453 — fortwo / forfour (2014-2024) — Fuel & Exhaust¶
Workshop and reference excerpts for 453 — fortwo / forfour (2014-2024) in the Fuel & Exhaust system.
42 excerpts from 1 sources.
2014-2024 Smart Fortwo 453 Workshop Manual.pdf¶
SI00.00-Z-0152A¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 64 · Applies to: 453 · AR: AR47.70-P-0017MFH, AR47.70-P-0017MEH, AR54.10-P-1215ME, AR47.70-P-0017EQ
Service Information: Evaluation of lithium-ion battery after an accident, fire or 22.01.2020 complaints Model all (CAR, smart) !!! Important !!!
On vehicles with lithium-ion batteries, all of the following information that is relevant for the vehicle must be observed to assess safety before starting work following an accident, fire or problems with the lithium-ion battery! Check
Risk of fire/risk of explosion due to short No fires, sparks, open flames, or smoking. AS54.10-Z-0001-01A Danger
circuit and escaping oxyhydrogen gas. Risk of Wear acid-resistant gloves, clothing, and (burn) injury caused by caustic burns to eyes, glasses. Pour battery acid only into suitable skin and mucous membranes from battery and appropriately marked containers. electrolyte/mist, short circuit and arcing. Risk of poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC. 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 Topical note Notes on battery AH54.10-P-0001-01A 1 Check whether you have the required Service Information: Qualification measures SI00.00-P-0156A qualification for assessing the safety of lithium- for working on high-voltage on-board electrical ion batteries systems and lithium-ion batteries The required Mercedes-Benz/smart
specific qualification/instructions can also be obtained from Mercedes-Benz Global Training. Your MPC can inform you about whether further qualifications/instructions are required for any additional country-specific regulations and laws. Do you have the required qualification? If no, you may not assess safety on vehicles with lithium-ion batteries! If the answer is yes, continue with operation step 2 2 Check lithium-ion battery Model 177, 247 with engine 282 AR47.70-P-0017MFH
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN)) Model 167.117/154/317/354 AR47.70-P-0017MEH
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in)) Model 167 AR54.10-P-1215ME
with code B01 (48V technology) Model 293 AR47.70-P-0017EQ
Before driving into the workshop, perform
an initial assessment for acute problems! Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, si00.00-z-0152a, Service Information: Evaluation of lithium-ion battery after an accident, fire or complaints Model all (CAR, smart)
B4/3¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 116 · Applies to: 453 · AR: PE47.40-P-2101BBA, PE54.18-P-2300BBA, PE07.61-P-2101BBB, PE07.61-P-2101BBC, PE54.18-P-2300BBB (+5 more)
Fuel tank pressure sensor 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 B4/3 Fuel tank pressure sensor 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 B4/4 Wide-open throttle purging pressure sensor Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBB year 2020 Plug AC B4/4 Wide-open throttle purging pressure sensor Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBC year 2020 Plug AB B41/1 Front passenger seat occupied recognition 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 B41/1 Front passenger seat occupied recognition 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 B44/5 Interior protection sensor 1 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) B44/6 Interior protection sensor 2 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) B48/1 Driver-side frontal acceleration 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 B48/2 Passenger-side frontal acceleration 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 B48/7 Driver door pressure sensor 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 B48/7 Driver door pressure 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 B48/8 Front passenger door pressure sensor 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 B48/8 Front passenger door pressure 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 B5/1 Charge pressure sensor Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBB year 2020 Plug AC B5/1 Charge pressure sensor Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBC year 2020 Plug AB B56/1 Transmission mode recognition sensor Transmission 700.4 in model 453.0/3/4 up to PE27.19-P-2106BBA model year 2020 with code 429 (twinamic) B6/15 Intake camshaft Hall sensor Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBC year 2020 Plug AB B64/1 Brake vacuum sensor 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 B8/10 Center rear parking system distance sensor 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 B8/10 Center rear parking system distance sensor 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) B8/8 Right rear parking system distance sensor 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 B8/8 Right rear parking system distance sensor 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) B8/9 Left rear parking system distance sensor 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 B8/9 Left rear parking system distance sensor 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) B82 Vehicle interior humidity and temperature Model 453.0 (except 453.091), 453.3 (except PE54.15-P-2001BBC sensor 453.391), 453.4 (except 453.491) up to model year 2020 F2 Plug AB to AE B82 Vehicle interior humidity and temperature Model 453.0 (except 453.091), 453.3 (except PE54.18-P-2300BBE sensor 453.391), 453.4 (except 453.491) up to model year 2020 Sheet5 Page 6 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
SI00.00-Z-0152A¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 227 · Applies to: 453 · AR: AR47.70-P-0017MFH, AR47.70-P-0017MEH, AR54.10-P-1215ME, AR47.70-P-0017EQ
Service Information: Evaluation of lithium-ion battery after an accident, fire or 22.01.2020 complaints Model all (CAR, smart) !!! Important !!!
On vehicles with lithium-ion batteries, all of the following information that is relevant for the vehicle must be observed to assess safety before starting work following an accident, fire or problems with the lithium-ion battery! Check
Risk of fire/risk of explosion due to short No fires, sparks, open flames, or smoking. AS54.10-Z-0001-01A Danger
circuit and escaping oxyhydrogen gas. Risk of Wear acid-resistant gloves, clothing, and (burn) injury caused by caustic burns to eyes, glasses. Pour battery acid only into suitable skin and mucous membranes from battery and appropriately marked containers. electrolyte/mist, short circuit and arcing. Risk of poisoning caused by swallowing battery electrolyte or absorption of lead through the skin or body orifices. Risk of death due to voltage U >= 30 V AC and U >= 60 V DC. 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 Topical note Notes on battery AH54.10-P-0001-01A 1 Check whether you have the required Service Information: Qualification measures SI00.00-P-0156A qualification for assessing the safety of lithium- for working on high-voltage on-board electrical ion batteries systems and lithium-ion batteries The required Mercedes-Benz/smart
specific qualification/instructions can also be obtained from Mercedes-Benz Global Training. Your MPC can inform you about whether further qualifications/instructions are required for any additional country-specific regulations and laws. Do you have the required qualification? If no, you may not assess safety on vehicles with lithium-ion batteries! If the answer is yes, continue with operation step 2 2 Check lithium-ion battery Model 177, 247 with engine 282 AR47.70-P-0017MFH
with code ME08 (Hybrid drive 75-84 kW VARIANT (INCLUDING PLUGIN)) Model 167.117/154/317/354 AR47.70-P-0017MEH
with code ME05 (Hybrid drive 85 kW-94 kW variant (incl. plug-in)) Model 167 AR54.10-P-1215ME
with code B01 (48V technology) Model 293 AR47.70-P-0017EQ
Before driving into the workshop, perform
an initial assessment for acute problems! Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, si00.00-z-0152a, Service Information: Evaluation of lithium-ion battery after an accident, fire or complaints Model all (CAR, smart)
If coolant was replaced on the vehicle as¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 489 · Applies to: 453 · AR: AP47.20-P-0780FF, AP20.00-P-2080FF, AP05.30-P-0560FF, AR05.00-P-7601FB, AP83.00-P-8384FF (+5 more)
part of an engine or accident repair, then the coolant is to be replaced correspondingly later. Document change of coolant in service booklet. Every 3 years or at 60,000 km Replace fuel filter AP47.20-P-0780FF on diesel engines
Document the fuel filter change in the service booklet. Every 4 years or at 80,000 km Replace coolant AP20.00-P-2080FF on gasoline engines
If coolant was replaced on the vehicle as part of an engine or accident repair, then the coolant is to be replaced correspondingly later. Document change of coolant in service booklet. Every 100,000 km Check valve clearance, set if necessary AP05.30-P-0560FF on gasoline engines except 90 and 130 kW Every 100,000 km Replace timing belt AR05.00-P-7601FB
on 130 kW BRABUS engine Document the timing belt change in the service booklet. Service Not OK A B Vehicle interior Replace combination filter On vehicles with code (I01) AP83.00-P-8384FF Air conditioning Plus or code (I43) Combination filter (DFO/FFO) or code (I77) Manual air conditioning Check headlamp flasher, hazard warning flasher, turn signal lamps for proper operation Check seat belts and buckles for external AP91.40-P-9150FF damage and correct operation Vehicle front, vehicle rear Check the front lamps, rear lamps and side marker lamps Check headlamp range adjustment of headlamps for proper operation Check headlamp and front fog lamp AP82.10-P-8260FF adjustment, correct if necessary Check function of headlamp cleaning system On vehicles with code (22Y) Headlamp cleaning system Trunk Correct spare tire inflation pressure On vehicles with code (R02) Emergency wheel For specified values of tire inflation pressure, see adhesive label on spare tire. Check tread depth of spare tire and check for On vehicles with code (R02) spare tire damage Emergency wheel TIREFIT puncture sealing compound - check AP40.10-P-4054FF On vehicles without code (R02) expiration date Emergency wheel Replace subject to a separate repair order. If the expiration date of the tire repair kit is reached, then the compressor should also be checked for proper operation. Engine compartment Engine and transmission: check for damage AP00.20-P-0050FF and leaks by means of visual inspection Fuel system: visually inspect for damage and AP47.00-P-4750FF leaks Cooling system: visually inspect for damage and leaks Brake lines and brake system: Check for fixing, damage and leaks by means of visual inspection Replace air filter element on gasoline engine except 130 kW BRABUS AP09.10-P-0980FF engine on diesel engine or 130 kW BRABUS engine AP09.10-P-0980FG Service fluids Battery: Check fluid level, correct if necessary AP54.10-P-5410FF Page 3 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
P09.40-2496-08¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 975 · Applies to: 453 · AR: AR49.10-P-6905SR
1 ATL 15 Banjo bolt 12 Nuts 16 Oil feed line 13 Bracket 17 Screw/bolts 14 Clip 18 Charge air 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. 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. 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 covering over engine Installation: Only install covering over
engine after the leak test. 4 Remove air intake hose (2) 5 Remove all heat shield over the CAT AR49.10-P-6905SR 6 Remove safety clamp (3) Installation: Replace safety clamp (3).
7 Remove control rod (4) from exhaust manifold (5) 8 Disconnect electrical connection (6) 9 Disconnect electrical connection (7) 10 Remove coolant hose (8) Collect escaping coolant in a suitable
container. Installation: Replace clamp if necessary.
*003589033700 Hose clamp pliers 11 Remove coolant hose (9) Collect escaping coolant in a suitable
container. Installation: Replace clamp if necessary.
003589033700 Hose clamp pliers 12 Remove screws/bolts (10) BA09.40-P-1004-02A Screw/bolt, oil return flow line to exhaust gas turbocharger 13 Detach oil return line (11) at ATL (1) 14 Lower vehicle with vehicle lift 15 Unscrew nuts (12) Page 2 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)
P09.40-2496-08¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 978 · Applies to: 453 · AR: AR49.10-P-6905SR, AR49.10-P-5500SRA
1 ATL 15 Banjo bolt 12 Nuts 16 Oil feed line 13 Bracket 17 Screw/bolts 14 Clamp 18 Charge air 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. 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. 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 covering over engine Installation: Only install covering over
engine after the leak test. 4 Remove air intake hose (2) 5 Remove all heat shield over the CAT AR49.10-P-6905SR 6 Remove catalytic converter AR49.10-P-5500SRA 7 Disconnect electrical connection (6) 8 Disconnect electrical connection (7) 9 Remove coolant hose (8) Collect escaping coolant in a suitable
container. Installation: Replace clamp if necessary.
*003589033700 Hose clamp pliers 10 Remove coolant hose (9) Collect escaping coolant in a suitable
container. Installation: Replace clamp if necessary.
003589033700 Hose clamp pliers 11 Remove screw/bolts (10) BA09.40-P-1004-02A Screw/bolt, oil return flow line to exhaust gas turbocharger 12 Unfasten oil return line (11) from ATL (1) 13 Lower vehicle with vehicle lift 14 Remove banjo bolt (15) *BA09.40-P-1003-02A Banjo bolt, oil feed line to exhaust gas turbocharger 15 Unfasten oil feed line (16) from ATL (1) Page 2 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
AZ14.40-P-1000FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1044 · Applies to: 453 · AR: AZ14.40-P-1000FF, AR49.10-P-5500FG
Retrofit diesel particulate filter 18.8.06 ENGINE 639.9 in MODEL 454.0 except CODE (K13) Diesel particulate filter Removing
1 Remove catalytic converter Remove, install catalytic converter AR49.10-P-5500FG
Install
2 Install catalytic converter diesel particulate The catalytic converter diesel particulate filter unit filter unit is installed instead of the catalytic converter. Remove, install catalytic converter AR49.10-P-5500FG
3.1 Enter special equipment in vehicle data card If workshop does not have access to a DMS and in vehicle's online data card Autoline 8.0 dealer system. Endorse code (40Z) Diesel particulate filter (accessory). 4 Place certificate/report for customer in the vehicle Retrofit diesel particulate reduction catalytic * for Germany only OF14.40-P-1000-01E converter, certificate Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, az14.40-p-1000ff, Retrofit diesel particulate filter ENGINE 639.9 in MODEL 454.0 except CODE (K13) Diesel particulate filter
AP47.00-P-4750FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1983 · Applies to: 453 · AR: AP47.00-P-4750FF
Fuel system - check for leaks and condition 25.11.04 ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0 Check 1 Carry out visual inspection for damage and If fuel system is damaged or leaky: leaktightness on fuel system Repair damage or leaks. - Subject to separate repair order. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap47.00-p-4750ff, Fuel system - check for leaks and condition ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0
AR47.10-P-4001FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1989 · Applies to: 453 · AR: AR47.10-P-4001FF, AR68.10-P-1500FF, AR68.10-P-1400FF
Empty, fill fuel tank 20.3.06 MODEL 454.0 with ENGINE 134.9, 135.9 1 Clamp 2 Fuel pipe 3 Fuel distributor 4 Adapter
5 Drain hose 6 Hose clamp P47.10-2313-06 P47.10-2379-07 7 Jumper cable K40/1 Fuse and relay module Removal
Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by fuel igniting, AS47.00-Z-0001-01A risk of poisoning Pour fuels only into suitable and appropriately caused by inhaling and swallowing fuel and risk of injury marked containers. to eyes and skin caused by contact with fuel. Wear protective clothing when handling fuel. 1.1 Remove cover below left of instrument panel On vehicles with code (LHD) left-hand drive AR68.10-P-1500FF vehicle 1.2 Remove glove compartment On vehicles with code (RHD) right-hand drive AR68.10-P-1400FF vehicle 2 Pull relay 2, fuel pump out of the fuse and relay module (K40/1) Fuse and relay box relay assignment GF54.15-P-1255-21FG
3 Unscrew the cap at the fuel tank filler neck So that there is no vacuum in the fuel tank when pumping out the fuel. 4 Open engine hood 5 Expand the clamp (1) by hand and pull the Catch fuel coming out in suitable vessel fuel line (2) from the connection of the fuel Seal off the opening at the connection of the distributor (3) fuel distributor (3) with a suitable plug. 6 Insert adapter (4) into the fuel line (2) Make sure the adapter (4) is correctly seated in the fuel line (2). *454589049100
7 Plug the drain hose (5) onto the adapter (4) *454589049100
and secure with the hose clamp (6) 8 Insert the other end of the drain hose (5) into a suitable safety canister Draining Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.10-p-4001ff, Empty, fill fuel tank MODEL 454.0 with ENGINE 134.9, 135.9
AR47.10-P-4001FG¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1991 · Applies to: 453 · AR: AR47.10-P-4001FG, AR68.10-P-1500FF, AR68.10-P-1400FF
Empty, fill fuel tank 20.3.06 MODEL 454.0 with ENGINE 639.9 P47.10-2378-07 1 Fuel pipe 5 Drain hose 3 Adapter
2 Fuel pipe 4 Hose clamp P47.10-2379-07 7 Jumper cable K40/1 Fuse and relay module Removal
Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by fuel igniting, AS47.00-Z-0001-01A risk of poisoning Pour fuels only into suitable and appropriately caused by inhaling and swallowing fuel and risk of injury marked containers. to eyes and skin caused by contact with fuel. Wear protective clothing when handling fuel. 1.1 Remove cover below left of instrument panel On vehicles with code (LHD) left-hand drive AR68.10-P-1500FF vehicle 1.2 Remove glove compartment On vehicles with code (RHD) right-hand drive AR68.10-P-1400FF vehicle 2 Pull relay 2, fuel pump out of the fuse and relay module (K40/1) Fuse and relay box relay assignment GF54.15-P-1255-21FG
Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A toppling off of the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 3 Raise vehicle 4 Carefully depress release (arrow) and Catch fuel coming out in suitable vessel disconnect fuel line (1) from fuel line (2) Use a suitable plug to seal the opening of the fuel line (2). 5 Insert adapter (3) into the fuel line (1) Make sure the adapter (3) is correctly seated in the fuel line (1). *454589049100
6 Plug the drain hose (5) onto the adapter (3) *454589049100
and secure with the hose clamp (4) 7 Insert the other end of the drain hose (5) into a suitable safety canister 8 Lower vehicle Draining 9 Unscrew the cap at the fuel tank filler neck So that there is no vacuum in the fuel tank when pumping out the fuel. 10 Insert the jumper cable (7), as shown, at the Use a suitable jumper cable (7). position of relay 2, fuel pump 11 Switch the ignition on and pump the fuel out of The fuel pump with fuel level sensor must the tank into the safety container not be allowed to dry for more than 3 minutes, otherwise it will be damaged. The delivery rate of the fuel pump with tank level sensor is approx. 1 liter/16.5 s. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.10-p-4001fg, Empty, fill fuel tank MODEL 454.0 with ENGINE 639.9
AR47.10-P-4001SR¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1993 · Applies to: 453 · AR: AR47.10-P-4001SR
Empty/fill fuel tank 4.5.15 Model 453 with engine 281 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. Discharge, fill 1 Open fuel filler flap and unscrew tank cap 2 Connect ground line of transfer device with vehicle 000 588 02 71 00 Pump WS47.00-P-0017B
3 Push extraction hose as far as possible through the filler pipe in the fuel tank 4 Pump off fuel into a safety container using the transfer device 5 Pull extraction hose through the filler pipe from the fuel tank 6 Detach ground line of the transfer device from vehicle 7 Screw on tank cap and close fuel filler flap 8 Fill in reverse order Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar47.10-p-4001sr, Empty/fill fuel tank Model 453 with engine 281
AR47.10-P-4100FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1994 · Applies to: 453 · AR: AR47.10-P-4100FF, AR47.10-P-4001FB, AR47.10-P-4001FF, AR47.10-P-4001FG
Remove, install fuel tank 20.3.06 MODEL 454.0 with ENGINE 122.9, 134.9, 135.9, 639.9 Shown on vehicle with engine 135.9 1 Fuel tank 2 Bolt 3 Hose clamp 4 Fuel tank filler neck 5 Hose 6 Hose 7 Electrical line 8 Locking ring 9 Heat shield 10 Retaining strap 11 Exhaust system 12 Base jack
M3/3 Fuel pump with fuel level sensor P47.10-2221-06 Remove/install
Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by fuel igniting, AS47.00-Z-0001-01A risk of poisoning Pour fuels only into suitable and appropriately caused by inhaling and swallowing fuel and risk of injury marked containers. to eyes and skin caused by contact with fuel. Wear protective clothing when handling fuel. 1 Drain fuel tank (1) Engine 122.9 AR47.10-P-4001FB Engines 134.9, 135.9 AR47.10-P-4001FF Engine 639.9 AR47.10-P-4001FG Installation:
when filling the fuel tank (1), look out for leaks in the fuel system around the fuel tank (1). 2 Unscrew bolt (2) at fuel tank filler neck (4) and Installation:
Install new self-locking bolt remove ground line (2) *BA47.10-P-1003-01H
3 Loosen the hose clamp (3) and pull the fuel Installation:
Pay attention to the correct filler neck (4) with ventilation line out of the positioning of the ventilation line in the fuel fuel tank (1) tank (1). 4 Support fuel tank (1) using base jack (12) and The base jacks (12) of the companies removal fixture Mazzola and AS Hydraulic can be used as required. *450589026200
WH58.30-Z-1011-07A Base jack Co. Mazzola WH58.30-Z-1011-07A Base jack Fa. AS Hydraulic 5 Unscrew nuts at retaining strap (10). Installation:
Replace self-locking nuts at the retaining strap (10). *BA47.10-P-1002-01H
6 Detach fuel tank (1) from body. Installation: Install new self-locking nuts. *BA47.10-P-1001-01H
7 Carefully lower fuel tank (1) until access to When lowering, bypass the fuel tank (1) at fuel pump and fuel level sensor (M3/3) is the exhaust system (11). possible 8 Dismantle hoses (5, 6) and electrical line (7) On vehicles with engine 122.9, in addition at fuel tank with fuel level sensor (M3/3) to hoses (5, 6), a further hose is located at the fuel pump with fuel level sensor (M3/3), which must be detached. 9 Lower fuel tank (1) The base jacks (12) of the companies Mazzola and AS Hydraulic are selectively usable. *450589026200
*WH58.30-Z-1011-07A Main lifter Co. Mazzola Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.10-p-4100ff, Remove, install fuel tank MODEL 454.0 with ENGINE 122.9, 134.9, 135.9, 639.9
AR47.10-P-7541FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1996 · Applies to: 453 · AR: AR47.10-P-7541FF, AR88.60-P-6023FF, AR47.10-P-4001FB, AR47.10-P-4001FF, AR47.10-P-4001FG
Remove/install filler neck of fuel tank 6.6.03 MODELS 454.0 with ENGINE 122.950, 134.9, 135.9, 639.939 1 Bolt 2 Fuel tank filler neck 3 Clamps 4 Ground cable 5 Fuel tank 6 Pressurization line P47.10-2220-06 Remove/Install
Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by fuel igniting, AS47.00-Z-0001-01A
risk of poisoning Pour fuels only into suitable and appropriately caused by inhaling and swallowing fuel as well as risk of injury marked containers. to eyes and skin caused by contact with fuel. Wear protective clothing when handling fuel. 1 Remove tank flap AR88.60-P-6023FF 2 Empty fuel tank (5) Engine 122.950 AR47.10-P-4001FB Engine 134.9, 135.9 AR47.10-P-4001FF Engine 639.939 AR47.10-P-4001FG Installation:
When refilling the fuel tank, pay attention to leaktightness of the fuel tank (5) in the area of the fuel tank (5). 3 Slacken clamp (3) on fuel tank (5) 4 Unscrew bolt (1) and remove ground Replace bolt (1). line (4). *BA47.10-P-1003-01H
5 Pull fuel tank filler neck (2) from fuel tank (5) Installation:
Make sure the vent line (6) is and remove from below correctly positioned in the fuel tank (5). 6.1 Detach the clamp (3) at filler neck of fuel tank When replacing filler neck of fuel tank (2). (2) and modify connector hose 7 Install in the reverse order Fuel tank
Number Designation Model 454.0 BA47.10-P-1003-01H Bolt of filler neck to body Nm 8 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.10-p-7541ff, Remove/install filler neck of fuel tank MODELS 454.0 with ENGINE 122.950, 134.9, 135.9, 639.939
AR47.10-P-4100SR¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1997 · Applies to: 453 · AR: AR47.10-P-4100SR
Remove/install fuel tank 12.1.16 Model 453 with engine 281 1 Screw/bolts 2 Filler neck 3 Nut 4 Ground line P47.10-2749-04 P47.10-2750-09 2 Filler neck 9 Coupling connection 5 Vent line 10 Fuel tank 6 Activated charcoal canister 11 Screw/bolts 7 Electrical connection 12 Electrical line 8 Fuel line Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.10-p-4100sr, Remove/install fuel tank Model 453 with engine 281
Filler neck¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1998 · Applies to: 453 · AR: AR47.10-P-4001SR, AR88.10-P-1400SRA, AR88.10-P-1400SR, AR61.10-P-5139SRC
2 Filler neck 6 Activated charcoal canister 8 Fuel line 10 Fuel tank P47.10-2751-12 Risk of explosion No fires, sparks, open flames or smoking. Danger ! caused by fuel igniting, risk AS47.00-Z-0001-01A
of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Remove/install
1 Drain fuel tank (10) AR47.10-P-4001SR 2 Remove fender liner in right rear fender Model 453.3/4 with engine 281 AR88.10-P-1400SRA Model 453.0 with engine 281 AR88.10-P-1400SR 3 Remove screws/bolts (1) at filler neck (2) 4 Unscrew nut (3) and remove ground line (4) 5.1 Remove rear underfloor paneling Model 453.3 with engine 281 5.2 Remove underfloor paneling at rear and centerModel 453.0 with engine 281 6 Remove diagonal strut and cross strut at the Model 453.4 with engine 281 rear AR61.10-P-5139SRC 7 Unlock vent line (5) on activated charcoal canister (6) and detach 8 Remove electrical connection (7) from undercarriage and separate 9 Unclip fuel line (8) on undercarriage 10 Disconnect fuel line (8) from coupling connection (9) 11 Support fuel tank (10) with a telescopic lifter and removal fixture 000 588 11 62 00 Major assembly mount WS01.00-P-0092B
450589026200 Removal fixture 12 Remove screw/bolts (11) and lower fuel tank BA47.10-P-1001-01Q Bolt, fuel tank to body (10) until the electrical line (12) is accessible 13 Unclip electrical line (12) from fuel tank (10) 14 Lower fuel tank (10) while leading the filler Helper required.
neck (2) out of the wheel well at the right rear 15 Remove fuel tank (10) Helper required.
16 Install in the reverse order Check
17 Check fuel tank (10) and connections for leaktightness Fuel tank Number Designation Model 453 with engine 281 BA47.10-P-1001-01Q Bolt, fuel tank to body Nm 21 Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.10-p-4100sr, Remove/install fuel tank Model 453 with engine 281
AR47.20-P-7000SR¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2002 · Applies to: 453 · AR: AR47.20-P-7000SR
Remove/install fuel pump and fill level sensor 04.10.2016 Model 453 with engine 281 Modification notes 23.08.2016 Special tool 001 589 00 07 00 replaced by 450 589 00 05 Operation step 8 00. P47.20-2536-09 Shown except CODE 494 (USA version) 1 Latch 4 Electrical connection 2 Fuel line 5 Sealing ring 3 Fuel tank M3/3 Fuel pump with fill level sensor and temperature sensor With code 494 (USA version), shown up to 31.05.2016 1 Latch 6 Anti-twist locks 8 Vent line B4/3 Fuel tank pressure sensor M3/3 Fuel pump with fill level sensor and temperature sensor P47.20-2572-11 Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.20-p-7000sr, Remove/install fuel pump and fill level sensor Model 453 with engine 281
M3/3¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2003 · Applies to: 453 · AR: AR47.10-P-4100SR
Fuel pump with fill level sensor and temperature sensor P47.20-2537-12 Risk of explosion No fires, sparks, open flames or smoking. Danger ! caused by fuel igniting, risk AS47.00-Z-0001-01A
of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Remove/install
1 Remove fuel tank (3) AR47.10-P-4100SR 2 Disconnect electrical connection (4) 3 Disconnect electrical connection on fuel tank Model 453 with engine 281 pressure sensor (B4/3) with code 494 (US version) 4 Unlock fuel line (2) fuel line and detach from fuel pump with fill level sensor and temperature sensor (M3/3) 5 Unlock vent line (8) and detach from fuel pump Model 453 with engine 281 with fill level sensor and temperature sensor with code 494 (US version) (M3/3) 6 Remove anti-twist locks (6) Model 453 up to 5/31/16 with engine 281 with code 494 (US version) AR47.20-P-7000-01SR Installation:
The bonding of the anti-twist locks (6) must be replaced by a felt strip laid around the latch (1). Already present felt strip must be installed new. Noise development or damage can occur otherwise. Felt strip *BR00.45-Z-1150-02A 7 Unfasten screw/bolts of anti-twist locks (6) and Model 453 as of 6/1/16 with engine 281 remove anti-twist locks (6) with code 494 (US version) Installation:
The bonding of the anti-twist locks (6) must be replaced by a felt strip laid around the latch (1). An already present felt strip must be installed new. Noise development or damage can occur otherwise. BA47.10-P-1002-01Q Screw/bolt, anti-twist lock to latch Felt strip BR00.45-Z-1150-02A 8 Model 453 with engine 281 Open latch (1) and remove except code 494 (US version) Installation: The markings (arrows) on the fuel tank (3) and on the locking ring (1) must be aligned with each other. *450589000500 Model 453 with engine 281 with code 494 (US version) Hook wrench Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.20-p-7000sr, Remove/install fuel pump and fill level sensor Model 453 with engine 281
AR47.20-P-7000FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2005 · Applies to: 453 · AR: AR47.20-P-7000FF
Remove/install fuel pump and fuel tank sensor 19.7.06 ENGINE 134.9, 135.9 in MODEL 454.0## ## up to 128917 1 Edge guard 2 Door sill molding 3 Bolts 4 Maintenance cover 5 Floor covering 6 Fuel pipe 7 Activated charcoal canister vent hose 8 Lug 9 Connector 10 Locking ring 11 Sealing ring M3/3 Fuel pump with fuel level sensor P47.20-2194-06 Removing
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 Detach left and right edge guard (1) for rear door in area of door sill molding (2) 2 Detach left and right door sill molding (2) in rear area 3 Fold back rear bench seat For vehicles with code (S33) Double folding rear bench seat (3 seats): place rear bench seat in its foremost position, retract head restraint and turnover rear seat backrest. Finally unlock rear bench seat and set vertically. Vehicles without code (S33) Double folding AR91.21-P-4000-01FF rear bench seat (3 seats) 4 Lift up floor mat (5) and support 5 Unscrew bolts (3) and remove the maintenance cover (4) 6 Unlock fuel line (6) and activated charcoal canister (7) vent hose at fuel pump with fuel level sensor (M3/3) and detach 7 Unscrew fish-plate (8) and remove the plug (9) 8 Unscrew locking ring (10) *450589000700
9 Take out fuel pump with fuel level sensor (M3/3) and sealing ring (11) Install
10 Take out fuel pump with fuel level sensor Replace sealing ring (11) on fuel pump (M3/3) and sealing ring (11) with fuel level sensor (M3/3). 11 Tighten locking ring (10) *450589000700
12 Connect plug (9) 13 Connect fuel line (6) and activated charcoal The fuel line (6) and activated charcoal canister (7) vent hose at fuel pump with a fuel canister (7) vent hose musty noticeable level sensor (M3/3) engage on fuel pump with fuel level sensor (M3/3). 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 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.20-p-7000ff, Remove/install fuel pump and fuel tank sensor ENGINE 134.9, 135.9 in MODEL 454.0## ## up to 128917
AR47.20-P-7000FG¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2007 · Applies to: 453 · AR: AR47.20-P-7000FG
Remove/install fuel pump and fuel tank sensor 19.7.06 ENGINE 639.9 in MODEL 454.0## ## up to 128917 1 Edge guard 2 Door sill molding 3 Bolts 4 Maintenance cover 5 Floor covering 6 Fuel pipe 7 Vent plug 8 Fuel pipe 9 Connector 10 Lug 11 Locking ring 12 Sealing ring M3/3 Fuel pump with fuel level sensor P47.20-2236-06 Removing
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. 1 Detach left and right edge guard (1) for rear door in the area of the door sill molding (2) 2 Detach left and right door sill molding (2) in rear area 3 Fold back rear bench seat For vehicles with code (S33) Double folding rear bench seat (3 seats): place rear bench seat in its foremost position, retract head restraint and turnover rear seat backrest. Finally unlock rear bench seat and set vertically. Vehicles without code (S33) Double folding AR91.21-P-4000-01FF rear bench seat (3 seats) 4 Lift up floor mat (5) and support 5 Unscrew bolts (3) and remove maintenance cover (4) 6 Unlock fuel lines (6, 8) at fuel pump with fuel level sensor (M3/3) and detach 7 Unscrew fish-plate (10) and remove plug (9) 8 Unscrew locking ring (11) *450589000700
9 Take out fuel pump with fuel level sensor (M3/3) and sealing ring (12) 10.1 Remove the vent plug (7) Only when replacing the fuel pump with fuel level sensor (M3/3). Install
11.1 Fit the vent plug (7) Only when replacing the fuel pump with fuel level sensor (M3/3). 12 Take out fuel pump with fuel level sensor Replace sealing ring (12) on fuel pump (M3/3) and sealing ring (12) with fuel level sensor (M3/3). 13 Tighten locking ring (11) *450589000700
14 Connect plug (9) 15 Connect fuel lines (6, 8) at fuel pump with fuel The fuel lines (6, 8) must noticeably level sensor (M3/3) engage on the fuel pump with fuel level sensor (M3/3). Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.20-p-7000fg, Remove/install fuel pump and fuel tank sensor ENGINE 639.9 in MODEL 454.0## ## up to 128917
AR47.20-P-7000FH¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2009 · Applies to: 453 · AR: AR47.20-P-7000FH, AR47.10-P-4100FF
Remove/install fuel pump and fuel tank sensor 19.7.06 ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0## ## as of 128918 1 Fuel tank 2 Locking ring M3/3 Fuel pump with fuel level sensor P47.20-2304-03 Remove/install
Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by fuel igniting, AS47.00-Z-0001-01A
risk of poisoning 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. 1 Remove fuel tank (1) AR47.10-P-4100FF 2 Unscrew locking ring (2) *450589000700
3 Remove fuel pump with fuel level sensor Installation:
Replace sealing ring on fuel (M3/3) and sealing ring from fuel tank (1) pump with fuel level sensor (M3/3). 4.1 Modify the vent plugs on the fuel pump with Only when replacing the fuel pump with fuel fuel level sensor (M3/3) level sensor (M3/3) for engine 639.9. 5 Install in the reverse order 450 589 00 07 00 Tank module tool Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.20-p-7000fh, Remove/install fuel pump and fuel tank sensor ENGINE 122.9, 134.9, 135.9, 639.9 in MODEL 454.0## ## as of 128918
AP47.20-P-0780FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2010 · Applies to: 453 · AR: AP47.20-P-0780FF, AR09.10-P-1150FG
Replace fuel filter 8.6.04 ENGINE 639.9 in MODEL 454.0 1 Fuel filter 2 Retaining strap 3 Fuel hoses P47.20-2229-04 Modification notes 16.3.05 Work step Remove trim on center piece in front of windshield taken away Remove/Install
Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by fuel igniting, AS47.00-Z-0001-01A
risk of poisoning Pour fuels only into suitable and appropriately caused by inhaling and swallowing fuel as well as risk of injury marked containers. to eyes and skin caused by contact with fuel. Wear protective clothing when handling fuel. 1 Remove air filter housing AR09.10-P-1150FG 2 Release fuel filter (1) from the tensioning strap (2) and detach fuel hoses (3) from fuel filter (1) 3 Remove fuel filter (1) 4 Install in the reverse order 5 Switch the ignition on and off three times For filling the fuel filter (1). 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 6 Carry out an engine test run and check the fuel system for leaks Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap47.20-p-0780ff, Replace fuel filter ENGINE 639.9 in MODEL 454.0
AR47.25-P-0025SR¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2011 · Applies to: 453 · AR: AR47.25-P-0025SR
Remove/install fuel line 11.08.2014 MODEL 453 with ENGINE 281 P47.25-2151-08 1 Fuel line 5 Coupling connection 2 Fuel line 6 Coupling connection 3 Fuel tank 7 Bracket 4 Bracket 2 Fuel line 3 Fuel tank 8 Coupling connection M3/3 Fuel pump with fill level sensor and temperature sensor P47.25-2152-12 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 explosion No fires, sparks, open flames or smoking. Danger ! caused by fuel igniting, risk AS47.00-Z-0001-01A
of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Remove/install
Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.25-p-0025sr, Remove/install fuel line MODEL 453 with ENGINE 281
Remove covering over engine¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2012 · Applies to: 453 · AR: AR47.10-P-4100SR
1 Remove covering over engine 2 Unclip fuel line (1) on bracket (4) 3 Release coupling connection (5) and detach fuel line (1) 4 Lift vehicle on vehicle lift 5 Release coupling connection (6) and detach fuel line (1) from fuel line (2) 6 Unclip fuel line (1) at brackets (7) and take off 7 Lower fuel tank (3) until the fuel line (2) is AR47.10-P-4100SR accessible 8 Release coupling connection (8) and detach fuel line (2) from fuel pump with fill level sensor and temperature sensor (M3/3) 9 Unclip fuel line (2) on fuel tank (3) and take off 10 Install in the reverse order Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.25-p-0025sr, Remove/install fuel line MODEL 453 with ENGINE 281
AR47.25-P-0009SR¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2013 · Applies to: 453 · AR: AR47.25-P-0009SR, AR20.40-P-5614SR
Remove/install fuel tank vent line 15.07.2016 Model 453 with engine 281 Modification notes 06.07.2016 Operation step 2.3 added 453.362/462 P47.30-2285-08 Shown on ENGINE 281.920 1 Vent line (engine 281.920) 4 Activated charcoal canister 2 Bracket 5 Bracket 3 Vent line Y58 Fuel tank vent valve ENGINE 281.910 2 Bracket 6 Vent line 7 Air intake hose 8 Bracket 9 Bracket Y58 Fuel tank vent valve P47.30-2286-11 Risk of explosion No fires, sparks, open flames or smoking. Danger ! caused by fuel igniting, risk AS47.00-Z-0001-01A
of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Remove/install
1 Remove fan AR20.40-P-5614SR 2.1 Unlock vent line (1) on fuel tank bleed valve Model 453 with engine 281.920 (Y58) and intake manifold and detach Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.25-p-0009sr, Remove/install fuel tank vent line Model 453 with engine 281
PE47.30-P-2052BBA¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2015 · Applies to: 453 · AR: PE47.30-P-2052BBA
Electrical function diagram for purging function 17.11.15 Engine 281.910 in model 453.0/3 Electrical function schematic for purge control PE47.30-P-2052-97BBA Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe47.30-p-2052bba, Electrical function diagram for purging function Engine 281.910 in model 453.0/3
PE47.30-P-2051BBA¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2016 · Applies to: 453 · AR: PE47.30-P-2051BBA
Electrical function schematic for system purging with leak test 17.11.15 Engine 281.910 in model 453.3/4 with code 494 (US version) Electrical function schematic for system PE47.30-P-2051-97BBA purging with leak test Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe47.30-p-2051bba, Electrical function schematic for system purging with leak test Engine 281.910 in model 453.3/4 with code 494 (US version)
AR47.30-P-1000SR¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2017 · Applies to: 453 · AR: AR47.30-P-1000SR, AR20.40-P-5614SR
Remove, install fuel tank bleed valve 02.12.2014 MODEL 453 with ENGINE 281 Shown on engine 281.920 1 Electrical connection 2 Vent line 3 Vent line 4 Bracket Y58 Fuel tank vent valve P47.20-2538-12 Risk of explosion No fires, sparks, open flames or smoking. Danger ! caused by fuel igniting, risk AS47.00-Z-0001-01A
of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Remove/install
1 Remove fan AR20.40-P-5614SR 2 Disconnect electrical connection (1) 3 Remove fuel tank bleed valve (Y58) with bracket (4) 4 Release and detach vent line (2) 5 Release and detach vent line (3) 6 Remove fuel tank bleed valve (Y58) with bracket (4) 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.30-p-1000sr, Remove, install fuel tank bleed valve MODEL 453 with ENGINE 281
AR47.30-P-8212FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2018 · Applies to: 453 · AR: AR47.30-P-8212FF, AR09.10-P-1150FF, AR09.10-P-1150FG
Remove/ install activated charcoal canister 6.6.03 MODELS 454.0 with ENGINES 122.9, 134.9, 135.9 Shown on engine 135.9 1 Activated charcoal canister 2 and hoses 3 Tubing P47.30-2082-04 Remove/Install
Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by fuel igniting, AS47.00-Z-0001-01A risk of poisoning Pour fuels only into suitable and appropriately caused by inhaling and swallowing fuel as well as risk of injury marked containers. to eyes and skin caused by contact with fuel. Wear protective clothing when handling fuel. 1 Remove air filter housing Engine 134.9, 135.9 AR09.10-P-1150FF Engine 122.9 AR09.10-P-1150FG 2 Take out the hose (3) from the clip at the splash wall 3 Take activated charcoal canister (1) towards the top and out of the bracket 4 Pull off the hoses (2) at the activated charcoal canister (1) 5 Take out the activated charcoal canister (1) 6.1 Detach the hose (3) from the activated Only when replacing activated charcoal charcoal canister (1) canister (1). 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar47.30-p-8212ff, Remove/ install activated charcoal canister MODELS 454.0 with ENGINES 122.9, 134.9, 135.9
AR47.30-P-8212SR¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2019 · Applies to: 453 · AR: AR47.30-P-8212SR
Remove/ install activated charcoal canister 04.08.2014 MODEL 453 with ENGINE 281 P47.30-2284-08 1 Activated charcoal canister 3 Hose 2 Bleed lines 4 Fuel tank 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 explosion No fires, sparks, open flames or smoking. Danger ! caused by fuel igniting, risk AS47.00-Z-0001-01A
of poisoning caused by inhaling and Pour fuels into suitable and appropriately swallowing fuel as well as risk of injury to eyes marked containers only. and skin caused by contactwith fuel. Wear protective clothing when handling fuel. Remove/install
1 Raise vehicle with vehicle lift 2 Remove rear underfloor paneling 3 Release and detach vent lines (2) on activated charcoal canister (1) 4 Remove hose (3) from fuel tank (4) 5 Unlock catches (arrows A), push activated charcoal canister (1) in direction of arrow and take off 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar47.30-p-8212sr, Remove/ install activated charcoal canister MODEL 453 with ENGINE 281
AR47.31-P-8023FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2020 · Applies to: 453 · AR: AR47.31-P-8023FF, AR09.10-P-1150FF
Remove/install shutoff valve 13.4.06 ENGINE 134.9, 135.9 in MODEL 454.0 Shown on engine 135.9 1 and hoses 2 Electrical connector 3 Bracket Y58 Activated charcoal filter shutoff valve P47.30-2083-04 Remove/install
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 Pour fuels only 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 Remove air filter housing AR09.10-P-1150FF 2 Detach hoses (1) 3 Disconnect electrical connector (2) 4 Disconnect the activated charcoal filter shutoff valve (Y58) at the bracket (3) 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, ar47.31-p-8023ff, Remove/install shutoff valve ENGINE 134.9, 135.9 in MODEL 454.0
PE47.40-P-2101BBA¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2025 · Applies to: 453 · AR: PE47.40-P-2101BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)
Wiring diagram for fuel pump control unit 11.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 Wiring diagram for FSCU PE47.40-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, pe47.40-p-2101bba, Wiring diagram for fuel pump control unit Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020
AR49.10-P-5500FG¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2034 · Applies to: 453 · AR: AR49.10-P-5500FG, AR01.20-P-5015FF
Remove, install catalytic converter 11.3.10 ENGINE 639.9 in MODEL 454.0 except CODE (K13) Diesel particulate filter 1 Cylinder head cover trim panel 2 Clip 3 Bracket 4 Catalytic converter 5 Clip 6 Bolt G3/2 O2 sensor upstream of TWC [KAT] G3/2x1 O2 sensor upstream of TWC [KAT] connector P49.10-2436-06 Remove/install
Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A toppling off of the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 1 Raise vehicle 2 Take off clamp (2) *BA49.10-P-1003-01P
3 Remove bracket (3) Installation:
Replace self-locking bolt and nut of bracket (3). 4 Lower vehicle 5 Remove trim panel of cylinder head cover (1) AR01.20-P-5015FF 6 Loosen connector for O2 sensor upstream of TWC (G3/2x1) from bracket and disconnect 7 Remove clamp (5) *BA49.10-P-1002-01P
8 Unscrew bolt (6) and remove catalytic Installation:
Install new self-locking bolt converter (4) with sealing ring from above (6) *BA49.10-P-1001-01P
9.1 Unscrew the O2 sensor upstream of TWC When replacing catalytic converter (4). [KAT] (G3/2) at the catalytic converter (4) *BA14.00-P-1001-01D
*450589040900
Paste *BR00.45-Z-1005-06A 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 Perform engine test run and inspect exhaust system around catalytic convertor (4) for leaks 12 Read out fault memory Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF
fault memory STAR DIAGNOSIS diagnosis system O2 probe Number Designation Engine 639.939 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar49.10-p-5500fg, Remove, install catalytic converter ENGINE 639.9 in MODEL 454.0 except CODE (K13) Diesel particulate filter
AR49.10-P-5501FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2036 · Applies to: 453 · AR: AR49.10-P-5501FF
Remove, install catalytic converter diesel particulate filter unit 11.3.10 ENGINE 639.9 in MODEL 454.0 with CODE (K13) Diesel particulate filter P49.10-2707-09 1 Bracket 7 Bracket B19/9 Temperature sensor upstream of diesel particulate filter 2 Clamp 8 Wiring harness B19/9x1 Temperature sensor connector 3 Catalytic converter diesel particulate 9 Bolt upstream of diesel particulate filter unit 10 Bolt filter 4 Purge lines 11 Hose clamp G3/2 O2 sensor upstream of TWC 5 Bracket 12 Tie strap [KAT] 6 Purge hoses G3/2x1 O2 sensor upstream of TWC [KAT] connector 3 Catalytic converter diesel particulate filter unit 4 Purge line 14 Bracket 15 Bolt 16 Nut 17 Bolt 18 Clamp P49.10-2706-04 3 Catalytic converter diesel particulate filter unit 19 Bolt P49.10-2718-11 Page 1 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
AR49.10-P-7170FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2039 · Applies to: 453 · AR: AR49.10-P-7170FF
Remove, install exhaust flex pipe 28.2.06 ENGINE 639.939 in MODEL 454.0 1 Clamp 2 Exhaust flex pipe 3 Catalytic converter 4 Clamp 5 Retaining rubber P49.10-2445-06 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 Loosen clamps (1, 4) *BA49.10-P-1003-01P
*BA49.10-P-1005-01P
3 Unclip retaining rubbers (5) Installation:
Check retaining rubbers (5), replace if necessary 4 Take out exhaust flex pipe (2) Installation:
Clean sealing surfaces. 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 Conduct engine test run and check exhaust system around the exhaust flex pipe (2) for leaks Exhaust system Number Designation Engine 639.9 BA49.10-P-1003-01P Nut connecting clamp of catalytic convertor to Nm 40 exhaust manifold BA49.10-P-1005-01P Nut connecting clamp of exhaust flex pipe to Nm 40 exhaust manifold Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar49.10-p-7170ff, Remove, install exhaust flex pipe ENGINE 639.939 in MODEL 454.0
AR49.10-P-5530FG¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2040 · Applies to: 453 · AR: AR49.10-P-5530FG, AR49.10-P-4951FF
Remove, install exhaust pipe 28.2.06 ENGINE 639.939 in MODEL 454.0 P49.10-2444-07 1 Clamp 3 Exhaust pipe 4 Exhaust flex pipe 2 Retaining rubber Remove/install
1 Remove rear muffler AR49.10-P-4951FF 2 Loosen the clamp (1) *BA49.10-P-1005-01P
3 Unclip retaining rubbers (2) Installation:
Check retaining rubbers (2), replace if necessary 4 Pull exhaust pipe (3) out of the exhaust flex pipe (4) 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 Conduct engine test run and check exhaust system around the exhaust pipe (3) for leaks Exhaust system Number Designation Engine 639.9 BA49.10-P-1005-01P Nut connecting clamp of exhaust flex pipe to Nm 40 exhaust manifold Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar49.10-p-5530fg, Remove, install exhaust pipe ENGINE 639.939 in MODEL 454.0
AR49.10-P-5500SRA¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2041 · Applies to: 453 · AR: AR49.10-P-5500SRA, AR49.10-P-6905SR
Remove/install catalytic converter 19.08.2014 ENGINE 281.910 in MODEL 453 P49.10-3081-08 1 Catalytic converter 4 Clamp 2 Nuts 5 Nut 3 Bracket 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 (1) AR49.10-P-6905SR Installation: Only install covering over
engine after the leak test. 2 Lower vehicle with vehicle lift 3 Unscrew nuts (2) 4 Remove bracket (3) 5 Unfasten clamp (4) and take off 6 Unscrew nut (5) 7 Raise vehicle with vehicle lift 8 Remove catalytic converter (1) downwards 9 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. 10 Perform engine test run and check exhaust system in the area of catalytic convertor (1) for leaktightness Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar49.10-p-5500sra, Remove/install catalytic converter ENGINE 281.910 in MODEL 453
AR49.10-P-6905SR¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2044 · Applies to: 453 · AR: AR49.10-P-6905SR, AR14.00-P-5303SR, AR49.10-P-4823SR
Remove/install heat shield above catalytic converter 04.08.2014 ENGINE 281 in MODEL 453 P49.10-3077-09 1 Heat shield 5 Screw/bolt 9 Screw/bolt 2 Heat shield 6 Nuts G3/1x1 Electrical connection for oxygen sensor downstream of catalytic converter 3 Heat shield 7 Screw/bolt G3/2x1 Electrical connection for oxygen sensor upstream of catalytic converter 4 Nut 8 Rear muffler 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 covering over engine 2 Unscrew nuts (4) For removal of heat shield (1) or heat shield (2) 3 Remove screw/bolt (5) For removal of heat shield (1) or heat shield (2) 4 Remove heat shield (1) from stud bolts of nuts For removal of heat shield (1) or heat shield (4a) and place to one side (2) 5 Remove oxygen sensor downstream of CAT For removal of heat shield (2) and oxygen sensor upstream of CAT AR14.00-P-5303SR 6 Unclip electrical connection for oxygen sensor For removal of heat shield (2) downstream of CAT (G3/2x1) or electrical connection for oxygen sensor downstream of CAT (G3/1x1) from heat shield (2) 7 Remove screw/bolt (7) For removal of heat shield (2) 8 Unscrew nuts (6) For removal of heat shield (2) or heat shield (3) 9 Remove heat shield (2) from stud bolts of nuts For removal of heat shield (2) (6a) and place to one side 10 Remove rear muffler (8). AR49.10-P-4823SR 11 Remove heat shield (1, 2) For removal of heat shield (1) or heat shield (2) 12 Remove screw/bolts (9) and remove heat For removal of heat shield (3) shield (3) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar49.10-p-6905sr, Remove/install heat shield above catalytic converter ENGINE 281 in MODEL 453
AR49.10-P-4823SR¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2046 · Applies to: 453 · AR: AR49.10-P-4823SR
Remove/install rear muffler 18.07.2016 Engine 281 in model 453 Modification notes 07.07.2016 Operation step 7.2 added 453.062/362/462 1 Rear muffler 2 Heat shield 2a Nut 2b Screw/bolt 3 Clamp 4 Catalytic converter 5 Elastomer bearing P49.10-3079-06 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 covering over engine Installation: Only install covering over
engine after the leak test. 2 Unscrew nuts (2a) 3 Remove screw/bolt (2b) 4 Remove heat shield (2) from stud bolts of nuts (2a) and place to one side 5 Loosen clamp (3) 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. 6 Raise vehicle with vehicle lift 7.1 Push rear muffler (1) out of the elastomer Model 453.04/05/34/35/44/45 bearings (5) and remove from CAT (4) Aid of helper required
*453589003700 Pliers 7.2 Also push elastomer bearing for center rear in model 453.06/36/46 muffler Aid of helper required
*453589003700 Pliers 8 Remove clamp (3) from CAT (4) Installation: Replace clamp (3).
9 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, ar49.10-p-4823sr, Remove/install rear muffler Engine 281 in model 453
AR49.10-P-5500FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2048 · Applies to: 453 · AR: AR49.10-P-5500FF, AR14.00-P-5303FG
Removing/installing a catalytic converter 17.11.03 ENGINES 134.9, 135.9 in MODEL 454.0 1 Catalytic converter 2 Nut 3 Rubber retainers 4 Center muffler 5 Spring 6 Bolts 7 Sealing ring 8 Exhaust manifold P49.10-2342-06 Removing/installing
1 Remove O2 sensor upstream of TWC AR14.00-P-5303FG Only unscrew the O2 sensor upstream TWC from the catalytic converter (1) when replacing the catalytic convertor (1). 2 Slacken nut at clamp (2). *BA49.10-P-1001-01M
3 Unscrew bolts (6) and remove with springs (5) 4 Suspend rubber retainers (3) at catalytic Installation:
Check rubber retainers (3) convertor (1) for damage, and replace if necessary. 5 Push back center muffler (4) and remove Secure center muffler (4) with an catalytic convertor (1) appropriate tie strap to the body against falling down. 6 Remove sealing ring (7) at exhaust manifold Installation:
Check the sealing ring (7) for (8) damage; replace if necessary. Clean sealing surfaces on center muffler (4), exhaust manifold (8) and catalytic converter (1). 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 Perform engine test run and inspect exhaust system around catalytic convertor (1) for leaks Exhaust system Number Designation Engine Engine Engine Engine 134.910 134.911 135.930 135.950 BA49.10-P-1001-01M Nut for center muffler clamp on catalytic Nm 43 43 43 43 converter Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar49.10-p-5500ff, Removing/installing a catalytic converter ENGINES 134.9, 135.9 in MODEL 454.0
AR49.10-P-4951FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2049 · Applies to: 453 · AR: AR49.10-P-4951FF
Replace rear muffler 28.2.06 ENGINE 134.9, 135.9, 639.9 in MODEL 454.0 1 Rear muffler 2 Nut 3 Retaining rubber 4 Exhaust pipe P49.10-2343-01 Remove/install
Risk of death Danger! caused by vehicle slipping or Align vehicle between the columns of the AS00.00-Z-0010-01A
toppling off of the lifting platform. lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer. 1 Raise vehicle 2 Loosen nut (2) BA49.10-P-1002-01M Engine 134, 135 BA49.10-P-1004-01P Engine 639 3 Detach retaining rubber (3) from rear muffler Installation:
Check retaining rubber (3) (1) for damage; replace if necessary. 4 Detach rear muffler (1) at exhaust pipe (4) 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 Perform engine test run and inspect exhaust system in the area of the rear muffler (1) for leaks Exhaust system Number Designation Engine Engine Engine Engine 134.910 134.911 135.930 135.950 BA49.10-P-1002-01M Nut connecting rear muffler clamp to center Nm 50 50 50 50 muffler Exhaust system Number Designation Engine 639.9 BA49.10-P-1004-01P Nut connecting rear muffler clamp to exhaust pipe Nm 45 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar49.10-p-4951ff, Replace rear muffler ENGINE 134.9, 135.9, 639.9 in MODEL 454.0
AN49.10-P-1003FF¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2050 · Applies to: 453 · AR: AN49.10-P-1003FF, AR49.10-P-4816FF
Retrofit BRABUS muffler 10.1.08 ENGINES 135.950 up to 8.4.05 in MODEL 454.0 except CODE (E50) Trailer hitch ENGINES 135.930 /950 as of 11.4.05 in MODEL 454.0 except CODE (E50) Trailer hitch 1 Series rear muffler 2 Nut 3 Retaining rubber 4 Center muffler 5 BRABUS muffler P49.10-2413-04 Removing
Risk of death Danger! caused by vehicle slipping or Align vehicle between columns of vehicle lift AS00.00-Z-0010-01A
toppling off of the lifting platform. and position four support plates at vehicle lift support points specified by vehicle manufacturer. 1 Raise vehicle 2 Loosen nut (2) 3 Detach the series rear muffler (1) from the Check the rubber retainers (3) for damage rubber retainers (3) and replace if required. 4 Remove the series rear muffler (1) from the center muffler (4) 5.1 Remove old center muffler (4) On vehicles with engine 135.930/950 as of production date 11.4.05. Remove/install center muffler AR49.10-P-4816FF
Install
6.1 Install new center muffler (4) On vehicles with engine 135.930/950 as of production date 11.4.05. The center muffler (4) on vehicles with engine 135.930/950 as of production date 11.4.05 must be replaced for a center muffler (4) for vehicles with engine 135.950 until production date 8.4.05. Remove/install center muffler AR49.10-P-4816FF
7 Slide the BRABUS muffler (5) onto the center muffler (4) 8 Hook the BRABUS muffler (5) into the rubber retainers (3) 9 Align the BRABUS muffler (5) and tighten the *BA49.10-P-1002-01M
nut (2) 10 Lower vehicle 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 11 Test run engine and check exhaust system for leaks 12 Include certificate * For Germany only Installation or attachment of exhaust mufflers Model 454.031 with engine 135.930 as of OF49.10-P-1000-01GA certificate production date 11.4.05. * For Germany only Registration papers must be amended. Model 454.032 with engine 135.950 as of OF49.10-P-1000-01FB production date 11.4.05. * For Germany only Model 454.032 with engine 135.950 until OF49.10-P-1000-01FA production date 8.4.05 * For Germany only 13.1 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. Retrofit Code (F04) sport exhaust system, Brabus (DFO). Page 1 of 2 © Mercedes-Benz AG, 5/20/18, L/07/20, an49.10-p-1003ff, Retrofit BRABUS muffler ENGINES 135.950 up to 8.4.05 in MODEL 454.0 except CODE (E50) Trailer hitch ENGINES 135.930 /950 as of 11.4.05 in MODEL 454.0 except CODE (E50) Trailer hitch
Wet/dry vacuum cleaner¶
2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3832 · Applies to: 453 · AR: AR47.20-P-7000FF, AR47.20-P-7000FH, AR47.10-P-4100FF
gotis://P_00.12_06.0 Cordless drill/driver, cordless drill gotis://G_58.0_01.1 12 Install in the reverse sequence Operation steps 8, 7, 6, 5.1 13.1 Remove fuel pump with fuel level sensor Remove/install fuel pump and fuel level With engine 134.9, 135.9 up to vehicle AR47.20-P-7000FF
sensor identification end no. 128917 With engine 134.9, 135.9 as of vehicle AR47.20-P-7000FH identification end no. 128918 14.1 Retrofit tank bleeder With engine 134.9, 135.9. AZ83.70-P-0020-02FF *BA47.20-P-1001-01D
450589017000 Twist drill bit set 450589000700 Tank module tool Cordless drill/driver, cordless drill gotis://G_58.0_01.1 Risk of injury Danger! caused by burns to skin and Work in well ventilated rooms only. Wear AS00.19-Z-0001-01A
eyes. Risk of poisoning caused by inhaling safety glasses with side protection and fumes when working with heat-shrinkable protective gloves. tubing. 15 Fabricate coolant hoses for connecting to Engine 134.9, 135.9 AZ83.70-P-0001-04FF cooling and heating circuit 450589016300 Hot-air gun Engine 639.9 AZ83.70-P-0001-04FG 450589016300 Hot-air gun 16 Prepare heater (4) for installation AZ83.70-P-0001-11FF *BA83.70-P-1001-01D
*BA83.70-P-1002-01D
17 Install heater (4) AZ83.70-P-0002-02FF The base jack from either Mazzola or AS Hydraulic may be used. 450589026200 Removal fixture Base jack Base jack Risk of explosion No fire, sparks, open flames or smoking. Danger! caused by fuel igniting, AS47.00-Z-0001-01A risk of poisoning Pour fuels only into suitable and appropriately caused by inhaling and swallowing fuel and risk of injury marked containers. to eyes and skin caused by contact with fuel Wear protective clothing when handling fuel. 18 Retrofit fuel supply for the stationary heater Engine 134.9, 135.9 AZ83.70-P-0020-01FF 452589029900 Wiring harness repair kit Engine 639.9 AZ83.70-P-0020-01FG *452589029900 Wiring harness repair kit 19.1 Assemble vehicle interior in area of fuel pump With engine 134.9, 135.9 up to vehicle with fuel level sensor identification end no. 128917 Remove/install fuel pump and fuel level AR47.20-P-7000FF
sensor 19.2 Install fuel tank With engine 134.9, 135.9 as of vehicle identification end no. 128918 Remove/install fuel tank AR47.10-P-4100FF
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. 20 Retrofit coolant line Engine 134.9, 135.9 AZ83.70-P-0008-03FF 450589017000 Twist drill bit set Cordless drill/driver, cordless drill gotis://G_58.0_01.1 Engine 639.9 AZ83.70-P-0008-03FH 450589017000 Twist drill bit set Rechargeable drill / screwdriver Notes on coolant AH20.00-N-2080-01A
21 Retrofitting exhaust pipe and muffler AZ83.70-P-0008-02FF 450589007000 Graduated drill 450589017000 Twist drill bit set Cordless drill/driver, cordless drill gotis://G_58.0_01.1 22 Install in the reverse sequence Operation steps 4, 3, 2, 1. Page 2 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