not turn anymore. Adjust parking brake 9 Adjust parking brake Model 453 up to 034584 If the setting for the parking brake according to the above-mentioned criteria is OK. Page 1 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

AR43.05-P-1320SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1908 · Applies to: 453 · AR: AR43.05-P-1320SR, AR20.40-P-5614SR

Remove/install vacuum pump 21.11.2014 MODEL 453 with ENGINE 281 with CODE 494 (USA version) 1 Electrical connector 2 Electrical wiring harness 3 Bracket 4 Vacuum line 5 Vent line 6 Screw M56 Vacuum pump P43.05-2096-06 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Remove fan AR20.40-P-5614SR 2 Disconnect electrical connector (1) 3 Unclip electrical wiring harness (2) from holder (3) 4 Release and detach vacuum line (4) 5 Unclip vent line (5) from bracket (3) 6 Remove screws/bolts (6) 7 Remove vacuum pump (M56) 8 Detach vent line (5) from vacuum pump (M56) When replacing vacuum pump (M56). 9 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar43.05-p-1320sr, Remove/install vacuum pump MODEL 453 with ENGINE 281 with CODE 494 (USA version)

AR43.10-P-0355FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1921 · Applies to: 453 · AR: AR43.10-P-0355FF, AR09.10-P-1150FF

Remove/install brake booster vacuum line 6.6.03 MODEL 454.0## 1# with ENGINE 134.9, 135.9 with CODE (LHD) Left-hand drive vehicle P43.10-2032-09 1 Brake booster vacuum line 3 Bracket 5 Catch hook 2 Bolt 4 Connector 6 Brake booster Remove/Install

1 Push down brake pedal several times In order to eliminate any vacuum present. 2 Remove air filter housing AR09.10-P-1150FF 3 Press together detent (5) and disconnect plug (4) 4 Unscrew screw (2) 5 Remove vacuum line to brake booster (1) from bracket (3) for activated charcoal canister 6 Pull brake booster vacuum line (1) out of the Installation:

Check rubber seal on the brake booster (6) and remove brake booster (6) and replace if necessary. 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar43.10-p-0355ff, Remove/install brake booster vacuum line MODEL 454.0## 1# with ENGINE 134.9, 135.9 with CODE (LHD) Left-hand drive vehicle

Component description for electric drive

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1964 · Applies to: 453 · AR: GF08.20-P-3001KJE, GF46.35-P-0999KJ

Model 453.091/391/491 GF08.20-P-3001KJE control unit N127 Contents, function description of electric GF46.35-P-0999KJ power steering (ES) Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, gf46.35-p-9997kj, Overview of system components of electric power steering (ES) Model 453.0/3/4

Remove/install

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2037 · Applies to: 453 · AR: AR01.20-P-5015FF, AR61.20-P-1105FF

1 Remove trim panel of cylinder head cover AR01.20-P-5015FF 2 Disconnect temperature sensor connector upstream of diesel particulate filter (B19/9x1) 3 Remove cable tie (12) and loosen the wiring harness (8) of the temperature sensor upstream of diesel particulate filter (B19/9) from the bracket (7) 4 Unscrew the bolt (19) of the catalytic Installation:

Install new self-locking bolt converter diesel particulate unit (3) at the (19) crankcase *BA49.10-P-1001-01P

5 Unscrew bolt (10) and remove bracket (5) for purge lines (4) 6 Loosen hose clamps (11) and pull the purge Pay attention to the installation position of hoses (6) out of the purge lines (4) the purge hoses (6) at the purge lines (4). 7 Loosen O2 sensor connector upstream TWC [KAT] (G3/2x1) from the bracket (1) and disconnect. 8 Unscrew bolt (9) and detach clamp (2) *BA49.10-P-1002-01P

9 Detach lower engine compartment paneling AR61.20-P-1105FF 10 Unscrew bolt (17) and detach clamp (18) *BA49.10-P-1003-01P

11 Unscrew bolt (15) and nut (16), remove Installation:

Replace self-locking bolt (15) bracket (14) and remove the catalytic and nut (16) of bracket (14). converter diesel particulate filter unit (3) with sealing ring from below 12.1 Unscrew O2 sensor upstream three way When replacing the catalytic converter diesel catalytic converter (G3/2) particulate filter unit (3). *450589040900

*BA14.00-P-1001-01D

Paste BR00.45-Z-1005-06A 13.1 Unscrew purge lines (4) at the catalytic When replacing the catalytic converter diesel converter diesel particulate filter unit (3) and particulate filter unit (3). remove BA49.10-P-1006-01P

*BA49.10-P-1007-01P

14.1 Unscrew the temperature sensor upstream of When replacing the catalytic converter diesel the diesel particulate filter (B19/9) from the particulate filter unit (3). catalytic converter diesel particulate filter unit (3) Installation: Coat temperature sensor

upstream of DPF (B19/9) with heat-resistant lubricant prior to installation. *BA07.04-P-1002-01J

Paste *BR00.45-Z-1005-06A 15 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 16 Perform engine test run and check exhaust system around the catalytic converter diesel particulate filter unit (3) for leaks 17 Read out fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory STAR DIAGNOSIS diagnosis system Sensors

Number Designation Engine 639.9 BA07.04-P-1002-01J Temperature sensor to diesel particulate Nm 20 filter Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar49.10-p-5501ff, Remove, install catalytic converter diesel particulate filter unit ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter

Component description for electric drive

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3419 · Applies to: 453 · AR: GF08.20-P-3001KJE, GF42.45-P-5119KJ, GF82.30-P-0997KJ

Model 453.091/391/491 with engine 780 GF08.20-P-3001KJE control unit N127 Component description for Electronic Stability N30/4 GF42.45-P-5119KJ Program control unit Table of contents for function description of GF82.30-P-0997KJ windshield wiper system Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, gf82.30-p-9996kj, Overview of system components for windshield wiper system Model 453.0/3/4

Block diagram for

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3469 · Applies to: 453 · AR: OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA, PE42.00-P-1100ZA (+2 more)

PE Block diagram for 8.3.06 82.60-P-2003ZB smart radio MODEL 454 as from 3.4.06 PE82.60-P-2003-99ZB Block diagram for smart radio PE82.60-P-2003-99ZB PE82.60-P-2003-60ZB Legend of block diagram for smart radio PE82.60-P-2003-60ZB 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) PE42.00-P-1100ZA Further wiring diagrams PE42.00-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE82.00-P-1100ZA Further wiring diagrams PE82.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe82.60-p-2003zb, Block diagram for smart radio MODEL 454 as from 3.4.06

Pull air conditioner housing (1) inwards in

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3762 · Applies to: 453 · AR: AR20.00-P-1142SR

21 Pull air conditioner housing (1) inwards in direction of arrow until the drain hose (2) is accessible 22 Pull drain hose (2) out of floor panel 23 Remove air conditioner housing (1) out of the

vehicle with assistant Carefully remove air conditioner housing (1). Otherwise components in the vehicle interior may be damaged. 24 Install in the reverse order 25 Fill coolant, bleed cooling system and check it Model 453 with engine 281 with code I01 (Air conditioning Plus) for leaks Model 453 with engine 281 with code I77 (Air conditioning, manual) AR20.00-P-1142SR Battery Number Designation Model 453 BA54.10-P-1001-01I Bolt, battery bracket to body Nm 21 Air conditioning Number Designation Model 453 BA83.30-P-1002-01G Bolt/nut, low-pressure and high-pressure lines to expansion valve Nm 8 129 589 00 91 00 003 589 03 37 00 Record plug Hose clamp pliers Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar83.30-p-5200sr, Remove/install air conditioner housing Model 453 with engine 281 with code I01 (Air conditioning Plus) Model 453 with engine 281 with code I77 (Air conditioning, manual) Model 453 with engine 780.997 with code I01 (Air ...

Remove air intake duct with air intake muffler On engine 639.9

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3824 · Applies to: 453 · AR: AP20.00-P-2010FF, AP20.00-P-2010FG, AR83.70-P-0017FF

9.1 Remove air intake duct with air intake muffler On engine 639.9 (24) of heater (9) from bracket on fender inner panel (3) 10 Remove expansion clips (arrows) of fender inner panel (3) 11 Unscrew bolt (2) of retaining bracket for coolant hoses (14, 16) from fender inner panel (3) and remove spacer sleeve 12 Use snap-release tool to release fender inner *452589016300

panel (3) in front area 13 Position base jack (6) with removal fixture (5) Either the base jack (6) from the Mazzola under heater (9) or AS Hydraulic company can be used. *450589026200

Base jack Base jack 14 Unscrew bolts (7) on washer fluid reservoir (4) and remove spacer washers between washer fluid reservoir (4) and bracket (21) 15 Carefully lower heater (9) until the Ejot bolts When lowering the heater (9), make sure (22), coolant hoses (14, 16) and the air intake that the electric wiring harnesses, the 2-pin duct with air intake muffler (24) and the 2-pin connector (10), 6-pin connector, and the connector (10) are accessible coolant hoses (14, 16) on the heater (9) are not damaged. The air intake duct with air intake muffler (24) need only be observed on engines 134.9, 135.9. *450589026200

Base jack Base jack 16.1 Detach hose clamp (20) and remove air intake On engines 134.9 and 135.9 duct with air intake muffler (24) from heater (9) Allow the air intake duct with air intake muffler (24) to hang on the coolant hoses (14, 16). 17 Unscrew Ejot bolts (22) on bracket (21) of *BA83.70-P-1001-01D

heater (9) 18 Remove bracket (21) of heater (9) 19 Unclip cover (11) on heater (9) using suitable screwdriver and remove 20 Detach 2-pin connector (10) and circulation pump (12) from heater (9) 21 Disconnect coolant hoses (14, 16) using suitable hose grippers (13) 22 Detach hose clamp (15) and remove coolant Collect escaping coolant in a suitable hose (14) container. 23 Detach hose clamp (17) and remove coolant Collect escaping coolant in a suitable hose (16) container. 24 Unscrew bolt (19) and remove retaining bracket (18) of circulation pump (12) 25 Remove circulation pump (12) Installation:

When replacing the circulation pump (12), modify the coolant connection (23) for the new circulation pump (12) to match the removed circulation pump (12). Install new gasket and screws. 26 Install in the reverse order Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 27 Conduct engine test run, check fuel system and cooling system for leaks 28 Check coolant level, top up if necessary Engine cooling system - check fluid level, Engines 134, 135 AP20.00-P-2010FF

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration Engine 639 AP20.00-P-2010FG 29 Perform test run of stationary heater; in the AR83.70-P-0017FF Stationary heater diagnostic tool: event of malfunction connect stationary heater Order number: Q002 1664 V000 000000 diagnostic tool and troubleshoot. Finally, delete the fault memory Stationary heater

Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar83.70-p-5700ff, Remove/install coolant circulation pump MODEL 454.0## 1# with ENGINE 639.9 with CODE (I58) stationary heater, diesel with CODE (LHD) Left-hand drive vehicle MODEL 454.0## 1# with ENGINE 134.9, 135.9 with CODE (I60) ...

Install in the reverse order

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3830 · Applies to: 453 · AR: AP20.00-P-2010FF, AP20.00-P-2010FG, AR83.70-P-0017FF

26 Install in the reverse order 27.1 Attach new duplicate plate to radiator support When replacing the heater (9). and remove non-applicable year data Risk of accident Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not grasp hot or rotating parts. running engine 28 Conduct engine test run, check fuel system and cooling system for leaks 29 Check coolant level, top up if necessary Engine cooling system - check fluid level, Engines 134, 135 AP20.00-P-2010FF

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration Engine 639 AP20.00-P-2010FG 30 Perform test run of stationary heater; in the AR83.70-P-0017FF Stationary heater diagnostic tool: event of malfunction connect stationary heater Order number: Q002 1664 V000 000000 diagnostic tool and troubleshoot. Finally, delete the fault memory Stationary heater

Number Designation Type 454 BA83.70-P-1001-01D Ejot bolt for bracket to heater Nm 10 BA83.70-P-1002-01D Ejot stud bolt to heater Nm 10 450 589 02 62 00 452 589 01 63 00 Removal assembly Snap-release tool Page 4 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar83.70-p-5302ff, Remove/install heater unit MODEL 454.0## 1# with ENGINE 639.9 with CODE (I58) stationary heater, diesel with CODE (LHD) Left-hand drive vehicle MODEL 454.0## 1# with ENGINE 134.9, 135.9 with CODE (I60) ...

Risk of accident

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3833 · Applies to: 453 · AR: AP20.00-P-2010FF, AP20.00-P-2010FG, AR83.70-P-0017FF

Secure vehicle to prevent it from moving by Danger! caused by vehicle starting AS00.00-Z-0005-01A

off by itself when engine is running. Risk of itself. injury Wear closed and snug-fitting work clothes. caused by contusions and burns during starting procedure or when working near the Do not touch hot or rotating parts. engine as it is running 23 Conduct engine test run, check fuel system and cooling system for leaks 24 Start up stationary heater AZ83.70-P-0008-04FF 25 Attach stationary heater duplicate plate AZ83.70-P-0008-05FF retroactively 26 Check coolant level, top up if necessary Engine cooling system - check fluid level, Engine 134.9, 135.9 AP20.00-P-2010FF

adjust to correct level. Inspect anticorrosion/ antifreeze protection, adjust to correct concentration Engine 639.9 AP20.00-P-2010FG 27 Perform test run of stationary heater; in the Stationary heater diagnostic tool: event of malfunction connect stationary heater Order number: Q002 1664 V000 000000 diagnostic tool and troubleshoot. Finally, delete the fault memory Connect diagnostic tool to auxiliary heater AR83.70-P-0017FF

(water heater) 28.1 Enter special equipment in the vehicle data If workshop does not have access to a DMS card and in the vehicle's online data card Autoline 8.0 dealer system. Add code (I58) Stationary heater, diesel or code (I60) Stationary heater, gasoline. Fuel pump

Number Designation Engine Engine Engine Engine 134.910 134.911 135.930 135.950 BA47.20-P-1001-01D Tank bleeder at fuel pump Nm 5 5 5 5 Stationary heater

Number Designation Model 454 BA83.70-P-1001-01D Ejot bolt for bracket to heater Nm 10 BA83.70-P-1002-01D Ejot stud bolt to heater Nm 10 450 589 00 07 00 450 589 00 70 00 450 589 01 63 00 450 589 01 70 00 Tank module tool Graduated drill Hot-air gun Twist drill bit set Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, az83.70-p-0020ff, Retrofit Webasto Thermo Top C water heater MODEL 454.0## 1# with ENGINE 134.9, 135.9, 639.9 with CODE (LHD) Left-hand drive vehicle