453 — fortwo / forfour (2014-2024) — Seats & Restraints

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

178 excerpts from 1 sources.

2014-2024 Smart Fortwo 453 Workshop Manual.pdf

N110

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 128 · Applies to: 453 · AR: PE91.60-P-2105BBA, PE82.85-P-2105BBA, PE82.85-P-2008BBA, PE27.19-P-2106BBA, PE27.19-P-2102BBA (+5 more)

Weight Sensing System (WSS) control unit 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 N112/2 Electric vehicle communication module control Model 453.0 (except 453.091), 453.3 (except PE82.85-P-2105BBA unit 453.391), 453.4 (except 453.491) up to model year 2020 with code 535 (smart media system) with code P02 (car2go) N112/3 Windshield reading system control unit 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) N15/13 Double clutch transmission control unit Transmission 700.4 in model 453.0/3/4 up to PE27.19-P-2106BBA model year 2020 with code 429 (twinamic) N15/5 Electronic selector lever module control unit Model 453.0/3/4 with transmission 700.4 up to PE27.19-P-2102BBA model year 2020 with code 429 (twinamic) N167 E-Call Russia (GLONASS) control unit 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) N167 E-Call Russia (GLONASS) control unit Model 453.0 (except 453.091), 453.3 (except PE82.95-P-2102BBA 453.391), 453.4 (except 453.491) up to model year 2020 N2/10 Supplemental restraint system 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 N2/10 Supplemental restraint system control unit 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 N2/10 Supplemental restraint system control unit 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 N20 Climate control operating unit 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 N20 Climate control operating 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 N20 Climate control operating unit 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) N22/1 Climate control control unit 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) N23 Heater/AC operating unit 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) N24 Multimedia operating unit Model 453.0 (except 453.091), 453.3 (except PE00.19-P-2150BBD 453.391), 453.4 (except 453.491) up to model year 2020 Multimedia N24 Multimedia operating unit 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 N24 Multimedia operating 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 N24 Multimedia operating unit 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 N24 Multimedia operating unit 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) N24 Multimedia operating unit 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 Page 18 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

R12/27

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 131 · Applies to: 453 · AR: PE91.60-P-2105BBA, PE82.25-P-2100BBA, PE91.60-P-2105BBB, PE00.19-P-2800BBC, PE54.18-P-2300BBB (+2 more)

Driver 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 R12/3 Driver airbag squib 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 R12/3 Driver airbag 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 R12/37 Driver-side anchor fitting tensioner 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 R12/38 Right front belt anchor fitting tensioner 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 R12/39 Left head/thorax side airbag 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 R12/39 Left head/thorax side airbag 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 R12/39 Left head/thorax side airbag 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 R12/4 Front passenger airbag 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 R12/40 Right head/thorax side airbag 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 R12/40 Right head/thorax side airbag 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 R12/40 Right head/thorax side airbag 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 R12/44 Front passenger airbag bleed valve 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 R12/5 Passenger airbag 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 R12/53 Left front emergency tensioning retractor squib 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 R12/54 Right front emergency tensioning retractor Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBB squib 453.391), 453.4 (except 453.491) up to model year 2020 Plug BA-BC R12/6 Left rear emergency tensioning retractor 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 R12/7 Right rear emergency tensioning retractor Model 453.0 (except 453.091), 453.3 (except PE91.60-P-2105BBA squib 453.391), 453.4 (except 453.491) up to model year 2020 Plug BB R12/8 Front passenger airbag 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 R13/1 Left seat heated cushion 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 R13/1 Left seat heated cushion Model 453.0 (except 453.091), 453.3 (except PE91.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 873 (Seat heater for driver's seat at left and right) R13/2 Left backrest heated cushion 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 R13/2 Left backrest heated cushion Model 453.0 (except 453.091), 453.3 (except PE91.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 873 (Seat heater for driver's seat at left and right) R13/3 Right seat heated cushion Model 453.0 (except 453.091), 453.3 (except PE91.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 873 (Seat heater for driver's seat at left and right) R13/4 Right backrest heated cushion 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 21 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

R13/4

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 132 · Applies to: 453 · AR: PE91.30-P-2000BBA, PE83.30-P-2000BBB, PE00.19-P-2800BBC, PE15.00-P-2103BBA, PE54.15-P-2001BBB (+5 more)

Right backrest heated cushion Model 453.0 (except 453.091), 453.3 (except PE91.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 873 (Seat heater for driver's seat at left and right) R14 Blower motor series resistor group 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) R3 Front cigarette lighter with ashtray illumination 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 R3 Front cigarette lighter with ashtray illumination 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 R3 Front cigarette lighter with ashtray illumination 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 R3 Front cigarette lighter with ashtray illumination 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 R3 Front cigarette lighter with ashtray illumination 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) R3 Front cigarette lighter with ashtray illumination 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 R3 Front cigarette lighter with ashtray illumination 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 R3 Front cigarette lighter with ashtray illumination Model 453.0 (except 453.091), 453.3 (except PE91.30-P-2000BBA 453.391), 453.4 (except 453.491) up to model year 2020 with code 873 (Seat heater for driver's seat at left and right) R48 Coolant thermostat heating element Engine 281 in model 453.0/3/4 up to model PE07.61-P-2101BBC year 2020 Plug AB R48 Coolant thermostat heating element 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 R48 Coolant thermostat heating element Model 453.0 (except 453.091), 453.3 (except PE54.21-P-2144BBA 453.391), 453.4 (except 453.491) up to model year 2020 RHD Right-hand drive vehicle 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 RHD Right-hand drive vehicle Model 453.3 (except 453.391), 453.4 (except PE72.29-P-2001BBB 453.491) up to model year 2020 with code 583 (Power windows) with code ICPA (Standard equipment) except code 584 (Power windows with convenience feature and reversing function) except code P74 (Comfort Package) except code V21 (Electrically adjustable and heated outside mirrors (FFO)) S1/1 Electric headlamp range adjustment selector Model 453.0 (except 453.091), 453.3 (except PE82.10-P-2000BBA wheel 453.391), 453.4 (except 453.491) up to model year 2020 S11 Brake fluid indicator switch 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 S11 Brake fluid indicator switch Model 453.0 (except 453.091), 453.3 (except PE54.30-P-2101BBA 453.391), 453.4 (except 453.491) up to model year 2020 S110 Left multifunction steering wheel button group 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 S110 Left multifunction steering wheel button group 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 S110/1 Steering wheel downshift button 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 S111 Right multifunction steering wheel button Model 453.0 (except 453.091), 453.3 (except PE30.30-P-2000BBA group 453.391), 453.4 (except 453.491) up to model year 2020 S111 Right multifunction steering wheel button Model 453.0 (except 453.091), 453.3 (except PE82.25-P-2100BBA group 453.391), 453.4 (except 453.491) up to model year 2020 S111/1 Steering wheel upshift button 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 Page 22 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

R12/6

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 180 · Applies to: 453 · AR: PE91.60-P-2105BEA, PE91.30-P-2000BEA, PE91.30-P-2000BEB, PE82.25-P-2100BEA, PE30.30-P-2000BEA (+5 more)

Left rear emergency tensioning retractor squib Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 R12/7 Right rear emergency tensioning retractor Model 453.091/391/491 up to model year PE91.60-P-2105BEA squib 2020 R12/8 Front passenger airbag squib Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 R13/1 Left seat heated cushion 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) R13/2 Left backrest heated cushion 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) R13/3 Right seat heated cushion 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) R13/4 Right backrest heated cushion 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) R13/5 Left rear seat cushion heater pad 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) R13/6 Left rear seat backrest heater pad 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) R13/7 Right rear seat cushion heater pad 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) R13/8 Right rear seat backrest heater pad 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) R22/4 Steering wheel heater Model 453.091/391/491 up to model year PE82.25-P-2100BEA 2020 R3 Front cigarette lighter with ashtray illumination Model 453.091/391/491 up to model year PE30.30-P-2000BEA 2020 R3 Front cigarette lighter with ashtray illumination Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA R3 Front cigarette lighter with ashtray illumination Model 453.091/391/491 up to model year PE54.65-P-2101BEA 2020 with code 220 (Rear parking assist) R3 Front cigarette lighter with ashtray illumination Model 453.091/391/491 up to model year PE82.00-P-2600BEA 2020 R3 Front cigarette lighter with ashtray illumination Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 R3 Front cigarette lighter with ashtray illumination 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) RHD Right-hand drive vehicle Model 453.091/391/491 up to model year PE00.19-P-2600BEA 2020 S1/1 Electric headlamp range adjustment selector Model 453.091/391/491 up to model year PE82.10-P-2000BEA wheel 2020 S11 Brake fluid indicator switch Model 453.091/391/491 up to model year PE54.30-P-2101BEA 2020 S110 Left multifunction steering wheel button group Model 453.091/391/491 up to model year PE30.30-P-2000BEA 2020 S110 Left multifunction steering wheel button group Model 453.091/391/491 up to model year PE82.25-P-2100BEA 2020 S111 Right multifunction steering wheel button Model 453.091/391/491 up to model year PE30.30-P-2000BEA group 2020 S111 Right multifunction steering wheel button Model 453.091/391/491 up to model year PE82.25-P-2100BEA group 2020 S12 Parking brake indicator switch Model 453.091/391/491 up to model year PE42.20-P-2000BEA 2020 S12 Parking brake indicator switch Model 453.091/391/491 up to model year PE54.30-P-2101BEA 2020 S12/1 Sound generator button Model 453.091/391/491 up to model year PE00.19-P-2600BEA 2020 S12/1 Sound generator button Engine 780.997 in model 453.091/391/491 up PE08.20-P-2000BEA to model year 2020 S15/1 Trunk lid/liftgate release switch Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 S15/1 Trunk lid/liftgate release switch Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK S15/1 Trunk lid/liftgate release switch Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version S15/3 Driver trunk lid/liftgate control button Model 453.091/391/491 up to model year PE00.19-P-2600BEA 2020 S15/3 Driver trunk lid/liftgate control button Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Page 15 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

S68/11

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 182 · Applies to: 453 · AR: PE91.60-P-2105BEA, PE08.00-P-2000BEA, PE54.10-P-2104BEA, PE77.20-P-2200BEA, PE77.39-P-2202BEA (+5 more)

Left rear seat belt buckle switch Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 S68/12 Right rear seat belt buckle switch Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 S68/15 Front passenger airbag shutoff switch Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 S68/2 Right front seat belt buckle switch Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 S8 High-voltage battery safety shutoff Engine 780.997 in model 453.091/391/491 up PE08.00-P-2000BEA to model year 2020 S8 High-voltage battery safety shutoff Model 453.091/391/491 up to model year PE54.10-P-2104BEA 2020 S84 Power soft top switch Model 453.091 up to model year 2020 PE77.20-P-2200BEA S84/37 Soft top microswitch Model 453.491 up to model year 2020 PE77.39-P-2202BEA S84/39 Right rear soft top microswitch Model 453.491 up to model year 2020 PE77.39-P-2202BEA S84/41 Left rear soft top microswitch Model 453.491 up to model year 2020 PE77.39-P-2202BEA S85/4 EDW switch, battery Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 S85/4 EDW switch, battery Model 453.091/391/491 up to model year PE80.50-P-2000BEA 2020 except code V19 (Anti-theft alarm system) S85/4 EDW switch, battery Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) S88/6 Trunk lid contact switch, right Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 S88/6 Trunk lid contact switch, right Model 453.391/491 up to model year 2020
PE68.49-P-2200BEA with code 494 (USA version) S88/6 Trunk lid contact switch, right Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK S88/6 Trunk lid contact switch, right Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version S9/1 Stop lamp switch Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 S9/1 Stop lamp switch Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA S9/1 Stop lamp switch Model 453.091/391/491 up to model year PE54.21-P-2127BEA 2020 N10/11 S9/1 Stop lamp switch Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 S9/1 Stop lamp switch Model 453.091/391/491 up to model year PE82.10-P-2300BEA 2020 S95 Parking system switch Model 453.091/391/491 up to model year PE00.19-P-2600BEA 2020 S95 Parking system switch Model 453.091/391/491 up to model year PE54.65-P-2101BEA 2020 with code 220 (Rear parking assist) S96 Lane Keeping Assist button Model 453.091/391/491 up to model year PE00.19-P-2600BEA 2020 S96 Lane Keeping Assist button Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA S96 Lane Keeping Assist button Model 453.091/391/491 up to model year PE54.21-P-2129BEA 2020 S97 Distance warning function button Model 453.091/391/491 up to model year PE00.19-P-2600BEA 2020 S97 Distance warning function button 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) W1/1 Cockpit frame ground point 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) W1/1 Cockpit frame ground point 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) W1/1 Cockpit frame ground point Model 453.091/391/491 up to model year PE42.45-P-2000BEA 2020 W1/1 Cockpit frame ground point Model 453.091/391/491 up to model year PE54.10-P-2005BEA 2020 W1/1 Cockpit frame ground point Model 453.091/391/491 up to model year PE54.21-P-2127BEA 2020 N10/11 W1/1 Cockpit frame ground point Model 453.091/391/491 up to model year PE54.21-P-2129BEA 2020 W1/1 Cockpit frame ground point Model 453.091/391/491 up to model year PE54.22-P-2000BEA 2020 W1/1 Cockpit frame ground point Model 453.091/391/491 up to model year PE54.30-P-2101BEA 2020 Page 17 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

Z50/43

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 196 · Applies to: 453 · AR: PE91.30-P-2000BEB, PE30.30-P-2105BEA, PE30.30-P-2105BEB, PE54.15-P-2001BEB, PE54.15-P-2001BEC (+5 more)

Circuit 15 (fused) connector sleeve Model 453.091 up to model year 2020 except PE91.30-P-2000BEB code 873 (Seat heater for driver's seat at left and right) Z50/44 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) Z50/44 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) Z50/44 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA Z50/44 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE54.15-P-2001BEC 2020 F2 Plug AB-AE Z50/44 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z50/44 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) Z50/44 Circuit 15 (fused) connector sleeve Model 453.091 up to model year 2020 except PE91.30-P-2000BEB code 873 (Seat heater for driver's seat at left and right) Z50/46 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA Z50/46 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEA 2020 N10/11 Z50/46 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z50/48 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE27.19-P-2102BEA 2020 Z50/48 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA Z50/48 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z50/48 Circuit 15 (fused) connector sleeve Model 453.091/391/491 up to model year PE82.30-P-2000BEA 2020 Z50/49 Circuit 30 (fused) end sleeve Model 453.091/391/491 up to model year PE54.10-P-2109BEA 2020 Z50/49 Circuit 30 (fused) end sleeve Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA Z50/49 Circuit 30 (fused) end sleeve Model 453.091/391/491 up to model year PE54.22-P-2000BEA 2020 Z50/49 Circuit 30 (fused) end sleeve 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) Z50/49 Circuit 30 (fused) end sleeve 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) Z50/49 Circuit 30 (fused) end sleeve 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 Z50/49 Circuit 30 (fused) end sleeve Model 453.091/391/491 up to model year PE82.60-P-2000BED 2020 with code C08 (Pre-installation for radio) except code 535 (smart media system)
except code 537 (smart audio system) Z50/49 Circuit 30 (fused) end sleeve 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) Z50/49 Circuit 30 (fused) end sleeve Model 453.091/391/491 up to model year PE82.60-P-2102BEA 2020 with code 535 (smart media system) Z50/49 Circuit 30 (fused) end sleeve Model 453.091/391/491 up to model year PE82.85-P-2008BEA 2020 with code P02 (car2go) Page 31 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

Z6/155

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 200 · Applies to: 453 · AR: PE91.60-P-2105BEA, PE20.00-P-2001BEA, PE54.00-P-2001BEA, PE54.15-P-2001BEB, PE80.50-P-2000BEB (+5 more)

Ground connection connector sleeve Model 453.091/391/491 up to model year PE91.60-P-2105BEA 2020 Z6/157 Ground connection connector sleeve Engine 780.997 in model 453.091/391/491 up PE20.00-P-2001BEA to model year 2020 Z6/157 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 Z6/157 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA Z6/157 Ground connection connector sleeve Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) Z6/157 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z6/157 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2200BEA 2020 Z6/157 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.25-P-2005BEA 2020 Z6/158 Ground connection connector sleeve Engine 780.997 in model 453.091/391/491 up PE20.00-P-2001BEA to model year 2020 Z6/158 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 Z6/158 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.15-P-2001BEB 2020 F2 Plug AA Z6/158 Ground connection connector sleeve Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) Z6/158 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2200BEA 2020 Z6/158 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.25-P-2005BEA 2020 Z6/160 Ground connection connector sleeve Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) Z6/160 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z6/160 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2200BEA 2020 Z6/161 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z6/162 Ground connection connector sleeve Engine 780.997 in model 453.091/391/491 up PE08.20-P-2000BEA to model year 2020 Z6/162 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.15-P-2001BEC 2020 F2 Plug AB-AE Z6/162 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z6/162 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.30-P-2101BEA 2020 Z6/162 Ground connection connector sleeve Model 453.091/391/491 up to model year PE80.50-P-2000BEA 2020 except code V19 (Anti-theft alarm system) Z6/162 Ground connection connector sleeve Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) Z6/162 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z6/162 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2200BEA 2020 Z6/163 Ground connection connector sleeve Engine 780.997 in model 453.091/391/491 up PE20.00-P-2001BEA to model year 2020 Z6/163 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) Z6/163 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2154BEB 2020 with code 908 (22 kW on-board charger) Z6/163 Ground connection connector sleeve Model 453.091 up to model year 2020 PE77.20-P-2200BEA Z6/163 Ground connection connector sleeve Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK Z6/163 Ground connection connector sleeve Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version Z6/163 Ground connection connector sleeve Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) Z6/163 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z6/163 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2200BEA 2020 Z6/163 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2300BEA 2020 Z6/163 Ground connection connector sleeve Model 453.091 up to model year 2020 except PE91.30-P-2000BEB code 873 (Seat heater for driver's seat at left and right) Page 35 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

Z6/164

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 201 · Applies to: 453 · AR: PE91.30-P-2000BEB, PE82.10-P-2000BEA, PE80.50-P-2000BEB, PE54.21-P-2127BEB, PE67.29-P-2000BEA (+5 more)

Ground connection connector sleeve Model 453.091 up to model year 2020 except PE91.30-P-2000BEB code 873 (Seat heater for driver's seat at left and right) Z6/165 Ground connection connector sleeve Model 453.091 up to model year 2020 except PE91.30-P-2000BEB code 873 (Seat heater for driver's seat at left and right) Z6/166 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z6/167 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) Z6/167 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z6/168 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z6/168 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE67.29-P-2000BEA 2020 Z6/168 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK Z6/168 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version Z6/168 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) Z6/168 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE82.10-P-2300BEA 2020 Z6/168 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE82.30-P-2000BEA 2020 Z6/169 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z6/169 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE67.29-P-2000BEA 2020 Z6/169 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK Z6/169 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version Z6/169 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE82.10-P-2300BEA 2020 Z6/169 Circuit 31 end sleeve Model 453.091/391/491 up to model year PE82.30-P-2000BEA 2020 Z6/170 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2127BEB 2020 N10/10 Z6/170 Ground connection connector sleeve Model 453.091/391/491 up to model year PE80.20-P-2000BEA 2020 Except UK Z6/170 Ground connection connector sleeve Model 453.091/391/491 up to model year PE80.20-P-2000BEB 2020 UK version Z6/170 Ground connection connector sleeve Model 453.091/391/491 up to model year PE80.50-P-2000BEB 2020 with code V19 (Anti-theft alarm system) Z6/170 Ground connection connector sleeve Model 453.091/391/491 up to model year PE82.10-P-2000BEA 2020 Z6/171 Ground connection connector sleeve Engine 780.997 in model 453.091/391/491 up PE20.00-P-2001BEA to model year 2020 Z6/171 Ground connection connector sleeve Model 453.091/391/491 up to model year PE43.05-P-2000BEA 2020 Z6/171 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.10-P-2104BEA 2020 Z6/171 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) Z6/171 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2154BEB 2020 with code 908 (22 kW on-board charger) Z6/171 Ground connection connector sleeve Model 453.091/391/491 up to model year PE83.55-P-2000BEA 2020 Z6/172 Ground connection connector sleeve Engine 780.997 in model 453.091/391/491 up PE20.00-P-2001BEA to model year 2020 Z6/172 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.00-P-2001BEA 2020 Z6/172 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.10-P-2003BEA 2020 Z6/172 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2154BEA 2020 except code 908 (22 kW on-board charger) Z6/172 Ground connection connector sleeve Model 453.091/391/491 up to model year PE54.21-P-2154BEB 2020 with code 908 (22 kW on-board charger) Z6/174 Ground connection 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) Page 36 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

AR91.60-P-0695FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 565 · Applies to: 453 · AR: AR91.60-P-0695FF, AR54.10-P-0003FF

Remove/install front seat sidebag unit 03.04.2019 Model 454.0 1 Nut 2 Side airbag unit 3 Electrical lines 4 Bracket 5 Lock 6 Backrest frame R12/20x1 Left front sidebag squib connector R12/21x1 Right front sidebag squib connector P91.60-2822-06 Remove/install

Risk of injury Warning caused by performing testing or Store airbag units with deployment side facing AS91.00-Z-0001-01A

repair work on airbag or emergency tensioning up; do not expose to temperatures greater retractor units. than 100 °C. When working on these units, disconnect the power supply. Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Legal requirements on handling and storing AH91.00-P-0004-01A airbags and emergency tensioning retractor units 1 Disconnect ground line of battery AR54.10-P-0003FF 2 Open zipper on outer cover of front seat AR91.18-P-1820-01FF backrest 454589013700 Pliers 3 Unscrew nut (1) BA91.60-P-1006-01D Nut, sidebag to backrest frame 4 Slide sidebag unit (2) downward and unhook Installation: Electric lines (3) must run

from seat backrest frame (6) between the holder (4) and sidebag unit (2). 5 Pull out lock (5) and disconnect connector coupling for front left side airbag squib (R12/20x1) or connector coupling for front right side airbag squib (R12/21x1) 6 Remove sidebag unit (2) Dispose of defective airbag unit and seat

belt tensioner properly and in an environmentally-appropriate way. 7 Install in the reverse order 8 Read out fault memory and delete errors AD00.00-P-2000-04FF

Airbag Number Designation Model 454.0 BA91.60-P-1006-01D Nut, sidebag to backrest frame Nm 6 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.60-p-0695ff, Remove/install front seat sidebag unit Model 454.0

Supplemental restraint system control unit,

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 1902 · Applies to: 453 · AR: GF91.60-P-4080KJ, GF07.61-P-6000KJ, GF07.61-P-6000KJF, GF54.21-P-7011KJ, GF54.21-P-7012KJ (+5 more)

N2/10 GF91.60-P-4080KJ component description Component description for ME-SFI (ME) with ENGINE 281.910 GF07.61-P-6000KJ control unit N3/10 with ENGINE 281.910 GF07.61-P-6000KJF Center SAM control unit, component N10/10 GF54.21-P-7011KJ description Driver-side SAM control unit, component N10/11 GF54.21-P-7012KJ description Dual clutch transmission control unit, with TRANSMISSION 700.4 GF27.60-P-5171KJ component description N15/13 Component description for Electronic Stability N30/4 GF42.45-P-5119KJ Program control unit Steering angle sensor, component description N49 GF42.45-P-5107KJ Vacuum pump control unit component Model 453.091/391/491 with engine 780 GF43.05-P-1210KJE description N65/3 Component description for electric drive Model 453.091/391/491 with engine 780 GF08.20-P-3001KJE control unit N127 Table of contents for function description, GF42.47-P-0999KJ adaptive brake (ABR) Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, gf42.47-p-9997kj, Overview of system components, Adaptive Brake (ABR) Model 453.0/3/4

Add cavity preserving agent

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2613 · Applies to: 453 · AR: AR97.20-P-1500SR, AR54.10-P-0003SR, AR54.10-P-1160SRE

17 Add cavity preserving agent AR97.20-P-1500SR 18 Install all detachable body components in area to be repaired 19.1 Connect ground cable to battery Model 453 (except 453.091/391/491) AR54.10-P-0003SR 19.2 Put high-voltage on-board electrical system Model 453.091/391/491 into operation AR54.10-P-1160SRE Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar60.00-p-0032sr, Replace ground point Model 453

Clean repair area

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2630 · Applies to: 453 · AR: AR97.10-P-4000SR, AR97.20-P-1500SR

8 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner 9 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

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

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

http://xentryportal.mercedes-benz.com 12 Add cavity preserving agent AR97.20-P-1500SR 13 Install all detachable body components in area to be repaired Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar61.10-p-0020src, Remove/install mounting bracket for front cross strut Model 453.4

Mounting console

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2643 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF

1 Mounting console P62.20-3005-01 P62.20-3006-01 Remove

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

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

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

set and attach vehicle 4 Expose and cut off spot welds in area of mounting support (1), remove damaged mounting support (1) 5 Grind mating surface B at longitudinal member (2) down to bare metal Install

6 Grind mating surface A at mounting support (1) down to bare metal on both sides Notes on replacing body parts AH60.00-P-0027-01FF The work instructions are based on one

mounting support (1), the repair can be extended to additional mounting supports (1) depending on the damage 7 Drill bores in mounting support (1) For hole pattern, see cut off mounting

support (1). 8 Install, adjust mounting support (1) and secure on straightener The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 9 Mounting support (1) in area of mating surface A as shown Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 10 Remove vehicle from straightening bench and remove straightening bench 11 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 12 Prime repair area using primer filler 13 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 14 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 15 Paint repair area adjacent surfaces 16 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 17 Reinstall all removed assembly parts Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1265ff, Replace consoles on front longitudinal member Model 454.0

P62.20-3016-01

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2646 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF

P62.20-3017-01 Remove

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

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

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

tool set and place the vehicle on it 4 Expose and mill off spot welds in the displayed areas on the end plate (1) of the console (2) and the longitudinal member (3), remove the damaged end plate (1) and console (2) 5 Grind the mating surfaces in the areas A to D on the end plate (1), console (2) and longitudinal member (3) down to bare metal Notes on replacing body parts AH60.00-P-0027-01FF 6 Attach holes for plug weldings in the area of mating surface E and grind both sides of mating surface E down to bare metal Install

7 Attach holes for plug weldings on the console Only when replacing the console (2). (2) Hole pattern: see console that has been

cut off (2). 8 Install end plate (1) and console (2), adjust it and attach it to the straightener The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 9 End plate (1) and console (2) in the areas of mating surfaces B, D and E as displayed Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 10 Take the vehicle off the straightening bench and dismantle the straightening bench 11 Clean the weld joints and metal flanges with wire brush and clean the repair areas 12 Prime repair area using primer filler 13 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 14 Supplement the standard underfloor protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underbody sealant 15 Paint repair area adjacent surfaces 16 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 17 Reinstall all removed assembly parts Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1267ff, Replace longitudinal member closing section Model 454.0

Cover all detachable parts remaining in vehicle

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2649 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF

2 Cover all detachable parts remaining in vehicle

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

set and attach vehicle 4 Separate longitudinal member front section Left AR62.20-P-1260-01FF Right AR62.20-P-1260-01FG 5 Prepare connecting points of longitudinal AR62.20-P-1260-06FF member front section Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint 6 Prepare longitudinal member front section AR62.20-P-1260-05FF Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding, BR00.45-Z-1001-07A replaced by A 000 986 28 00 1K zinc dust paint Install

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

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 7 Weld in longitudinal member front section AR62.20-P-1260-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 8 Remove vehicle from straightening bench and remove straightening bench 9 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 10 Prime repair area using primer filler 11 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 12 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 13 Paint repair area adjacent surfaces 14 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 15 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding, replaced by A 000 986 A 000 986 34 42 28 00 1K zinc dust paint BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1260ff, Replace longitudinal member front section Model 454.0

White sealing compound, 310 ml, DBL

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2651 · Applies to: 453 · AR: AR97.20-P-1500FF

BR00.45-Z-1003-01A 6069.20 12 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 13 Paint repair area adjacent surfaces 14 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 15 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1232fg, Replace suspension strut tower Model 454.0

Commercially available tools

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2653 · Applies to: 453 · AR: AR97.10-P-4000SR, AR97.20-P-1500SR

-Round wire brush - Manual temporary fastener, 6.35 mm - Spot welder Blind rivet tool Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Blind rivet 6.5 12.5 (clamping BR00.45-Z-1012-13A range 2 mm to 5 mm, draw-off strength min. 19 kN) 6 Clean weld joints and sheet metal flange with Commercially available tools

round wire brush -Round wire brush 7 Remove spark protection blankets 8 Clean repair area Commercially available tools

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

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 9 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

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

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

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

http://aftersales.mercedes-benz.com 12 Add cavity preserving agent AR97.20-P-1500SR 13 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off BR00.45-Z-1012-13A A 004 990 16 97 strength min. 19 kN) Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.20-p-1286sr, Replace upper front longitudinal member Model 453

Clean weld joints and metal flanges with a wire

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2657 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR63.30-P-0815FF

8 Clean weld joints and metal flanges with a wire brush and clean repair areas 9 Prime repair area using primer filler 10 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 11 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 12 Paint repair area adjacent surfaces 13 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 14 Install side front longitudinal member AR63.30-P-0815FF 15 Take vehicle of the straightening bench and remove straightening bench 16 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding, replaced by A 000 986 A 000 986 34 42 28 00 1K zinc dust paint BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.25-p-1100ff, Partially remove/install lower firewall Model 454.0

Clean weld joints and metal flanges with a wire

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2663 · Applies to: 453 · AR: AR97.10-P-4000FF, AR62.25-P-1100FF, AR62.30-P-1352FF, AR60.10-P-0100FF, AR60.10-P-0100FG (+2 more)

11 Clean weld joints and metal flanges with a wire brush and clean repair areas 12 Prime repair area using primer filler 13 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 14 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 15 Paint repair area adjacent surfaces 16 Partially install bottom left and right firewall AR62.25-P-1100FF 17 Install cross member AR62.30-P-1352FF 18 Remove Car-O-Flex holding system 19 Take body off the straightening bench and AR60.10-P-0100FF remove straightening bench AR60.10-P-0100FG AR60.10-P-0100FH AR60.10-P-0100FJ 20 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding, replaced by A 000 986 A 000 986 34 42 28 00 1K zinc dust paint BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.25-p-5752ff, Remove/install firewall bottom section Model 454.0

Remove/install frontal acceleration sensor

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2666 · Applies to: 453 · AR: AR91.60-P-0750FF

AR91.60-P-0750FF 3 Remove expansion clip (2). 4.1 Unclip refrigerant line (3) from bracket (19) on For vehicles with code (I01) Air conditioning front module (1) in area of right front lamp unit Plus (with outside temperature indicator) (E2) (FFO) 5.1 Unclip refrigerant line (3) from bracket (20) on On vehicles with code (I01) Air conditioning alarm signal horn with additional battery plus (with outside temperature indicator) (H3/1) in area of right front lamp unit (E2) (FFO) and code (V40) Alarm system 6 Disconnect electrical connectors (16) from horn (H2) 7 Unclip retaining clamp (17) 8 Unthread horn wiring harness (14) from front module (1) and lay down to side 9 Remove expansion clip (4) from air intake connection (5) 10 Remove air intake connection (5) Installation:

Ensure that the air intake connection (5) is seated correctly on the air cleaner. 11.1 Unscrew bolt (22) on charge air duct mount in With engine 122.9 or 639.9 back of charge air cooler. 11.2 Unscrew bolt (22) from fuse and relay holder On vehicles with code (I60) Stationary heater, gasoline 12.1 Loosen STH wiring harness (28) or ATA On vehicles with code (V40) Alarm system or wiring harness (29) from front module (1) code (I60) Stationary heater, gasoline or code (I58) Stationary heater, diesel 13.1 Disconnect electrical connector (21) from ATA On vehicles with code (V40) Alarm system engine hood switch and lay wiring harness down to side. 14.1 Disconnect connector from alarm signal horn On vehicles with code (V40) Alarm system with additional battery (H3/1x1) 15 Unhook engine hood cable (7) from bracket (12) 16 Unhook engine hood cable (7) from bracket (6) and engine hood lock (8) 17 Disconnect electrical connector (11) from left front lamp unit (E1) and right front lamp unit (E2) 18 Unthread wiring harnesses from left front lamp unit (E1) and right front lamp unit (E2) from front module (1) 19 Remove expansion clips (13) in left and right The expansion rivet (13) is located in the front fender liner. outer area of the service flap for changing the low beam bulbs. 20.1 Unclip outside temperature display For vehicles with code (I01) Air conditioning temperature sensor (B14) from front module Plus (with outside temperature indicator) (1). (FFO) 21.1 Loosen wiring harness (25) on outside For vehicles with code (I01) Air conditioning temperature display temperature sensor (B14) Plus (with outside temperature indicator) from front module (1). (FFO) 22.1 Unscrew bolt (23) from charge air cooler (24) With engine 122.9 or 639.9 23.1 Unscrew bolts (26) from bracket on exhaust On vehicles with code (I60) Stationary heater, muffler (27) gasoline or code (I58) Stationary heater, diesel 24 Unscrew bolt (15) from left and right upper bracket of radiator (10) 25 Unscrew bolts (9) and bolts (arrows) from The front module (1) is held by a total of six front module (1). bolts (9) and two bolts (arrows). 26 Lift left and right front module (1) out of guide (18) and move toward front until radiator (10) can be removed upward. 27 Lift radiator (10) upward out of lower brackets Aid of helper required and secure. Prop up coolant hoses and refrigerant lines to relieve load.Secure radiator (10) against falling down. 28 Remove front module (1) Aid of helper required 29 Install in the reverse order 30 Check left front lamp unit (E1), right front lamp Function check of alarm system only on unit (E2), horn (H2), engine hood lock (8) and, vehicles with code (V40) Alarm system. if necessary, alarm system. Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.30-p-1575ff, Remove/install front module MODEL 454.0 with ENGINE 122.9, 134.9, 135.9, 639.9

White sealing compound, 310 ml, DBL

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2676 · Applies to: 453 · AR: AR97.20-P-1500FF, AR62.20-P-1856FF

BR00.45-Z-1003-01A 6069.20 11 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 12 Paint repair area adjacent surfaces 13 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 14 Install left and right wheel well with front AR62.20-P-1856FF longitudinal member 15 Take vehicle of the straightening bench and remove straightening bench 16 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding, replaced by A 000 986 A 000 986 34 42 28 00 1K zinc dust paint BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar62.30-p-1352ff, Replace crossmember Model 454.0

Install

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2683 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR64.20-P-1000FF, AR63.10-P-9151FF, AR63.20-P-0860FF (+4 more)

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

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 10 Install and weld in entire rear wheel well (2) AR63.10-P-0661-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 11 Install inner C-pillar side wall (1) AR63.10-P-0700-04FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 12 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 13 Prime repair area using primer filler 14 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 15 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 16 Paint repair area adjacent surfaces 17 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 18 Remove lower rear center section AR64.20-P-1000FF 19 Install tank filler neck reinforcement AR63.10-P-9151FF 20 Install side wall reinforcement AR63.20-P-0860FF 21 Install weld-on part under rear lamp AR63.20-P-2012FF 22 Install rear lamp reinforcement AR63.20-P-2011FF 23.1 Install side wall paneling If entire sidewall paneling was removed due to damage history. AR63.10-P-0110FF 23.2 Install C-pillar paneling If sidewall paneling in area of C-pillar was removed due to damage history. AR63.20-P-0098FF 24 Take vehicle of the straightening bench and remove straightening bench 25 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-0700ff, Completely replace inner C-pillar side wall Model 454.0

Clean weld joints and sheet metal flanges with

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2685 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR64.20-P-1240FF, AR64.20-P-1000FF, AR64.20-P-5731FF

9 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 10 Prime repair area using primer filler 11 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 12 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 13 Paint repair area adjacent surfaces 14 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 15 Install end section at rear longitudinal member AR64.20-P-1240FF 16 Completely install lower rear center section AR64.20-P-1000FF 17 Install end plate AR64.20-P-5731FF 18 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding, replaced by A 000 986 A 000 986 34 42 28 00 1K zinc dust paint BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-0662ff, Partially replace rear wheel well Model 454.0

Notes on replacing body parts

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2687 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF

AH60.00-P-0027-01FF When replacing body panels under

sidewall paneling lower section (1), this area of the sidewall paneling lower section (1) must be separately treated. Install

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

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6.1 Install lower side wall paneling (1) Only if no reinforcements or body panels located underneath were replaced. Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work AR63.10-P-0745-03FF The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6.2 Install lower side wall paneling (1) Only if reinforcements or body panels located underneath were replaced. Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work AR63.10-P-0745-03FG 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 11 Paint repair area adjacent surfaces 12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 13 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-0745ff, Remove/install lower side wall paneling Model 454.0

Topical note

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2691 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF

Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work AR63.10-P-0110-06FF The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6.2 Install side wall paneling (1) Only when replacing sidewall paneling (1) and additional reinforcements or body panels located underneath. Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work AR63.10-P-0110-06FG 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 11 Paint repair area adjacent surfaces 12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 13 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding, replaced by A 000 986 A 000 986 34 42 28 00 1K zinc dust paint BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1007-02A Window adhesive, 310 ml TEROSTAT MS 930 A 005 989 61 71 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-0110ff, Remove/install side wall paneling Model 454.0

Install side wall paneling (1)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2693 · Applies to: 453 · AR: AR97.10-P-4000SR, AR97.20-P-1500SR

5 Install side wall paneling (1) AR63.10-P-0110-06SR 000 588 01 84 00 Welder WS60.00-P-0021K

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

Commercially available devices/tools

Round wire brush Body power jigsaw Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Parts kit for 2-component adhesive for body BR00.45-Z-1162-02A 6 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 7 Remove spark protection blankets 8 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner 9 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

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

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

http://xentryportal.mercedes-benz.com 12 Add cavity preserving agent AR97.20-P-1500SR 13 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-0110sr, Remove/install side wall paneling Model 453.0/3

Install side wall paneling (1)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2695 · Applies to: 453 · AR: AR97.10-P-4000SR, AR97.20-P-1500SR

5 Install side wall paneling (1) AR63.10-P-0110-06SRC 000 588 01 84 00 Welder WS60.00-P-0021K

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

Commercially available devices/tools

Round wire brush Body power jigsaw Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Parts kit for 2-component adhesive for body BR00.45-Z-1162-02A 6 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 7 Remove spark protection blankets 8 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner 9 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

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

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

http://xentryportal.mercedes-benz.com 12 Add cavity preserving agent AR97.20-P-1500SR 13 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71 Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar63.10-p-0110src, Remove/install side wall paneling Model 453.4

Supplement hollow cavity preservation after

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2697 · Applies to: 453 · AR: AR97.20-P-1500FF

11 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 12 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding, replaced by A 000 986 A 000 986 34 42 28 00 1K zinc dust paint BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1007-02A Window adhesive, 310 ml TEROSTAT MS 930 A 005 989 61 71 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.10-p-9151ff, Replace tank filler fitting reinforcement Model 454.0

Determine positioning of the Car-O-Flex

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2702 · Applies to: 453 · AR: AR97.10-P-4000FF, AR63.10-P-0745FF, AR63.20-P-0098FF, AR63.10-P-0110FF, AR60.10-P-0100FF (+3 more)

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

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

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 9 Install bottom side wall reinforcement (1) AR63.20-P-0861-04FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 10 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 11 Prime repair area using primer filler 12 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL *BR00.45-Z-1003-01A 6069.20 13.1 Install sidewall paneling lower section When installing the sidewall paneling in the bottom area. AR63.10-P-0745FF 13.2 Install C-pillar paneling When installing the sidewall paneling in the area of the C-pillar. AR63.20-P-0098FF 13.3 Install side wall paneling When installing the entire sidewall paneling. AR63.10-P-0110FF 14 Remove Car-O-Flex holding system Only for CAR-O-Liner straightening system. 15 Take body off the straightening bench and CAR-BENCH straightening systems AR60.10-P-0100FF remove straightening bench Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 16 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-0862ff, Partially replace side wall reinforcement Model 454.0 Lower side wall reinforcement

Notes on replacing body parts

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2704 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF

AH60.00-P-0027-01FF When installing new body panels under the

A-pillar outer section (1), this area of the A- pillar outer section (1) must be treated separately. Install

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

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6.1 Install A-pillar outer section (1) Only if no reinforcements or body panels located underneath were replaced. AR63.20-P-1102-03FF 6.2 Install A-pillar outer section (1) Only if reinforcements or body panels located underneath were replaced. AR63.20-P-1102-03FG 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 11 Paint repair area adjacent surfaces 12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 13 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1102ff, Remove/install A-pillar outer section Model 454.0

Determine positioning of the Car-O-Flex

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2710 · Applies to: 453 · AR: AR97.10-P-4000FF, AR63.30-P-1110FF, AR63.30-P-1102FF, AR63.20-P-1352FF, AR63.20-P-1351FF (+4 more)

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

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

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 9 Install B-pillar inner section (1) AR63.20-P-1350-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 10 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 11 Prime repair area using primer filler 12 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL *BR00.45-Z-1003-01A 6069.20 13 Paint repair area adjacent surfaces 14.1 Install center longitudinal member outer shell When installing longitudinal member outer at entrance shell in center area. AR63.30-P-1110FF 14.2 Install longitudinal member outer shell on When installing entire longitudinal member entrance outer shell. AR63.30-P-1102FF 15.1 Install lower and center B-pillar reinforcement When installing B-pillar reinforcement in lower and center area. AR63.20-P-1352FF 15.2 Install B-pillar reinforcement When installing entire B-pillar reinforcement. AR63.20-P-1351FF 16 Remove Car-O-Flex holding system Only in case of CAR-O-Liner straightening system. CAR-O-Liner "Car-O-Flex", universal

holding fixture for insertion of new body panels. CAR-O-Liner adapter for "Car-O-Flex". CAR-O-Liner measuring system Car-O-Tronic "Classic". CAR-O-Liner measuring system Car-O-Tronic "Vision". 17 Take body off the straightening bench and CAR-BENCH straightening systems AR60.10-P-0100FF remove straightening bench Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 18 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1355ff, Remove/install B-pillar inner section Model 454.0

Prepare connecting points of B-pillar outer

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2712 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF

4 Prepare connecting points of B-pillar outer AR63.20-P-1121-06FF section (1) at body 5 Prepare B-pillar outer section (1) for AR63.20-P-1121-02FF installation Notes on replacing body parts AH60.00-P-0027-01FF When replacing body panels under B-pillar

outer section (1), this area of the B-pillar outer section must be separately treated. Install

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

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6.1 Fit B-pillar outer section (1) Only if no reinforcements or body panels located underneath were replaced. AR63.20-P-1121-03FF 6.2 Fit B-pillar outer section (1) Only if reinforcements or body panels located underneath were replaced. AR63.20-P-1121-03FG 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 11 Paint repair area adjacent surfaces 12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 13 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1121ff, Remove/install B-pillar outer section Model 454.0

Supplement hollow cavity preservation after

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2714 · Applies to: 453 · AR: AR97.20-P-1500FF, AR63.20-P-0098FF, AR63.10-P-0110FF

12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 13.1 Install C-pillar paneling Only when installing the sidewall paneling in the area of the C-pillar. AR63.20-P-0098FF 13.2 Install side wall paneling Only when installing the entire sidewall paneling. AR63.10-P-0110FF 14 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-2011ff, Remove/install taillamp reinforcement Model 454.0

C-pillar paneling (1) can be cut in the areas

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2716 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF

A to D. Replacement of C-pillar paneling (1) is shown by way of example at cuts A and D. Cuts must be adapted to repair process. 4 Prepare connecting points of C-pillar paneling AR63.20-P-0098-03FF (1) on body Window adhesive, 310 ml TEROSTAT MS 930*BR00.45-Z-1007-02A 5 Prepare C-pillar paneling (1) for installation AR63.20-P-0098-01FF Notes on replacing body parts AH60.00-P-0027-01FF If body panels located under C-pillar

paneling (1) will be replaced, this area of C- pillar paneling (1) must be separately treated. Install

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

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 6.1 Install C-pillar paneling (1) Only if no reinforcements or body panels located underneath were replaced. AR63.20-P-0098-04FF Window adhesive, 310 ml TEROSTAT MS 930BR00.45-Z-1007-02A 6.2 Install C-pillar paneling (1) Only if reinforcements or body panels located underneath were replaced. AR63.20-P-0098-04FG Window adhesive, 310 ml TEROSTAT MS 930BR00.45-Z-1007-02A 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 11 Paint repair area adjacent surfaces 12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 13 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1007-02A Window adhesive, 310 ml TEROSTAT MS 930 A 005 989 61 71 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-0098ff, Removing, installing paneling of C-pillar Model 454.0

Supply standard seam seals with body sealant

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2722 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR63.10-P-0110FF, AR63.20-P-1102FF

10 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 Window adhesive, 310 ml TEROSTAT MS 930BR00.45-Z-1007-02A 11 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 12.1 Install side wall paneling When installing entire sidewall paneling. AR63.10-P-0110FF 12.2 Install A-pillar outer section When installing sidewall paneling in area of A- pillar. AR63.20-P-1102FF 13 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1007-02A Window adhesive, 310 ml TEROSTAT MS 930 A 005 989 61 71 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1110ff, Replace A-pillar reinforcement Model 454.0

The high voltage used for electric welding

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2724 · Applies to: 453 · AR: AR97.10-P-4000FF, AR63.10-P-0110FF, AR63.20-P-1121FF, AR60.10-P-0100FF, AR60.10-P-0100FG (+2 more)

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

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 9 Install B-pillar reinforcement (1) AR63.10-P-0696-05FF 10 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 11 Prime repair area using primer filler 12 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL *BR00.45-Z-1003-01A 6069.20 13.1 Install side wall paneling When installing entire sidewall paneling. AR63.10-P-0110FF 13.2 Install outer section of B-pillar When installing sidewall paneling in area of B- pillar. AR63.20-P-1121FF 14 Remove Car-O-Flex holding system Only in case of CAR-O-Liner straightening system. CAR-O-Liner "Car-O-Flex", universal

holding fixture for insertion of new body panels. CAR-O-Liner adapter for "Car-O-Flex" CAR-O-Liner measuring system Car-O-Tronic "Classic" CAR-O-Liner measuring system Car-O-Tronic "Vision" 15 Take body off the straightening bench and CAR-BENCH straightening systems AR60.10-P-0100FF remove straightening bench Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 16 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1351ff, Replace B-pillar reinforcement Model 454.0

000 588 01 84 00 Welder

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2726 · Applies to: 453 · AR: AR97.10-P-4000SR, AR97.20-P-1500SR

WS60.00-P-0021K

Commercially available devices/tools

Round wire brush Blind rivet tool Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Blind rivet 6.5 12.5 (clamping BR00.45-Z-1012-13A range 2 mm to 5 mm, draw-off strength min. 19 kN) 7 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 8 Remove spark protection blankets 9 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner 10 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

AG: http://xentryportal.mercedes-benz.com 11 Seal seam following repairs AR97.10-P-4000SR Supplement standard seals with sealant.

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

http://xentryportal.mercedes-benz.com 13 Add cavity preserving agent AR97.20-P-1500SR 14 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off BR00.45-Z-1012-13A A 004 990 16 97 strength min. 19 kN) Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar63.20-p-1351src, Replace B-pillar reinforcement Model 453.4

Prime repair area using primer filler

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2728 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR63.20-P-1110FF

10 Prime repair area using primer filler 11 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q BR00.45-Z-1008-05A 13 Install reinforcement on the A-pillar AR63.20-P-1110FF 14 Take vehicle of the straightening bench and remove straightening bench 15 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1100ff, Replace complete A-pillar Model 454.0 Complete A-pillar with inner section

White sealing compound, 310 ml, DBL

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2730 · Applies to: 453 · AR: AR97.20-P-1500FF, AR63.20-P-1110FF

BR00.45-Z-1003-01A 6069.20 12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q BR00.45-Z-1008-05A 13 Install reinforcement on the A-pillar AR63.20-P-1110FF 14 Take vehicle of the straightening bench and remove straightening bench 15 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-1100fg, Replace complete A-pillar Model 454.0 Outer A-pillar

Clean weld joints and sheet metal flanges with

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2734 · Applies to: 453 · AR: AR97.10-P-4000FF, AR63.10-P-0110FF, AR63.20-P-0098FF, AR60.10-P-0100FF, AR60.10-P-0100FG (+2 more)

10 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 11 Prime repair area using primer filler 12 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL *BR00.45-Z-1003-01A 6069.20 13.1 Install side wall paneling When installing entire sidewall paneling. AR63.10-P-0110FF 13.2 Install C-pillar paneling When installing sidewall paneling in area of C- pillar. AR63.20-P-0098FF 14 Remove Car-O-Flex holding system Only in case of CAR-O-Liner straightening system. 15 Take body off the straightening bench and CAR-BENCH straightening systems AR60.10-P-0100FF remove straightening bench Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 16 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-0860ff, Replace side wall reinforcement Model 454.0

Topical note

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2738 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR63.30-P-1110FF, AR63.30-P-1102FF, AR63.20-P-0860FF (+1 more)

Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 8 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 9 Prime repair area using primer filler 10 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 11 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 12 Paint repair area adjacent surfaces 13 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 14.1 Install longitudinal member outer shell at When installing longitudinal member outer entrance section shell in rear area. AR63.30-P-1110FF 14.2 Install longitudinal member outer shell at When installing entire longitudinal member entrance outer shell. AR63.30-P-1102FF 15.1 Install side wall reinforcement When installing entire side wall reinforcement. AR63.20-P-0860FF 15.2 Install part of side wall reinforcement When installing side wall reinforcement in lower area. AR63.20-P-0862FF 16 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.20-p-0013ff, Replace wheel well end section Model 454.0

Supply standard seam seals with body sealant

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2740 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR63.30-P-0815FF

10 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 11 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 12 Paint repair area adjacent surfaces 13 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 14 Install side front longitudinal member AR63.30-P-0815FF 15 Take vehicle of the straightening bench and remove straightening bench 16 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-1143ff, Partially replace longitudinal member inner shell on entrance Model 454.0

Remove longitudinal member outer shell (1) at When removing center longitudinal member

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2744 · Applies to: 453 · AR: AR97.10-P-4000FF, AR63.20-P-1100FF, AR63.20-P-1100FG, AR63.20-P-1352FF, AR63.20-P-1351FF (+5 more)

7.2 Remove longitudinal member outer shell (1) at When removing center longitudinal member center entrance outer shell (1.2). AR63.30-P-1110-01FG 7.3 Remove longitudinal member outer shell (1) at When removing rear longitudinal member rear entrance outer shell (1.3). AR63.30-P-1110-01FH 8.1 Prepare longitudinal member outer shell (1) at When preparing front longitudinal member front entrance for installation outer shell (1.1). AR63.30-P-1110-02FF 8.2 Prepare longitudinal member outer shell (1) at When preparing center longitudinal member center entrance for installation outer shell (1.2). AR63.30-P-1110-02FG Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 8.3 Prepare longitudinal member outer shell (1) at When preparing rear longitudinal member rear entrance for installation outer shell (1.3). AR63.30-P-1110-02FH 9.1 Prepare connecting points of longitudinal When preparing connecting points of front member outer shell (1) at front body for longitudinal member outer shell (1.1). installation AR63.30-P-1110-04FF 9.2 Prepare connecting points of longitudinal When preparing connecting points of center member outer shell (1) at center body for longitudinal member outer shell (1.2). installation AR63.30-P-1110-04FG Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A 9.3 Prepare connecting points of longitudinal When preparing connecting points of rear member outer shell (1) at rear body for longitudinal member outer shell (1.3). installation AR63.30-P-1110-04FH 10 Mount Car-O-Flex holding fixture for Only in case of CAR-O-Liner straightening installation of rear, center or front longitudinal system. member outer shell (1) Determine positioning of the Car-O-Flex

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

11.1 Install longitudinal member outer shell (1) at When installing front longitudinal member front entrance outer shell (1.1). AR63.30-P-1110-03FF 11.2 Install longitudinal member outer shell (1) at When installing center longitudinal member center entrance outer shell (1.2). AR63.30-P-1110-03FG 11.3 Install longitudinal member outer shell (1) at When installing rear longitudinal member outer rear entrance shell (1.3). AR63.30-P-1110-03FH 12 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 13 Prime repair area using primer filler 14 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 15 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 16.1 Install entire A-pillar When installing entire A-pillar. AR63.20-P-1100FF 16.2 Install entire A-pillar When installing outer A-pillar. AR63.20-P-1100FG 17.1 Install lower B-pillar reinforcement When installing B-pillar reinforcement in lower area. AR63.20-P-1352FF 17.2 Install B-pillar reinforcement When installing entire B-pillar reinforcement. AR63.20-P-1351FF 18.1 Install side wall paneling lower section When installing side wall paneling in area of longitudinal member outer shell (1). AR63.10-P-0745FF 18.2 Install side wall paneling When installing entire sidewall paneling. AR63.10-P-0110FF 19 Remove Car-O-Flex holding system Only in case of CAR-O-Liner straightening system. 20 Take body off the straightening bench and CAR-BENCH straightening systems AR60.10-P-0100FF remove straightening bench Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-1110ff, Partially replace outer longitudinal member shell on entry Model 454.0

Install outer side longitudinal member (1)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2747 · Applies to: 453 · AR: AR97.10-P-4000SR, AR97.20-P-1500SR

5 Install outer side longitudinal member (1) AR63.30-P-1050-03SRC 000 588 01 84 00 Welder WS60.00-P-0021K

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

Commercially available devices/tools

Round wire brush Body power jigsaw Wet/dry vacuum cleaner Zinc dust paint suitable for spot welding BR00.45-Z-1001-07A Parts kit for 2-component adhesive for body BR00.45-Z-1162-02A 6 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 7 Remove spark protection blankets 8 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner 9 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

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

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

http://xentryportal.mercedes-benz.com 12 Add cavity preserving agent AR97.20-P-1500SR 13 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-1050src, Partially replace outer side longitudinal member Model 453.3/4

Prime repair area using primer filler

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2749 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR62.25-P-1100FF, AR63.40-P-1180FG

10 Prime repair area using primer filler 11 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 12 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 13 Paint repair area adjacent surfaces 14 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 15 Install left or right lower firewall section AR62.25-P-1100FF 16 Install entire side of main floor AR63.40-P-1180FG 17 Take vehicle of the straightening bench and remove straightening bench 18 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-0846ff, Remove/install center side longitudinal member Model 454.0

White sealing compound, 310 ml, DBL

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2751 · Applies to: 453 · AR: AR97.20-P-1500FF, AR63.30-P-1102FF, AR63.30-P-1110FF, AR63.20-P-1100FF

BR00.45-Z-1003-01A 6069.20 12 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 13 Paint repair area adjacent surfaces 14 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 15.1 Install longitudinal member outer shell at the During installation of the entire longitudinal entrance member outer shell. AR63.30-P-1102FF 15.2 Partially install longitudinal member outer shell During installation of the longitudinal member at the entrance outer shell in the front area. AR63.30-P-1110FF 16 Completely install A-pillar AR63.20-P-1100FF 17 Take vehicle of the straightening bench and remove straightening bench 18 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-0815ff, Remove/install front side longitudinal member Model 454.0

Clean weld joints and sheet metal flanges with

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2753 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR63.20-P-1355FF, AR63.30-P-0815FF, AR63.30-P-1102FF

10 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 11 Prime repair area using primer filler 12 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 13 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 14 Paint repair area adjacent surfaces 15 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 16 Install B-pillar inner section AR63.20-P-1355FF 17 Install side front longitudinal member AR63.30-P-0815FF 18 Install longitudinal member outer shell on AR63.30-P-1102FF entrance 19 Take vehicle of the straightening bench and remove straightening bench 20 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-1164ff, Replace longitudinal member inner shell on entry Model 454.0

Clean weld joints and sheet metal flanges with

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2755 · Applies to: 453 · AR: AR97.10-P-4000FF, AR63.20-P-1100FF, AR63.20-P-1351FF, AR63.10-P-0110FF, AR60.10-P-0100FF (+3 more)

11 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 12 Prime repair area using primer filler 13 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 14 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 15 Completely install A-pillar AR63.20-P-1100FF 16 Install B-pillar reinforcement AR63.20-P-1351FF 17 Install side wall paneling AR63.10-P-0110FF 18 Remove Car-O-Flex holding system Only for CAR-O-Liner straightening system. 19 Take body off the straightening bench and CAR-BENCH straightening systems AR60.10-P-0100FF remove straightening bench Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 20 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.30-p-1102ff, Replace longitudinal member outer shell on entrance Model 454.0

Supplement hollow cavity preservation after

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2759 · Applies to: 453 · AR: AR97.20-P-1500FF

12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 13 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1110ff, Replace center main floor panel reinforcement Model 454.0

Clean weld joints and sheet metal flanges with

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2763 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF

6 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 7 Prime repair area using primer filler 8 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 9 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 10 Paint repair area adjacent surfaces 11 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 12 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1191ff, Replace crossmember below front seat Model 454.0 Crossmember below front seat

Supplement standard underbody protection

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2765 · Applies to: 453 · AR: AR97.20-P-1500FF, AR63.40-P-1180FG

10 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 11 Paint repair area adjacent surfaces 12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q BR00.45-Z-1008-05A 13 Install left or right main floor AR63.40-P-1180FG 14 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1191fh, Replace crossmember below front seat Model 454.0 Rear crossmember

Supplement hollow cavity preservation after

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2767 · Applies to: 453 · AR: AR97.20-P-1500FF, AR63.40-P-1180FG

12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 13 Install left or right main floor AR63.40-P-1180FG 14 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1191fj, Replace crossmember below front seat Model 454.0 Front crossmember

Topical note

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2769 · Applies to: 453 · AR: AR97.10-P-4000FF, AR62.25-P-1100FF, AR60.10-P-0100FF, AR60.10-P-0100FG, AR60.10-P-0100FH (+1 more)

Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 10 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 11 Prime repair area using primer filler 12 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 13 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 14 Paint repair area adjacent surfaces 15 Partially install bottom firewall AR62.25-P-1100FF 16 Remove Car-O-Flex holding system Only in case of CAR-O-Liner straightening system. 17 Take body off the straightening bench and CAR-BENCH straightening systems AR60.10-P-0100FF remove straightening bench Celette straightening systems AR60.10-P-0100FG BLACKHAWK straightening systems AR60.10-P-0100FH CAR-O-Liner straightening systems AR60.10-P-0100FJ 18 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1100ff, Replace outer main floor panel reinforcement Model 454.0

Prime repair area using primer filler

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2771 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR63.30-P-1143FF, AR63.30-P-1164FF, AR63.40-P-1191FF

10 Prime repair area using primer filler 11 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 12 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 13 Paint repair area adjacent surfaces 14 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 15.1 Partially install longitudinal member inner shell If only front area of longitudinal member inner on entrance shell must be installed due to damage history. AR63.30-P-1143FF 15.2 Install longitudinal member inner shell on entry If entire longitudinal member inner shell must be installed due to damage history. AR63.30-P-1164FF 16 Install crossmember under front seat AR63.40-P-1191FF 17 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1180ff, Replace partial main floor Model 454.0 Front footwell

White sealing compound, 310 ml, DBL

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2773 · Applies to: 453 · AR: AR97.20-P-1500FF, AR63.30-P-1164FF, AR63.40-P-1110FF

BR00.45-Z-1003-01A 6069.20 12 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 13 Paint repair area adjacent surfaces 14 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 15 Install longitudinal member inner shell on entry AR63.30-P-1164FF 16 Install center main floor reinforcement AR63.40-P-1110FF 17 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1180fg, Replace partial main floor Model 454.0 Complete side

Supplement standard underbody protection

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2777 · Applies to: 453 · AR: AR97.20-P-1500FF, AR63.40-P-1180FG

11 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 12 Paint repair area adjacent surfaces 13 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q BR00.45-Z-1008-05A 14 Install left or right main floor AR63.40-P-1180FG 15 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar63.40-p-1185ff, Replace reinforcement on tunnel Model 454.0

Install mounting bracket (1) for engine

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2782 · Applies to: 453 · AR: AR97.10-P-4000SR, AR97.20-P-1500SR

5 Install mounting bracket (1) for engine suspension 000 588 01 84 00 Welder WS60.00-P-0021K

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

AR64.10-P-2000-03SR Commercially available devices/tools

Round wire brush Blind rivet tool Wet/dry vacuum cleaner Adhesive kit, body, 2-component adhesive BR00.45-Z-1092-02A Blind rivet 6.5 12.5 (clamping BR00.45-Z-1012-13A range 2 mm to 5 mm, draw-off strength min. 19 kN) 6 Clean weld joints and sheet metal flange with Commercially available devices/tools

round wire brush Round wire brush 7 Remove spark protection blankets 8 Clean repair area Commercially available devices/tools

Wet/dry vacuum cleaner 9 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

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

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

http://xentryportal.mercedes-benz.com 12 Add cavity preserving agent AR97.20-P-1500SR 13 Install detachable parts in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Blind rivet 6.5 12.5 (clamping range 2 mm to 5 mm, draw-off BR00.45-Z-1012-13A A 004 990 16 97 strength min. 19 kN) BR00.45-Z-1092-02A Adhesive kit, body, 2-component adhesive A 012 989 17 71 Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar64.10-p-2000sr, Replace mounting bracket for engine suspension Model 453.0/3/4

Supplement hollow cavity preservation after

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2788 · Applies to: 453 · AR: AR97.20-P-1500FF, AR63.10-P-0700FF

13 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 14 Install entire inner C-pillar side wall AR63.10-P-0700FF 15 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1300ff, Completely replace rear floor Model 454.0 When replacing individual rear-end floor

Supplement hollow cavity preservation after

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2790 · Applies to: 453 · AR: AR97.20-P-1500FF, AR64.20-P-1240FF

14 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 15 Install end section at left and right rear AR64.20-P-1240FF longitudinal member 16 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1310ff, Partially replace rear floor assembly Model 454.0

Supply standard seam seals with body sealant

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2792 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR64.20-P-1300FF, AR64.20-P-1310FF, AR63.10-P-0700FF (+1 more)

11 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 12 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 13 Paint repair area adjacent surfaces 14 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 15.1 Completely install rear-end floor If, because of the damage history, the rear- end floor has to be completely installed. AR64.20-P-1300FF 15.2 Partially install rear-end floor If, because of the damage history, the rear- end floor has to be partially installed. AR64.20-P-1310FF 16.1 Install inner C-pillar side wall If, because of the damage history, the C-pillar side wall has to be installed. AR63.10-P-0700FF 16.2 Install rear wheel well section If, because of the damage history, the rear well wheel well has to be partially installed. AR63.10-P-0662FF 17 Take vehicle of the straightening bench and remove straightening bench 18 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1260ff, Partially replace rear longitudinal member Model 454.0

Supplement standard underbody protection

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2799 · Applies to: 453 · AR: AR97.20-P-1500FF

11 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 12 Paint repair area adjacent surfaces 13 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q BR00.45-Z-1008-05A 14 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1000ff, Replace complete bottom rear center section Model 454.0

Commercially available tools

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2801 · Applies to: 453 · AR: AR97.10-P-4000SR, AR97.20-P-1500SR

-Round wire brush - Spot welder MIG-MAG inert gas welder 6 Clean weld joints and sheet metal flange with Commercially available tools

round wire brush -Round wire brush 7 Remove spark protection blankets 8 Clean repair area Commercially available tools

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

igniting. Risk of poisoning caused by inhaling protection, protective clothing, gloves, safety paint vapors. glasses and protective skin cream. Ensure that the area is well ventilated. 9 Prime repair area using primer filler Topical note Notes on paintwork repairs AH98.00-P-9408-02MCC Use only primer filler approved by Daimler

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

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

http://aftersales.mercedes-benz.com 12 Add cavity preserving agent AR97.20-P-1500SR 13 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1000sr, Replace complete bottom rear center section Model 453

Prepare entire rear-end floor (1) for installation

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2805 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR63.10-P-0700FF

12 Prepare entire rear-end floor (1) for installation AR64.20-P-1300-02FG Notes on replacing body parts AH60.00-P-0027-01FF Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 13 Install upper section of crossmember under AR64.20-P-1140-03FF rear-end floor (3) and lower section of crossmember under rear-end floor (2) with entire rear-end floor (1) Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 14 Install entire rear-end floor (1) AR64.20-P-1300-04FG Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 15 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 16 Prime repair area using primer filler 17 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 18 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 19 Paint repair area adjacent surfaces 20 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 21 Install entire inner C-pillar side wall AR63.10-P-0700FF 22 Take vehicle of the straightening bench and remove straightening bench 23 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar64.20-p-1140ff, Replace crossmember on bottom front rear floor assembly Model 454.0

Side roof paneling (1) can be cut in the

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2819 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF

areas A to E. Replacement of side roof paneling (1) is shown by way of example at cuts A, C, E. Cuts must be adapted to repair process. 4 Prepare mating surfaces at vehicle for side AR65.10-P-1020-04FF roof paneling (1) 5 Prepare side roof paneling (1) AR65.10-P-1020-02FF Notes on replacing body parts AH60.00-P-0027-01FF When replacing body panels under side

roof paneling (1), this area of side roof paneling (1) must be separately treated. Install

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

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6.1 Install side roof paneling (1) and weld in Only if no reinforcements or body panels located underneath were replaced. Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work AR65.10-P-1020-03FF The high voltage used for electric welding Use insulating mats. Wear protective clothing, AS00.00-Z-0007-01A Danger

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6.2 Install side roof paneling (1) and weld in Only if reinforcements or body panels located underneath were replaced. Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work AR65.10-P-1020-03FG 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Supplement standard underbody protection Underfloor protection 800 ml BR00.45-Z-1001-05A with permanent underfloor protection 11 Paint repair area adjacent surfaces 12 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q *BR00.45-Z-1008-05A 13 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.10-p-1020ff, Replace complete side roof paneling Model 454.0

AR65.20-P-1006FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2820 · Applies to: 453 · AR: AR65.20-P-1006FF, AR97.10-P-4000FF, AR97.20-P-1500FF

Remove/install front roof frame 12.04.2019 Model 454.0 1 Front roof frame P65.20-2203-05 Remove

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

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

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove front roof frame (1) AR65.20-P-1006-02FF 4 Prepare connecting points of the front roof AR65.20-P-1006-08FF frame (1) on the body 5 Prepare front roof frame (1) for installation AR65.20-P-1006-04FF Notes on replacing body parts AH60.00-P-0027-01FF Install

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

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6 Install front roof frame (1) AR65.20-P-1006-05FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Paint repair area adjacent surfaces 11 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q BR00.45-Z-1008-05A 12 Reinstall all removed assembly parts Repair materials Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.20-p-1006ff, Remove/install front roof frame Model 454.0

Install roof paneling

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2823 · Applies to: 453 · AR: AR65.10-P-1000SRA, AR97.10-P-4000SR, AR97.20-P-1500SR

7 Install roof paneling Model 453.0 AR65.10-P-1000SRA with code E23 (solid roof) 8 Clean weld joints and sheet metal flange with Commercially available devices/tools

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

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

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

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

http://xentryportal.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1162-02A Parts kit for 2-component adhesive for body A 012 989 17 71 Page 2 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar65.20-p-1006sr, Remove/install front roof frame Model 453.0/3/4

AR65.20-P-1008FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2824 · Applies to: 453 · AR: AR65.20-P-1008FF, AR97.10-P-4000FF, AR97.20-P-1500FF

Remove/install rear roof frame 12.04.2019 Model 454.0 1 Rear roof frame P65.20-2350-04 Remove

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

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

(area to be repaired) Use fire-resistant tarp to prevent damage due to flying sparks. 3 Remove rear roof frame (1) AR65.20-P-1008-01FF 4 Prepare rear roof frame (1) for installation AR65.20-P-1008-02FF Notes on replacing body parts AH60.00-P-0027-01FF 5 Prepare mating surfaces on the vehicle for the AR65.20-P-1008-04FF installation of the rear roof frame (1) Install

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

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

from welding in areas close to highly highly inflammable materials from the hazard inflammable materials. Risk of injury from area. Use air extraction system. weld splatter and UV-light when welding. Risk of poisoning from inhaling welding gases 6 Install rear roof frame (1) AR65.20-P-1008-03FF Topical note Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 7 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 8 Prime repair area using primer filler 9 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 10 Paint repair area adjacent surfaces 11 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q BR00.45-Z-1008-05A 12 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.20-p-1008ff, Remove/install rear roof frame Model 454.0

Commercially available devices/tools

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2826 · Applies to: 453 · AR: AR65.10-P-1000SRA, AR97.10-P-4000SR, AR97.20-P-1500SR

Round wire brush Wet/dry vacuum cleaner 7 Install roof paneling Model 453.0 AR65.10-P-1000SRA with code E23 (solid roof) 8 Clean weld joints and sheet metal flange with Commercially available devices/tools

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

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

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

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

http://xentryportal.mercedes-benz.com 14 Add cavity preserving agent AR97.20-P-1500SR 15 Install all detachable body components in area to be repaired Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.20-p-1008sr, Remove/install rear roof frame Model 453.0/3

Topical note

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 2828 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF, AR63.20-P-1351FF, AR63.20-P-1352FF, AR65.10-P-1020FF (+2 more)

Measures for preventing damage to vehicles AH00.00-N-0005-01A or components when performing electric welding work 10 Clean weld joints and sheet metal flanges with wire brush and clean repair areas 11 Prime repair area using primer filler 12 Supply standard seam seals with body sealant AR97.10-P-4000FF White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 13 Paint repair area adjacent surfaces 14 Supplement hollow cavity preservation after AR97.20-P-1500FF repair work Teroson protective wax, art. no: 122.73Q BR00.45-Z-1008-05A 15.1 Install B-pillar reinforcement When installing entire B-pillar reinforcement. AR63.20-P-1351FF 15.2 Install upper B-pillar reinforcement When installing B-pillar reinforcement in upper area. AR63.20-P-1352FF 16.1 Install side roof paneling When installing sidewall paneling in area of outer roof frame (1). AR65.10-P-1020FF 16.2 Install side wall paneling When installing entire sidewall paneling. AR63.10-P-0110FF 17 Install front roof frame AR65.20-P-1006FF 18 Reinstall all removed assembly parts Repair materials Number Designation Order number BR00.45-Z-1001-07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1008-05A Teroson protective wax, art. no: 122.73Q Henkel Loctite www.Loctite.de Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar65.20-p-1200ff, Remove/install side roof frame Model 454.0

Unclip retaining clips (arrow A) of antenna

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3551 · Applies to: 453 · AR: AR91.10-P-1000FF, AR68.10-P-1400FF, AR68.30-P-4100FF, AR82.64-P-7508FF, AR82.60-P-7502FF

11 Unclip retaining clips (arrow A) of antenna Pay attention to the radio antenna plug wiring harness (12) and expose antenna (10) of the radio connection (15) and the radio wiring harness (12) in area of roof and at right antenna power supply coupling (9) of the A-pillar power supply connection (14) when exposing the antenna wiring harness (12). In vehicles with code (C26) smart radio multimedia navigator or code (C29) smart radio navigator, attention must also be paid to the GPS antenna coupling (11) of the GPS antenna connection (A2/23x1). 12 Remove right front seat AR91.10-P-1000FF 13 Remove glove compartment AR68.10-P-1400FF 14 Remove right-hand side entrance strip AR68.30-P-4100FF 15 Remove CD changer (A2/6) AR82.64-P-7508FF 16 Lift front floor covering (17) until CD changer Take care when lifting floor covering (17) branch-off line (8) is accessible to avoid kinking or cracking. 17 Unclip retaining clips (arrows C) and expose Please ensure that the relevant protection CD changer branch-off line (8) as far as cable cap on the CD changer fiber optic cable duct (16) connector (8.2) is not removed when exposing the CD changer branch-off line (8). 18 Guide antenna wiring harness (12) out of cable duct (16) and expose 19 Undo nut of ground (right footwell) (W36), Installation:

Replace cable ties (arrows remove cable tie (arrows B) and expose B). antenna wiring harness (12) 20 Remove smart radio six, smart radio navigator AR82.60-P-7502FF or smart radio multimedia navigator (A40/3) 21 Remove control unit bracket AR54.21-P-0001-01FF 22 Disconnect interior/audio connector (X39/52) The interior/audio connector (X39/52) is located behind the carrier of the central gateway control unit and connects the antenna wiring harness (12) and the adapter wiring harness (3). Installation:

make interior/audio connector connection (X39/52) with adapter wiring harness power supply coupling (2) and adapter wiring harness power supply connector (4). 23 Unclip fiber optic cable connector (1.1) from combination plug (1) and fit protective cap 24 Unclip retaining clips (arrows D), remove Please ensure that the protective cap of cable ties (arrows E) and expose antenna the fiber optic cable connector (1.1) is not wiring harness (12) beneath instrument panel removed when the antenna wiring harness (12) is being exposed. Installation:

Replace cable ties (arrows E). 25 Remove antenna wiring harness (12) Installation:

Before installing the antenna wiring harness (12), please ensure that the relevant protective caps on the fiber optic cable connector (1.1) and the CD changer fiber optic cable connector (8.2) are present. 26 Install in the reverse order 27 Read fault memory, erase if necessary Connect STAR DIAGNOSIS and read out AD00.00-P-2000-04FF

fault memory *WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system 28 Perform a function test Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system, Compact Passenger Car 6511 1801 00 Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar82.62-p-1200fh, Remove/install antenna cable MODEL 454.0 with CODE (C20) smart CD changer

P82.64-2905-01

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3578 · Applies to: 453 · AR: AR91.10-P-1000FF

Remove

1 Remove right front sear (1) AR91.10-P-1000FF 2 Separate electrical plug connection (3) 3 Disconnect and cover fiber optic cable AR82.95-P-0005-01A Fiber optical cables must not be kinked, coupling and fiber optic cable (4) routed over sharp edges or bent in radii of less than 25 mm, otherwise the fiber optic cable core will be yellowed and broken. Yellowed or broken fiber optical cables weaken the light. 4 Fold corners (arrows) of floor lining (2) forward 5 Remove CD changer (A2/6) with bracket (5) upwards 6.1 Remove screws (6) and remove CD changer When replacing the CD changer (A2/6). (A2/6) from bracket (5). Install

7.1 Remove transport protections for CD changer When replacing the CD changer (A2/6). (A2/6) as shown in attached instructions 8.1 Remove the left and right covering cap (7) When replacing the CD changer (A2/6). and behind them, set the adjusting bolt (8) for H = Horizontal installation position the horizontal installation position of the CD changer (A2/6) 9.1 Use suitable screwdriver to bend stop (9) of When converting the CD changer (A2/6) to a bracket (5) to the rear CD changer (A2/6) with integrated MP3 player. 10.1 Mount CD changer (A2/6) onto bracket (5) When replacing the CD changer (A2/6). and tighten with screws (6) 11 Fold corners (arrows) of floor covering (2) backward 12 Insert bracket (5) with CD changer (A2/6) from above 13 Remove covers of fiber optic cables and AR82.95-P-0005-01A Fiber optical cables must not be kinked, connect fiber optic cable coupling (4) routed over sharp edges or bent in radii of less than 25 mm, otherwise the fiber optic cable core will be yellowed and broken. Yellowed or broken fiber optical cables weaken the light. 14 Connect electrical connector (3) 15 Install right front sear (1) AR91.10-P-1000FF 16 Carry out function check Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar82.64-p-7508ff, Removing and installing CD changer MODEL 454.0 with CODE (C20) smart CD changer

Retrofit holder for CD changer (1) with CD

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3581 · Applies to: 453 · AR: AR91.10-P-1000FF

28 Retrofit holder for CD changer (1) with CD AZ82.64-P-0001-13FF changer (A2/6) under right front seat 29 Install right front seat Remove/install front seat AR91.10-P-1000FF

30 Use STAR DIAGNOSIS, in the Audio gateway control unit menu, to activate the CD changer (A2/6) via a MOST ring query Connect STAR DIAGNOSIS and read out

AD00.00-P-2000-04FF

fault memory *WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system 31 Read out fault memory, delete if necessary and activate smart radio six (A2/4), smart radio navigator (A2/56) or smart radio multimedia navigator (A40/3) using STAR DIAGNOSIS Connect STAR DIAGNOSIS and read out

AD00.00-P-2000-04FF

fault memory *WH58.30-Z-1048-13A STAR DIAGNOSIS diagnosis system 32.1 Enter special equipment in the vehicle data At workshops without DMS Autoline 8.0 card and in the vehicle's online data card dealer system. Add code (C20) smart CD changer. Commercially available tools Number Designation WH58.30-Z-1048-13A STAR DIAGNOSIS Compact diagnosis system for passenger cars 6511 1801 00 Parts ordering notes Part no. Designation Quantity Design group 82 (see CD changer EPC) Design group 82 (see CD changer fastening holder EPC) In combination with Design group 82 (see Antenna wiring harness EPC) Depending on vehicle equipment Design group 82 (see Adapter line EPC) Page 3 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.64-p-0001ff, Retrofit CD changer MODEL 454.0 with CODE (C25) smart radio six Retrofit CD changer MODEL 454.0 with CODE (C26) smart radio multimedia navigator Retrofit CD changer MODEL 454.0 with CODE (C29) ...

AZ82.70-P-0005FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3593 · Applies to: 453 · AR: AZ82.70-P-0005FF, AR91.10-P-1000FF, AR68.30-P-4050FF, AR68.30-P-4010FF, AR68.30-P-4100FF (+4 more)

Retrofit hands-free system 18.8.06 MODEL 454.0 with CODE (C28) smart radio five Retrofit hands-free system accessories MODEL 454.0 with CODE (C25) smart radio six except CODE (C27) Telephone preparation incl. fastener and antenna (DFO/FFO) Retrofit hands-free system accessories P82.70-5108-09 1 Wiring harness 3 Telephone console 5 Microphone 2 Hands-free system control unit 4 Antenna Remove/install

1 Remove right front seat Remove/install front seat AR91.10-P-1000FF 2 Remove paneling of right A-pillar Remove/install paneling on A-pillar AR68.30-P-4050FF 3 Remove paneling on right in footwell Remove/install paneling in footwell AR68.30-P-4010FF 4 Remove right-hand side entrance strip Remove/install door sill molding AR68.30-P-4100FF 5 Remove right sun visor Remove/install sun visor AR68.60-P-5480FF 6 Remove smart radio five or smart radio six Remove/install radio For vehicles with code (C25) smart radio six AR82.60-P-7502FF For vehicles with code (C28) smart radio five AR82.60-P-7502FG 7 Retrofit electrical wiring harness (1) of hands- For vehicles with code (C28) smart radio five AZ82.70-P-0005-02FF free system For vehicles with code (C25) smart radio six AZ82.70-P-0005-02FH 8 Install in the reverse sequence Step 6 9 Retrofit microphone (5) of hands-free system AZ82.70-P-0001-02FF 10 Retrofit antenna (4) of hands-free system AZ82.70-P-0009-02FF 11 Retrofit telephone console (3) of hands-free AZ82.70-P-0010FF system 12 Retrofit hands-free system control unit (2) of AZ82.70-P-0005-04FF hands-free system 13 Install in the reverse sequence Work steps 5, 4, 3, 2, 1 14 Carry out hands-free system function test AZ82.70-P-0005-06FF 15.1 Enter special equipment in the vehicle data If the workshop does not have access to a card and in the vehicle's online data card DMS Autoline 8.0 dealer system. Add code (C30) Hands-free system. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, az82.70-p-0005ff, Retrofit hands-free system MODEL 454.0 with CODE (C28) smart radio five Retrofit hands-free system accessories MODEL 454.0 with CODE (C25) smart radio six except CODE (C27) Telephone preparation incl. ...

PE91.00-P-2001ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3970 · Applies to: 453 · AR: PE91.00-P-2001ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+3 more)

Block diagram for airbag (AB), emergency tensioning retractor (ETR) 12.3.04 MODELS 454 PE91.00-P-2001-99ZA Block diagram for airbag (AB), emergency PE91.00-P-2001-99ZA tensioning retractor (ETR) PE91.00-P-2001-60ZA Legend for block diagram for airbag (AB), PE91.00-P-2001-60ZA emergency tensioning retractor (ETR) 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 GF00.19-P-3000ZA Z connector 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 PE91.00-P-1100ZA Further wiring diagrams PE91.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe91.00-p-2001za, Block diagram for airbag (AB), emergency tensioning retractor (ETR) MODELS 454

PE91.00-P-2000ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3973 · Applies to: 453 · AR: PE91.00-P-2000ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram of airbag (AB), emergency tensioning retractor (ETR) 16.12.03 MODEL 454 up to 2.4.06 PE91.00-P-2000-99ZA Wiring diagram of airbag (AB), emergency PE91.00-P-2000-99ZA tensioning retractor (ETR) PE91.00-P-2000-60ZA Legend of wiring diagram for airbag (AB), PE91.00-P-2000-60ZA emergency tensioning retractor (ETR) OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Arrangement and assignment of the wiring GF00.19-P-1000ZA and plug connectors GF00.19-P-2000ZA Arrangement and assignment of ground GF00.19-P-2000ZA points GF00.19-P-3000ZA Arrangement and assignment of Z connector GF00.19-P-3000ZA sleeves (wiring connections in wiring harness) PE00.19-P-1100ZA Further wiring diagrams PE00.19-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe91.00-p-2000za, Wiring diagram of airbag (AB), emergency tensioning retractor (ETR) MODEL 454 up to 2.4.06

PE91.00-P-2000ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3974 · Applies to: 453 · AR: PE91.00-P-2000ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram of airbag (AB), emergency tensioning retractor (ETR) 8.3.06 MODEL 454 as from 3.4.06 PE91.00-P-2000-99ZB Wiring diagram of airbag (AB), emergency PE91.00-P-2000-99ZB tensioning retractor (ETR) PE91.00-P-2000-60ZB Legend of wiring diagram for airbag (AB), PE91.00-P-2000-60ZB emergency tensioning retractor (ETR) OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Location and assignment of line and plug GF00.19-P-1000ZA connectors GF00.19-P-2000ZA Location and assignment of ground points GF00.19-P-2000ZA GF00.19-P-3000ZA Location and assignment of Z connector GF00.19-P-3000ZA sleeves (line connectors in wiring harness) PE00.19-P-1100ZA Further wiring diagrams PE00.19-P-1100ZA PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe91.00-p-2000zb, Wiring diagram of airbag (AB), emergency tensioning retractor (ETR) MODEL 454 as from 3.4.06

AR91.10-P-3330FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3975 · Applies to: 453 · AR: AR91.10-P-3330FF

Remove and install seat frame 6.8.04 MODEL 454.0 P91.10-2780-07 Shown on right front seat with code (S21) Lumbar support (FFO) and code (S31) Lounge of front seat system (FFO) 1 Backrest frame 6 Adjustment unit (with code (S21) 9 Cable (with code (S21) Lumbar 2 Screw Lumbar support (FFO)) support (FFO)) 3 Stop plate 7 Clip 10 Spring frame 4 Stop 8 Bracket (with code (S21) Lumbar 11 Rivet (with code (S21) Lumbar 5 Spring support (FFO)) support (FFO)) Shown on right front seat with code (S20) Seat height adjustment (FFO), code (S21) Lumbar support (FFO) and code (S31) Lounge of front seat system (FFO) 12 Seat cushion frame 13 Spring frame 14 Cover P91.10-2781-04 P91.10-2782-07 Shown on right front seat with code (S20) 1 Backrest frame 16 Screw Seat height adjustment (FFO), code (S21) 12 Seat cushion frame 17 Nuts Lumbar support (FFO) and code (S31) 15 Sleeve Lounge of front seat system (FFO) Page 1 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-3330ff, Remove and install seat frame MODEL 454.0

Shown on right front seat with code (S20)

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3976 · Applies to: 453 · AR: AR91.10-P-1000FF, AR91.40-P-1515FF, AR91.60-P-0695FF, AR91.18-P-1820FF, AR91.10-P-1120FF (+2 more)

Seat height adjustment (FFO), code (S21) Lumbar support (FFO) and code (S31) Lounge of front seat system (FFO) 13 Spring frame 18 Seat frame 19 Clip 20 Sidebag unit wiring harness 21 Clip 22 Bracket P91.10-2783-06 20 Sidebag unit wiring harness 23 Inner guide rail 24 Connector 25 Clip P91.10-2795-04 Remove

In case of damage, always replace both

backrest frame (1) and seat cushion frame (12) 1 Remove front seat AR91.10-P-1000FF 2 Remove seat belt buckle from front seat AR91.40-P-1515FF 3 Removing front seat sidebag unit AR91.60-P-0695FF 4.1 Remove foam part with cover from front seat On vehicles without code (S17) Heated seats AR91.18-P-1820FF backrest (FFO) Remove cover only when replacing foam part. 4.2 Remove front seat backrest foam On vehicles with code (S17) Heated seats AR91.10-P-1120FF (FFO) Remove cover only when replacing foam part. 5.1 Remove foam part with cover from front seat On vehicles without code (S17) Heated seats AR91.18-P-1800FF cushion (FFO) Remove cover only when replacing foam part. 5.2 Remove seat upholstery from front seat On vehicles with code (S17) Heated seats AR91.10-P-3290FF (FFO) Remove cover only when replacing foam part. Disassemble

6 Unclip clips (19, 21) of sidebag unit wiring Pay attention to installation position of harness (20) from seat frame (18) and spring sidebag unit wiring harness (20). frame (13) 7 Unhook sidebag unit wiring harness (20) from bracket (22) Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-3330ff, Remove and install seat frame MODEL 454.0

Unclip plug (24) and clip (25) of sidebag unit

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3977 · Applies to: 453 · AR: AR91.10-P-3290FF, AR91.18-P-1800FF

8 Unclip plug (24) and clip (25) of sidebag unit wiring harness (20) from inner guide rail (23) on seat cushion frame (12) and remove sidebag unit wiring harness (20) 9 Remove protective cap in rear of inner guide rail (23) 10 Place seat frame (18) to one side If the seat frame (18) is further disassembled, in other words if the backrest frame (1) is removed from the seat cushion frame (12), then always both parts have to be replaced. Assembly

11.1 Clamp backrest frame (1) in vise with the right Only when installing new backrest frame (1) side facing up and seat frame (18). Clamp in backrest frame (1) and ensure that the hollow sections are not bent or damaged. 12.1 Fit on spring (5) Only when installing new backrest frame (1) and seat frame (18). Note correct installation positions. 13.1 Fit on stop plate (3) and attach using bolt (2) Only when installing new backrest frame (1) and seat frame (18). Do not tighten the bolt (2) fully. 14.1 Lift spring (5) above stop (4) using an Only when installing new backrest frame (1) appropriate tool and seat frame (18). 15.1 Tighten screw (2) Only when installing new backrest frame (1) and seat frame (18). *BA91.10-P-1006-01J

16.1 Detach backrest frame (1) from vise and put Only when installing new backrest frame (1) down and seat frame (18). 17.1 Insert clips (7) into backrest frame (1) and Only when installing new backrest frame (1) latch spring frame (10) in place into clips (7) and seat frame (18). Four clips (7) have to be installed on vehicles with code (S21) Lumbar support (FFO) and six clips (7) on vehicles without code (S21) Lumbar support (FFO). 18.1 Latch left and right cable (9) of spring frame On vehicles with code (S21) Lumbar support (10) into place on backrest frame (1) with (FFO) and when installing new backrest frame bracket (8) (1) and seat frame (18). 19.1 Latch adjustment unit (6) of spring frame (10) On vehicles with code (S21) Lumbar support into place in backrest frame (1) and fasten (FFO) and when installing new backrest frame with rivet (11) (1) and seat frame (18). 20.1 Latch spring frame (13) into place in seat Only when installing new backrest frame (1) cushion frame (12) and seat frame (18). 21.1 Clip covers (14) into seat cushion frame (12) Only when installing new backrest frame (1) and seat frame (18). 22.1 Latch backrest frame (1) into place in seat On vehicles with code (S31) Lounge front seat cushion frame (12) in horizontal position system (FFO) and when installing new backrest frame (1) and seat frame (18). 22.2 Latch backrest frame (1) into place in seat On vehicles without code (S31) Lounge front cushion frame (12) while backrest frame is seat system (FFO) and when installing new slightly tilted forward backrest frame (1) and seat frame (18). 23.1 Tighten bolt (16) with sleeve (15) Only when installing new backrest frame (1) and seat frame (18). *BA91.10-P-1005-01J

24.1 Tighten nuts (17) Only when installing new backrest frame (1) and seat frame (18). *BA91.10-P-1004-01J

25.1 Move backrest frame (1) into the vertical Only when installing new backrest frame (1) position and seat frame (18). Use adjusting lever. 26 Clip plug (24) and clip (25) of sidebag unit Note correct installation positions. wiring harness (20) into inner guide rail (23) on seat cushion frame (12) 27 Route sidebag unit wiring harness (20) on seat frame (18) and latch in place in bracket (22) 28 Clip clips (19, 21) of sidebag unit wiring Note correct installation positions. harness (20) into seat frame (18) and spring frame (13) Install

29.1 Install seat upholstery of front seat On vehicles with code (S17) Heated seats AR91.10-P-3290FF (FFO) 29.2 Install foam part with cover at front seat On vehicles without code (S17) Heated seats AR91.18-P-1800FF cushion (FFO) Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-3330ff, Remove and install seat frame MODEL 454.0

Install foam part of front seat backrest

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3978 · Applies to: 453 · AR: AR91.10-P-1120FF, AR91.18-P-1820FF, AR91.60-P-0695FF, AR91.40-P-1515FF, AR91.10-P-1000FF

30.1 Install foam part of front seat backrest On vehicles with code (S17) Heated seats AR91.10-P-1120FF (FFO) 30.2 Install foam part with cover at front seat On vehicles without code (S17) Heated seats AR91.18-P-1820FF backrest (FFO) 31 Install front seat sidebag unit AR91.60-P-0695FF 32 Install seat belt buckle into front seat AR91.40-P-1515FF 33 Install protective cap in rear of inner guide rail 34 Install front seat AR91.10-P-1000FF Front seats Number Designation Model 454.0 BA91.10-P-1004-01J Nut, backrest frame to seat console 1st Nm 20 stage 2nd Nm 65 stage BA91.10-P-1005-01J Nut, backrest frame to seat console Nm 27 BA91.10-P-1006-01J Bolt, stop plate to backrest frame Nm 22 Page 4 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-3330ff, Remove and install seat frame MODEL 454.0

AR91.10-P-3455FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3979 · Applies to: 453 · AR: AR91.10-P-3455FF

Remove and install seat height adjustment lever 11.2.10 MODEL 454.0 with CODE (S20) Seat height adjustment (FFO) Shown on driver seat 1 Cap 2 Screw 3 Operating lever for seat height adjustment P91.12-2690-04 Remove/Install

1 Remove cap (1) Installation:

Replace cap (1). 2 Remove screw (2) Replace bolt (2) and coat it with sealing compound. *BA91.10-P-1003-01J

*BR00.45-Z-1066-01A 3 Remove operating lever for seat height Pay attention to installation position of adjustment (3) operating lever for seat height adjustment (3). 4 Install in the reverse order Front seats Number Designation Model 454.0 BA91.10-P-1003-01J Bolt, operating lever for seat height adjustment to front Nm 15 seat Repair materials Number Designation Order number BR00.45-Z-1066-01A Loctite 243 A 613 989 09 71 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-3455ff, Remove and install seat height adjustment lever MODEL 454.0 with CODE (S20) Seat height adjustment (FFO)

AR91.10-P-0002SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3980 · Applies to: 453 · AR: AR91.10-P-0002SR, AR91.10-P-1200SR

Remove/install ISOFIX child seat attachment 22.03.2016 Model 453 P91.10-3999-08 1 ISOFIX cover 1.1 Catch 2 Cover 3 Bolts 4 Bolts 5 Tensioning straps 6 ISOFIX child seat attachment P91.10-4000-06 Remove/install

1 Adjust backrest so that ISOFIX covers (1) are exposed 2 In each case press both catches (1.1) upwards and remove ISOFIX covers (1) 3 Detach panel (2) until screws/bolts (3) are AR91.10-P-1200SR accessible 4 Adjust front seat such that screws/bolts (3, 4) can be removed 5 Detach tensioning straps (5) at seat frame and route upwards with section of cover Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar91.10-p-0002sr, Remove/install ISOFIX child seat attachment Model 453

AR91.10-P-8656SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3982 · Applies to: 453 · AR: AR91.10-P-8656SR

Remove/install cover for backrest at front seat 15.03.2018 Model 453 Modification notes 16.02.2018 "Remove/install seat belt guide from holder" added. Operation step 3, 20 16.02.2018 "Make cutout for holder of seat belt guide in new cover" Operation step 11 added. P91.10-4042-08 Shown on model 453.0 with code 866 (Preinstallation for tablet bracket) 13 Cover 14 Catch hook 15 Bracket Shown on left front seat of model 453.0 1 Cover 2 Latches 3 Seat backrest P91.10-4001-06 Page 1 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-8656sr, Remove/install cover for backrest at front seat Model 453

P91.10-4002-09

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3983 · Applies to: 453 · AR: AR91.10-P-1000SR, AR91.10-P-1200SR

1 Cover 7 Staple wires 5 Latches 8 Staple rail 6 Latches 9 Latches 7 Staple wire 8 Staple rail 10 Wire ring 11 Side cutting pliers 12 Backrest padding P91.10-4049-03 Remove

1 Remove front seat. AR91.10-P-1000SR 2 Remove panels from front seat frame. AR91.10-P-1200SR 3 Remove seat belt guide from holder. Model 453.3/4 except code 460 (Canada version) except code 494 (US version) if installed due to conversionModel 453.3/4 with code 460 (Canada version) Model 453.3/4 with code 494 (US version) Page 2 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-8656sr, Remove/install cover for backrest at front seat Model 453

Model 453.3/4

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3984 · Applies to: 453 · AR: AR91.45-P-0500SR, AR91.60-P-0695SR, AR91.10-P-1200SR, AR91.10-P-1000SR

AR91.45-P-0500SR with code 460 (Canada version) Model 453.3/4 with code 494 (US version) The holder of the seat belt guide remains

on the seat backrest frame. 4 Open flap of cover (13), release catch hooks Model 453.0 (14) of holder (15) and pull out cover (13). with code 866 (Pre-installation for iPad cradle) *110589035900 Mounting wedge 5 Remove front seat sidebag unit. AR91.60-P-0695SR 6 Unhook latches (2) in direction of arrow. 7 Unhook latches (5, 6, 9) in direction of arrow. 8 Release cover (1) at sides of seat backrest padding (12) and turn inside out. 9 Remove wire rings (10) on inner side of seat

backrest padding (12) using side cutting pliers Carefully remove residue of wire rings (10). (11). Otherwise, seat backrest padding (12) or cover (1) can be damaged. 10 Remove cover (1) in upward direction. Install

11 Make cutout for holder of seat belt guide in Model 453.3/4 except code 460 (Canada version) new cover (1). except code 494 (US version) if installed due to conversionModel 453.3/4 with code 460 (Canada version) Model 453.3/4 with code 494 (US version) When replacing cover (1) or if holder is installed. Transfer cutout for holder of seat belt

guide from old cover (1). 12 Pull cover (1) over integrated head restraint and align. 13 Align cover (1) on seat backrest padding (12). 14 Hook in new wire rings (10) (arrow A) starting at top of respective staple rail (8). 15 Hook in new wire rings (10) on staple wire (7) *454589033700 Padding clip pliers of seat backrest padding (12) and close completely with upholstery clip pliers (arrow B). 16 Pull cover (1) over sides of seat backrest padding (12). 17 Hook in latches (5, 6, 9) on cover (1). 18 Hook in latches (2). 19 Install front seat sidebag unit. AR91.60-P-0695SR 20 Install seat belt guide at holder. Model 453.3/4 except code 460 (Canada version) except code 494 (US version) if installed due to conversionModel 453.3/4 with code 460 (Canada version) Model 453.3/4 with code 494 (US version) If installed on model 453.3/4 due to conversion. Model 453.3/4 AR91.45-P-0500SR with code 460 (Canada version) Model 453.3/4 with code 494 (US version) 21 Attach panels to front seat frame. AR91.10-P-1200SR 22 Position cutout for cover (13) on cover (1). Model 453.0 with code 866 (Pre-installation for iPad cradle) When replacing the cover (1). AR91.10-P-8656-02SR 23 Insert cover (13) into holder (15). Model 453.0 with code 866 (Pre-installation for iPad cradle) Ensure that it arrest securely.

24 Install front seat. AR91.10-P-1000SR Page 3 of 4 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-8656sr, Remove/install cover for backrest at front seat Model 453

AR91.10-P-1000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3986 · Applies to: 453 · AR: AR91.10-P-1000FF, AR54.10-P-0003FF

Remove/install front seat 14.8.03 MODEL 454.0 P91.10-2699-09 Shown on model 454.031 1 Cover (except model 454.033) 4 Bolts 7 Connector 2 Screw (except model 454.033) 5 Nuts 8 Front seat 3 Panel (except model 454.033) 6 Fish-plate 9 Connector Remove/install

1 Disconnect battery ground cable AR54.10-P-0003FF 2 Retract head restraints 3 Move front seat (8) all the way forward Make sure that both seat rails engage in position. 4.1 Pull covering (1) to rear and off Except model 454.033 Note the catch hook. 5.1 Remove screw (2) and then pull panel (3) Except model 454.033 carefully out towards the front Note the catch hook. 6 Remove bolts (4) *BA91.10-P-1001-01J

7 Move front seat (8) all the way back Make sure that both seat rails engage in position. 8 Unscrew nuts (5). Installation:

Both seat rails must be engaged. Position the nuts (5) but only tighten them down after the screws (4) are tightened. *BA91.10-P-1002-01J

9 Raise front seat (8) carefully 10 Release tab (6) downward and separate Installation:

Ensure plug connection (9) is connector (9). correctly located. 11.1 Unplug connector (7) Only when removing the front seat (8) on the driver side. 12.1 Disconnect the connector for the heated seats Only on vehicles with code (S17) Heated under front seat (8) seats (FFO) 13 Lift front seat (8) out of vehicle Helper required 14 Install in the reverse order Front seats

Number Designation Model 454.0 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-1000ff, Remove/install front seat MODEL 454.0

AR91.10-P-1000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3988 · Applies to: 453 · AR: AR91.10-P-1000SR, AR54.10-P-0003SR

Remove/install front seat 08.11.2017 Model 453 P91.10-3823-09 Shown on model 453.0, driver side 1 Front seat 4 Front seat rail covers 7 Electrical connector 2 Rear seat rail covers 5 Screw 8 Electrical line 3 Screw 6 Electrical connector 9 Retaining clips Risk of injury Warning caused by performing testing or Store airbag units with deployment side facing AS91.00-Z-0001-01A

repair work on airbag or emergency tensioning up; do not expose to temperatures greater retractor units. than 100 °C. When working on these units, disconnect the power supply. Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Legal requirements on handling and storing AH91.00-P-0004-01A airbags and emergency tensioning retractor units Remove/install

1 Detach ground line of on-board electrical AR54.10-P-0003SR system battery 2 Move steering column all the way forward and Only when removing driver seat. all the way up 3 Adjust front seat (1) to front 4 Release rear seat rail covers (2) by pulling in Installation: Ensure that rear seat rail

direction of arrow (a) and detach to rear from cover (2) is correctly seated. seat rails 5 Remove bolts (3) *BA91.10-P-1001-01K Front seat on vehicle floor 6 Position front seat (1) to rear 7 Detach front seat rail covers (4) in direction of arrow (b) 8 Remove screws (5) Installation: Before tightening, fasten all

bolts (3, 5) on the seat tracks. *BA91.10-P-1001-01K Front seat on vehicle floor 9 Tilt back front seat (1) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-1000sr, Remove/install front seat Model 453

AR91.10-P-1060SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3990 · Applies to: 453 · AR: AR91.10-P-1060SR, AR91.10-P-1000SR, AR91.10-P-1200SR

Remove/install front seat backrest 13.08.2014 MODEL 453 P91.10-3843-09 Shown on front passenger seat with CODE 873 (Seat heater) 1 Retaining clip 5 Electrical wiring harness 9 Bolts 2 Retaining clamp 6 Electrical connector X28/18 Seat occupied recognition electrical connector 3 Cover for front seat backrest 7 Retaining clip X54/13 Electrical connector for front seat heater 4 Electrical connector 8 Backrest for front seat X55/4 Front passenger seat connector block Remove/install

1 Remove front seat AR91.10-P-1000SR 2 Remove paneling on front seat frame AR91.10-P-1200SR 3 Disconnect electrical connector (4) 4 Unclip retaining clip (1) for electrical wiring 452589016300 Clip remover harness (5) 5 Unhook retaining clamp (2) and place to one side with cover for backrest on front seat (3) 6 Unclip retaining clip (7) for electrical wiring 452589016300 Clip remover harness (5) 7 Unclip front seat heater connector housing (X54/13) and front passenger seat connector block (X55/4) 8 Disconnect seat occupied recognition electrical connector (X28/18) and electrical connector (6) from front passenger seat connector block (X55/4) 9 Guide electrical wiring harness (5) out of seat frame 10 Remove screws/bolts (9) and remove *BA91.10-P-1002-01K Backrest to seat frame backrest for front seat (8) 11 Install in the reverse order Front seats Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar91.10-p-1060sr, Remove/install front seat backrest MODEL 453

AR91.10-P-1465FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3992 · Applies to: 453 · AR: AR91.10-P-1465FF

Remove/install front seat backrest 6.3.04 MODELS 454.0 P91.12-2689-07 Shown with front seat removed 1 Cap 2 Screw 3 Release lever Remove/Install

1 Remove the cover (1) Installation:

Install new cover (1). 2 Unscrew screw (2) Installation:

Replace bolt (2). 3 Remove release lever (3) Observe installation position of release lever (3). 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-1465ff, Remove/install front seat backrest MODELS 454.0

AR91.10-P-1910FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3993 · Applies to: 453 · AR: AR91.10-P-1910FF

Remove/install front seat backrest seat-back lining 6.3.04 MODELS 454.0 1 Tensioning element P91.10-2702-01 Remove/Install

1 Extend the head restraint See Operating Instructions 2 Fold front seat backrest forward See Operating Instructions 3 Remove the screws (arrows) at the lower side of the seat-back lining (1) 4 Raise the seat-back lining (1) slightly and then pull it downward 5 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-1910ff, Remove/install front seat backrest seat-back lining MODELS 454.0

AR91.10-P-1200SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3994 · Applies to: 453 · AR: AR91.10-P-1200SR

Remove/install front seat frame covers 13.08.2014 MODEL 453 P91.10-3839-09 Shown on MODEL 453 on driver side front seat with CODE 873 (Seat heater) and without CODE S55 (Vertically adjustable driver seat) 1 Outer cover 8 Pin S51/1 Left front seat heater switch 2 Control lever 9 Electrical connector 3 Screw 10 Guide lugs Shown on MODEL 453 on driver side front seat without CODE S55 (Vertically adjustable driver seat) 11 Inner paneling 12 Screw 14 Guide lugs P91.10-3840-01 Remove/install outer cover (1) 1 Adjust front seat to foremost position 2 Adjust front seat to the uppermost position MODEL 453 with CODE S55 (Driver's seat) When working on the driver seat. 3 Pry off adjusting lever (2) *110589035900 Mounting wedge 4 Unscrew bolt (3) 5 Detach outer cover (1) in the rear area

Carefully detach outer cover (1). Otherwise the guide tabs (10) may be damaged. 6 Release catch hook on pin (8) (arrows b) and push pin (8) of outer cover (1) out of guide in seat frame Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-1200sr, Remove/install front seat frame covers MODEL 453

AR91.10-P-3290FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3996 · Applies to: 453 · AR: AR91.10-P-3290FF, AR91.10-P-1056FF, AR91.10-P-1056FH, AR91.10-P-1056FG

Remove/install front seat padding 4.8.04 MODEL 454.0 with CODE (S17) Heated seats (FFO) P91.18-2163-09 Shown on right front seat without code (S20) Seat height adjustment (FFO) 1 Terminal strip 3 Clip 5 Cover 2 Seat cushion frame 4 Seat cushion Shown on removed right front seat with code (S20) Seat height adjustment (FFO) 6 Cross strut 7 Electrical connector 8 Bracket 9 Clip 10 Connector 11 Cover 12 Heated seats wiring harness 13 Foam part P91.30-2198-11 Remove/Install

1.1 Remove outer paneling from seat frame In vehicles without code (S20) Seat height AR91.10-P-1056FF adjustment (FFO) 1.2 Remove seat height adjustment paneling from In vehicles with code (S20) Seat height AR91.10-P-1056FH seat frame adjustment (FFO) 2 Remove seat backrest unlocking mechanism AR91.10-P-1056FG paneling from seat frame 3 Unplug electrical connector (7) 4 Unclip clips (9) of heated seats wiring harness Installation: Install new clips (9).

(12) 5 Unclip plugs (10) of heated seats wiring Note correct installation positions. harness (12) 6 Detach heated seats wiring harness (12) from bracket (8) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-3290ff, Remove/install front seat padding MODEL 454.0 with CODE (S17) Heated seats (FFO)

Push down seat cushion (4) at rear and

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3997 · Applies to: 453 · AR: AR91.30-P-0005FF

7 Push down seat cushion (4) at rear and detach rear terminal strip (1) from seat cushion frame (2) 8 Run cover (5) with terminal strip (1) between seat cushion (4) and seat backrest 9 Remove clips (3) 10 Push down seat cushion (4) and detach remaining terminal strips (arrows) from seat cushion frame (2) 11 Remove seat cushion (4) Installation: lead heated seats wiring

harness (12) between cross strut (6) of seat cushion frame (2) and cover (11) of seat cushion frame (2). 12 Detach cover (5) from foam part (13) AR91.18-P-1820-03FG *454589023700

Installation:

When replacing the foam part (13), a new heated cushion must be glued to the new foam part (13). See Remove/install heated cushion, front seat AR91.30-P-0005FF cushion 13 Install in the reverse order 454 589 02 37 00 Pliers Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-3290ff, Remove/install front seat padding MODEL 454.0 with CODE (S17) Heated seats (FFO)

AR91.10-P-6630FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3998 · Applies to: 453 · AR: AR91.10-P-6630FF, AR91.18-P-1820FG, AR91.18-P-1820FF

Remove/install mechanical lumbar support 24.8.04 MODEL 454.0 with CODE (S21) Lumbar support (FFO) Shown on removed right front seat with code (S17) Heated seats (FFO) 1 Cover 2 Foam part 3 Bracket 4 Control cable 5 Clip 6 Lumbar support 7 Backrest frame 8 Adjusting unit 9 Rivet 10 Cover P91.10-2787-06 Removal/installation

1 Remove cover (1) and foam part (2) from Do not detach cover (1) from foam part (2) backrest frame (7) In vehicles with code (S17) Heated seats AR91.18-P-1820FG (FFO) In vehicles without code (S17) Heated seats AR91.18-P-1820FF (FFO) 2 Remove rivet (9) Cover (10) must not be damaged, since the inner part can only be replaced with the entire seat frame. Installation: Replace rivet (9) with a

suitable bolt with self-locking nut and shims. 3 Slide adjusting unit (8) upwards and remove from backrest frame (7) 4 Detach left and right cable (4) from bracket (3) Check bracket (3), replace if necessary. on backrest frame (7) 5 Detach lumbar support (6) from clips (5) and Check clips (5) and replace if necessary. remove 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-6630ff, Remove/install mechanical lumbar support MODEL 454.0 with CODE (S21) Lumbar support (FFO)

AR91.10-P-3310SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 3999 · Applies to: 453 · AR: AR91.10-P-3310SR, AR91.10-P-1000SR, AR91.10-P-1200SR, AR91.10-P-0002SR

Remove/install seat cushion 22.03.2016 Model 453 Modification notes 08.03.2016 "Detach/attach ISOFIX child seat attachment" added Operation step 8 P91.10-3837-09 Shown with CODE 873 (Seat heater for driver and front passenger) 1 Seat cushion 5 Retaining clip (with code 873 (Seat 10 Seat cushion cover heater for driver and front passenger)) 2 Tab 7 Tab 11 Seat cushion frame 3 Electrical connector (with code 873 8 Terminal strip (Seat heater for driver and front passenger)) 4 Electrical wiring harness (with code 9 Profile 873 (Seat heater for driver and front passenger)) Remove/install

1 Remove front seat AR91.10-P-1000SR 2 Remove paneling from seat frame AR91.10-P-1200SR 3 Disconnect electrical connector (3) Model 453 with code 873 (Seat heating for driver and front passenger) 4 Unclip retaining clip (5) of electrical wiring Model 453 harness (4) at seat frame with code 873 (Seat heating for driver and front passenger) 452589016300 Clip remover 5 Unhook shackles (2) 6 Remove cable ties at tabs (7) 7 Unhook shackles (7) 8 Remove ISOFIX child seat attachment When removing seat cushion (1) of front passenger seat AR91.10-P-0002SR 9 Detach clamping rail (8) of seat cushion 140589023300 Extraction hook cover (10) from profile (9) using extraction hook Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-3310sr, Remove/install seat cushion Model 453

AR91.10-P-3312SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4001 · Applies to: 453 · AR: AR91.10-P-3312SR, AR91.10-P-3310SR

Remove/install seat cushion cover 08.10.2014 MODEL 453 Shown on MODEL 453 with CODE 873 (Seat heater) 1 Seat cushion cover 2 Padding 5 Wire rings 6 Staple edge stripping 8 Staple wires 10 Seat heater mat P91.10-3838-06 Remove

1 Remove seat cushion from left or right front AR91.10-P-3310SR seat 2 Release seat cushion cover (1) from padding (2) until wire rings (5) are accessible 3 Remove wire rings (5) on inside of padding

(2) for seat cushion using side cutting pliers Carefully remove residue of wire rings (5). Otherwise the padding (2) or the seat cushion cover (1) may be damaged. 4 MODEL 453 Remove seat cushion cover (1) with CODE 873 (Seat heating for driver and front passenger) The seat heater mat (10) is bonded to the padding (2). When replacing the padding (2) or the seat heater mat (10), both parts must be replaced. Install

5 Align seat cushion cover (1) over padding (2) Ensure that seat cushion cover (1) is correctly seated. 6 Fasten staple edge stripping (6) of seat cushion cover (1) with wire rings (5) to the staple wires (8) of padding (2) using a suitable tool starting from inside 7 Slip seat cushion cover (1) over padding (2) 8 Install seat cushion for left or right front seat AR91.10-P-3310SR Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar91.10-p-3312sr, Remove/install seat cushion cover MODEL 453

AR91.10-P-1056FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4002 · Applies to: 453 · AR: AR91.10-P-1056FF

Remove/install trim cover at the seat frame 6.3.04 MODELS 454.0 except CODE (S20) Seat height adjustment (FFO) outer trim cover Shown with front seat removed 1 Screw 2 Trim cover at seat frame P91.10-2701-04 Remove/Install

1 Unscrew bolt (1) 2 Unclip the rear of the trim cover at the seat Check locking tabs. frame (2) and then detach the cover by carefully moving it upward and forward Installation:

Ensure that the trim cover at the seat frame (2) is seated correctly. 3 Remove trim cover (2) at seat frame 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-1056ff, Remove/install trim cover at the seat frame MODELS 454.0 except CODE (S20) Seat height adjustment (FFO) outer trim cover

AR91.10-P-1056FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4003 · Applies to: 453 · AR: AR91.10-P-1056FG

Remove/install trim cover at the seat frame 18.3.04 MODEL 454.0 Trim cover at backrest release Shown with front seat removed 1 Cap 2 Screw 3 Release lever 4 Screw 5 Panel P91.12-2681-06 Remove/Install

1 Remove the cover (1) Installation:

Install new cover (1). 2 Unscrew screw (2) Installation:

Replace bolt (2). 3 Remove release lever (3) Observe installation position of release lever (3). 4 Unscrew bolt (4) 5 Unclip the bottom of the trim cover (5) and Check locking tabs. then detach the cover by carefully moving it upward and forward Installation:

Make sure the trim cover (5) is correctly seated. 6 Detach paneling (5) 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-1056fg, Remove/install trim cover at the seat frame MODEL 454.0 Trim cover at backrest release

AR91.10-P-1056FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4004 · Applies to: 453 · AR: AR91.10-P-1056FH

Remove/install trim on seat frame 11.2.10 MODEL 454.0 with CODE (S20) Seat height adjustment (FFO) Paneling for seat height adjustment Shown on driver seat 1 Cap 2 Screw 3 Operating lever for seat height adjustment 4 Screw 5 Trim panel P91.10-2700-06 Remove/Install

1 Remove cap (1) Installation:

Replace cap (1). 2 Remove screw (2) Replace bolt (2) and coat it with sealing compound. *BA91.10-P-1003-01J

*BR00.45-Z-1066-01A 3 Remove operating lever for seat height Pay attention to installation position of adjustment (3) operating lever for seat height adjustment (3). 4 Unscrew bolt (4) 5 Unclip lower paneling (5) (arrow) and detach Check locking tabs. carefully upward and to front Installation:

Ensure paneling (5) is seated correctly. 6 Remove trim panel (5) 7 Install in the reverse order Front seats Number Designation Model 454.0 BA91.10-P-1003-01J Bolt, operating lever for seat height adjustment to front Nm 15 seat Repair materials Number Designation Order number BR00.45-Z-1066-01A Loctite 243 A 613 989 09 71 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-1056fh, Remove/install trim on seat frame MODEL 454.0 with CODE (S20) Seat height adjustment (FFO) Paneling for seat height adjustment

AR91.10-P-1120FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4005 · Applies to: 453 · AR: AR91.10-P-1120FF, AR91.10-P-1056FF, AR91.10-P-1056FH, AR91.10-P-6620FF, AR91.60-P-0695FF (+1 more)

Removing and installing front seat backrest foam part 6.8.04 MODEL 454.0 with CODE (S17) Heated seats (FFO) Shown on removed right front seat with code (S20) Seat height adjustment (FFO) and code (S21) Lumbar support (FFO) 1 Seat cushion 2 Terminal strip 3 Terminal strips 4 Electrical connector 5 Terminal strips 6 Clip 7 Wiring harness P91.10-2784-05 P91.10-2785-08 Shown on removed right front seat with code (S20) Seat height adjustment (FFO) and code (S21) Lumbar support (FFO) 1 Seat cushion 7 Wiring harness 9 Clip 13 Sidebag unit wiring harness 8 Seat height adjustment (with code 10 Cover 14 Cover (S20) Seat height adjustment (FFO)) 11 Backrest frame 15 Clip 12 Clip 16 Foam part Removal/installation

1.1 Remove outer paneling from seat frame In vehicles without code (S20) Seat height AR91.10-P-1056FF adjustment (FFO) 1.2 Remove seat height adjustment paneling from In vehicles with code (S20) Seat height AR91.10-P-1056FH seat frame adjustment (FFO) 2.1 Remove lumbar support thumb wheel In vehicles with code (S21) Lumbar support AR91.10-P-6620FF (FFO) 3 Removing front seat sidebag unit AR91.60-P-0695FF 4 Remove head restraint guide from front seat AR91.16-P-0050FF 5 Push down seat cushion (1) at rear and detach terminal strips (5) from seat frame 6 Push down seat cushion (1) at front and side and detach terminal strips (2, 3) from seat frame 7 Disconnect electrical connector (4) 8 Unclip clip (6) of wiring harness (7) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-1120ff, Removing and installing front seat backrest foam part MODEL 454.0 with CODE (S17) Heated seats (FFO)

AR91.10-P-1120SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4007 · Applies to: 453 · AR: AR91.10-P-1120SR, AR91.10-P-8656SR

Removing and installing front seat backrest foam part 20.04.2017 Model 453 Modification notes 18.04.2017 Application of cutout for universal bracket integrated. Step 4 P91.10-4048-09 Shown with CODE 873 (Seat heater for driver and front passenger) 1 Backrest padding 4 Heater pad 2 Backrest frame 5 Electrical connector 3 Electrical wiring harness Remove

1 Remove cover for seat backrest on front seat AR91.10-P-8656SR 2 Disconnect electrical connector (5), and place Model 453 electrical wiring harness (3) to one side with code 873 (Seat heaters for driver and front passenger) 3 Remove seat backrest padding (1) from Seat backrest padding (1) is glued on in

backrest frame (2) area of integrated head restraint. Install

4 Apply cutout for universal bracket on new seat Model 453.0 with code 866 (Pre-installation for iPad cradle) backrest padding (1) When replacing the backrest padding (1). AR91.10-P-1120-01SR 5 Apply adhesive, corresponding to old bonding, Adhesive Terokal 2444 *BR00.45-Z-1002-02A in area of integrated head restraint 6 Position seat backrest padding (1) on backrest Model 453 frame (2) with code 873 (Seat heaters for driver and front passenger) Ensure that electrical wiring harness (3) is routed correctly. 7 Connect electrical connection (5) Model 453 with code 873 (Seat heaters for driver and front passenger) 8 Attach cover for seat backrest on front seat AR91.10-P-8656SR Page 1 of 2 © Mercedes-Benz AG, 5/22/18, L/07/20, ar91.10-p-1120sr, Removing and installing front seat backrest foam part Model 453

AR91.10-P-2000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4009 · Applies to: 453 · AR: AR91.10-P-2000FF, AR91.60-P-0695FF

Removing and installing spring frame from front seat backrest 4.8.04 MODEL 454.0 except CODE (S21) Lumbar support (FFO) Shown on removed right front seat with code (S17) Heated seats (FFO) 1 Clip 2 Spring frame 3 Backrest frame 4 Foam part P91.10-2786-05 Removal/installation

1 Removing front seat sidebag unit AR91.60-P-0695FF 2 Unhook spring frame (2) from clips (1) on Check clips (1) and replace if necessary. backrest frame (3) at left and right Installation: In order to position the clips

(1), push foam part (4) away from backrest frame (3) slightly and clip clips (1) into backrest frame (3) from the outside. 3 Remove spring frame (2) 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-2000ff, Removing and installing spring frame from front seat backrest MODEL 454.0 except CODE (S21) Lumbar support (FFO)

AR91.10-P-2100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4010 · Applies to: 453 · AR: AR91.10-P-2100FF, AR91.10-P-1056FH

Removing and installing spring frame to/from front seat frame 16.8.04 MODEL 454.0 P91.10-2776-08 Shown on removed right front seat with code (S17) Heated seats (FFO) and code (S20) Seat height adjustment (FFO) 1 Seat cushion 4 Clip 7 Hook 2 Terminal strips 5 Spring frame 8 Seat height adjustment (with code 3 Bracket (S20) Seat height adjustment (FFO)) 6 Cross strut Removal/installation

1.1 Remove seat height adjustment paneling from In vehicles with code (S20) Seat height AR91.10-P-1056FH seat frame adjustment (FFO) 2 Unclip clips (4) The number of clips (4) depends on the vehicle equipment. Note installation position of clips (4). Installation: Install new clips (4).

3 Detach wiring harnesses from bracket (3) 4 Push down seat cushion (1) at front and side and detach terminal strips (2) from seat frame 5.1 Run cover of seat cushion (1) past seat height In vehicles with code (S20) Seat height adjustment mechanism (8) adjustment (FFO) 6 Lift seat cushion (1) at front until the spring Carefully lift seat cushion (1) in order to frame (5) is accessible prevent damage to the cover of the seat cushion (1). 7 Unclip spring frame (5) from cross strut (6) of seat frame 8 Detach spring frame (5) from hook (7) and remove 9 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-2100ff, Removing and installing spring frame to/from front seat frame MODEL 454.0

AR91.10-P-6620FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4011 · Applies to: 453 · AR: AR91.10-P-6620FF

Removing and installing thumb wheel of lumbar support 24.8.04 MODEL 454.0 with CODE (S21) Lumbar support (FFO) Shown with left front seat removed 1 Front seat 2 Lumbar support thumb wheel 3 Cover P91.10-2779-06 Remove/Install

1 Push lumbar support thumb wheel (2) against seat padding and unclip cover (3) from lumbar support thumb wheel (2) using a suitable screwdriver 2 Pull lumbar support thumb wheel (2) from adjusting unit 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.10-p-6620ff, Removing and installing thumb wheel of lumbar support MODEL 454.0 with CODE (S21) Lumbar support (FFO)

AZ91.10-P-0003FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4012 · Applies to: 453 · AR: AZ91.10-P-0003FF, AR91.10-P-1000FF

Retrofit seat drawer under front seat 17.1.06 MODEL 454.0 except CODE (C20) smart CD changer MODEL 454.0 except CODE (C22) Sound package (FFO) Shown on left front seat 1 Seat drawer P91.10-2735-04 Removing

1 Remove front seat On vehicles with code (C20) smart CD changer, the seat drawer (1) can only be installed under the left front seat. For vehicles with code (C22) Sound package (FFO), the seat drawer (1) can only be installed under the right front seat. Remove/install front seat AR91.10-P-1000FF

Install

2 Assemble seat drawer (1) AZ91.10-P-0003-01FF 3 Position and align seat drawer (1) at lift The seat drawer rails (1) must lock into support points of front seat (arrows) place. 4 Install front seat Before bolting the front seat into place, check that the seat drawer (1) is not held in place under tension by moving the front seat to and fro slightly, as otherwise the seat drawer (1) may be damaged. Remove/install front seat AR91.10-P-1000FF

5 Move front seat to furthermost position and perform function check on seat drawer (1) 6.1 Enter special equipment in the vehicle data If the workshop does not have recourse to the card and in the vehicle's online data card DMS Autoline 8.0 dealer system. Add code (J22) Right seat drawer assembly kit or code (J23) Left seat drawer assembly kit. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, az91.10-p-0003ff, Retrofit seat drawer under front seat MODEL 454.0 except CODE (C20) smart CD changer MODEL 454.0 except CODE (C22) Sound package (FFO)

AR91.12-P-1745FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4016 · Applies to: 453 · AR: AR91.12-P-1745FF

Remove/install armrest at rear seat backrest 5.3.04 MODELS 454.0 with CODE (S25) Rear center armrest (FFO) 1 Armrest 2 Rail 3 Bolts P91.12-2680-06 Remove/Install

1 Fold out the armrest (1) 2 Detach the carrier (2) 3 Unscrew bolts (3) 4 Turn the armrest (1) 90° to the left 5 Remove arm rest (1) 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.12-p-1745ff, Remove/install armrest at rear seat backrest MODELS 454.0 with CODE (S25) Rear center armrest (FFO)

AR91.12-P-1100FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4017 · Applies to: 453 · AR: AR91.12-P-1100FF, AR91.18-P-1850FF

Remove/install cover on bottom of rear seat 25.7.04 MODEL 454.0 1 Control cable 2 Release lever 3 Nuts 4 Cover on rear seat P91.12-2751-11 Remove/Install

1 Remove rear seat cushion AR91.18-P-1850FF Do not remove the cover from the foam padding. 2 Unhook the Bowden cable (1) from the Do not change adjustment of Bowden release lever (2) cable (1) 3 Remove the clips (arrows) 4 Unscrew nuts (3). 5 Remove cover from the rear seat (4) Installation:

Ensure that the cover is seated correctly on the rear seat (4). 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.12-p-1100ff, Remove/install cover on bottom of rear seat MODEL 454.0

AR91.12-P-1600FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4018 · Applies to: 453 · AR: AR91.12-P-1600FF, AR91.12-P-8457FF

Remove/install rear seat backrest 10.8.04 MODEL 454.0 1 Left rear seat backrest 2 Right rear seat backrest 3 Seat cover 4 Bolts 5 Left backrest frame 6 Nut P91.12-2758-06 Remove

1 Remove upholstery with cover (3) of left rear AR91.12-P-8457FF seat backrest (1) 2 Fold left rear seat backrest (1) forward by Helper needed to hold it. approx. 45° 3 Remove nut (6) and bolts (4) 4 Take out left backrest frame (5) Install

5 Insert left backrest frame (5) and position at Helper needed to hold it. an angle of approx. 45° 6 Screw in nut (6) and bolts (4) Replace screws (4). Do not tighten the bolts (4) and nut (6) fully. 7 Place left backrest frame (5) in a vertical See Operator's Manual position 8 Place upholstery with cover (3) over the left Upholstery with cover (3) is required to backrest frame (5) align the left backrest frame (5). 9 Fold over left rear seat backrest (1) and right See Operator's Manual rear seat backrest (2) 10 Align left rear seat backrest (1) with the right rear seat backrest (2) 11 Tighten nut (6) *BA91.22-P-1004-01A

12 Place right rear seat backrest (2) in a vertical See Operator's Manual position 13 Tighten bolts (4) *BA91.22-P-1003-01A

14 Fold up left rear seat backrest (1) See Operator's Manual 15 Check that the left rear seat backrest (1) is aligned with the right rear seat backrest (2) 16 Install upholstery with cover (3) of the left rear AR91.12-P-8457FF seat backrest (1) Bench seat

Number Designation Model 454.0 BA91.22-P-1003-01A Bolt of backrest frame to seat frame M8 Nm 34 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.12-p-1600ff, Remove/install rear seat backrest MODEL 454.0

AR91.12-P-1732FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4020 · Applies to: 453 · AR: AR91.12-P-1732FF

Remove/install rear seat backrest release lever 7.3.04 MODELS 454.0 1 Release lever 2 Screw 3 Panel 4 Panel P91.12-2688-04 Remove/Install

1 Fold down both rear seat backrests See Operating Instructions 2 Pry off the release lever (1) with a suitable Installation:

Install new release screwdriver lever (1). 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.12-p-1732ff, Remove/install rear seat backrest release lever MODELS 454.0

AR91.12-P-1650FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4021 · Applies to: 453 · AR: AR91.12-P-1650FF, AR91.12-P-8457FF

Remove/install right rear seat backrest 7.3.04 MODEL 454.0 P91.12-2682-07 1 Bolts 3 Right rear seat backrest 4 Left rear seat backrest 2 Bolts Remove

1 Remove upholstery with cover of right rear AR91.12-P-8457FF seat backrest 2 Unscrew bolts (1, 2) 3 Remove right rear seat backrest (3) Install

4 Insert right rear seat backrest (3) and screw in Replace bolts (1, 2). bolts (1, 2) Do not tighten bolts (1, 2) fully. 5 Place upholstery with cover over the right rear seat backrest (3) 6 Fold over right rear seat backrest (3) and left rear seat backrest (4) 7 Align right rear seat backrest (3) with the left rear seat backrest (4) 8 Tighten screws (1) *BA91.22-P-1003-01A

9 Place left rear seat backrest (4) in a vertical position 10 Tighten bolts (2) *BA91.22-P-1003-01A

11 Place right rear seat backrest (3) in a vertical position 12 Check that the right rear seat backrest (3) is aligned with the left rear seat backrest (4) 13 Install upholstery with cover of right rear seat AR91.12-P-8457FF backrest Bench seat

Number Designation Model 454.0 BA91.22-P-1003-01A Bolt of backrest frame to seat frame M8 Nm 34 M10 Nm 59 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.12-p-1650ff, Remove/install right rear seat backrest MODEL 454.0

AR91.12-P-1520FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4022 · Applies to: 453 · AR: AR91.12-P-1520FF, AR91.18-P-1850FF

Remove/install seat adjustment mechanism at rear seat 17.1.06 MODEL 454.0 Shown on vehicles with code (S33) Double folding rear bench seat (3 seats) 1 Seat frame 2 Nuts 3 Nut 4 Front adjusting lever 5 Bowden cable (for code (S33) Double folding rear bench seat (3 seats)) P91.21-2035-06 P91.21-2034-09 Shown on vehicles with code (S33) Double folding rear bench seat (3 seats) 4 Front adjusting lever 8 Rear release lever (for code (S33) 10 Lug 6 Rivet Double folding rear bench seat (3 11 Guide seats)) 7 Guide rail 12 Pin 9 Synchronization plate Removing

1 Remove rear seat cushion with cover Cover need not be removed from rear seat cushion. Refer to: Remove and install cover on rear seat AR91.18-P-1850FF cushion 2 Unscrew nuts (3) and remove seat belt buckles Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.12-p-1520ff, Remove/install seat adjustment mechanism at rear seat MODEL 454.0

Remove covering on bottom of rear seat

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4023 · Applies to: 453 · AR: AR91.12-P-1100FF, AR91.18-P-1850FF

3.1 Remove covering on bottom of rear seat For vehicles with code (S33) Double folding AR91.12-P-1100FF rear bench seat (3 seats) 3.2 Unscrew nuts (2) and remove seat frame (1) For vehicles without code (S33) Double with backrest upwards folding rear bench seat (3 seats) Disassemble/assemble

It is only necessary to disassemble or

assemble the seat adjustment mechanism when separate parts are to be replaced, or if the new seat adjustment mechanism is delivered in a disassembled condition. 4 Unclip circlip on bolt (12) of left and right seat Assembly: Replace circlips on bolts (12). rails (7) 5 Apply a suitable screwdriver to one side of front adjusting lever (4) first to pry it out of the guide (11) and bolt (12) and then remove from the other side 6 Turn seat adjustment mechanism to rear side 7.1 Bend tab (10) downwards, press rear release For vehicles with code (S33) Double folding lever (8) in direction of arrow (arrows A) and rear bench seat (3 seats) remove rear release lever (8) Assembly: The springs (arrow B) at left

and right on the rear release lever (8) must be positioned at the top of the seat rails (7). Bend tab (10) approx. 30° outward. If the tab (10) is bent too far outward, a grinding noise will be heard when sliding the rear bench seat. 8 Drill out rivets (6) and remove synchronization Drill out rivets (6) carefully to avoid plate (9) damaging the seat rails (7) or the synchronization plate (9). 450589017000 Twist drill set Rechargeable drill / screwdriver WH58.30-Z-1007-20A Assembly:

Align seat rails (7) parallel to each other, position synchronization plate (9) and press in new rivets (6) using riveter. *450589003900 Rivet gun 9 Assemble in the reverse order Install

10.1 Install covering on bottom of rear seat For vehicles with code (S33) Double folding AR91.12-P-1100FF rear bench seat (3 seats) 10.2 Position seat frame (1) with backrest onto For vehicles without code (S33) Double seat adjustment mechanism and tighten nuts folding rear bench seat (3 seats) (2) 11 Install seat belt buckles and fasten in place *BA91.40-P-1006-01J

using nuts (3) 12 Install rear seat cushion with cover See: Remove and install cover on rear seat AR91.18-P-1850FF cushion Seat belts/emergency tensioning retractors Number Designation Model 454.0 BA91.40-P-1006-01J Bolt for seat belt buckle to bench seat Nm 45 450 589 00 39 00 450 589 01 70 00 Rivet gun Twist drill set Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.12-p-1520ff, Remove/install seat adjustment mechanism at rear seat MODEL 454.0

AR91.12-P-8457FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4025 · Applies to: 453 · AR: AR91.12-P-8457FF, AR91.12-P-1745FF, AR91.16-P-1775FF

Remove/install the seat cover and upholstery on the rear seat backrest 6.3.04 MODELS 454.0 P91.18-2162-09 Shown on the right rear seat backrest with code (S33) rear bench seat foldable in two sections (3-person seat) 1 Nut (with code (S33) rear bench 4 Cover (with code (S33) rear bench 7 Seat belt (with code (S33) rear seat foldable in two sections (3- seat foldable in two sections bench seat foldable in two sections person seat)) (3-person seat)) (3-person seat)) 2 Belt end fitting (with code (S33) rear 5 Rear seat backrest 8 Clamp bench seat foldable in two sections 6 Belt blocker (with code (S33) rear 9 Retaining strap (3-person seat)) bench seat foldable in two sections 10 Backrest frame 3 Rear bench seat (3-person seat)) 11 Foam rubber 12 Upholstery Remove/Install

1.1 Remove armrest from rear-seat backrest. Only on vehicles with code (S25) rear center AR91.12-P-1745FF armrest (FFO) and when removing the right rear seat backrest. 2.1 Unscrew the nut (1) and remove the belt end Only when removing the right rear seat fitting (2) from the rear bench seat (3) backrest and with code (S33) rear bench seat foldable in two sections (3-person seat)) Observe the installation position of the belt end fitting (2) on the rear bench seat (3). *BA91.40-P-1007-01J

3.1 Detach cover (4) from the rear seat backrest Only when removing the right rear seat (5) backrest and with code (S33) rear bench seat foldable in two sections (3-person seat)) Installation:

Insert the cover (4) underneath the belt blocker (6). Ensure that the cover (4) is seated correctly. The seat belt (7) can only be pulled out of the automatic belt retractor when the rear seat backrest (5) is in a vertical position. 4 Remove headrest guides from rear seat AR91.16-P-1775FF backrest 5 Remove clips (8) and loosen the retaining Installation:

Install new clips (8). straps (9) from the backrest frame (10) The retaining straps (9) must be correctly tensioned when attaching the clips (8). 6 Press the foam section (11) in the lower area out of the backrest frame (10) (arrows) 7 Detach the cover (12) with foam section (11) from the backrest frame (10) and pull it upward Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.12-p-8457ff, Remove/install the seat cover and upholstery on the rear seat backrest MODELS 454.0

AR91.12-P-1735FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4027 · Applies to: 453 · AR: AR91.12-P-1735FF

Remove/install trim cover for rear seat backrest release lever 17.3.04 MODELS 454.0 1 Release lever 2 Screw 3 Panel 4 Panel P91.12-2683-04 Remove/Install

1 Fold down both rear seat backrests See Operating Instructions 2 Pry off the release lever (1) off with a suitable Installation:

Install new release screwdriver lever (1). 3 Unscrew screw (2) 4 Detach trim cover (3) from trim cover (4) 5 Fold both rear seat backrests back up See Operating Instructions 6 Detach and remove the trim cover (4) at the Installation:

Make sure the trim cover (4) backrest frame engages at the backrest frame. 7 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.12-p-1735ff, Remove/install trim cover for rear seat backrest release lever MODELS 454.0

AR91.16-P-0050FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4028 · Applies to: 453 · AR: AR91.16-P-0050FF, AR91.10-P-1910FF

Remove/install headrest guide on front seat 3.3.04 MODELS 454.0 Illustrated on the right front seat 1 Tensioning element 2 Headrest guides 3 Backrest cover P91.60-2821-06 Remove/Install

1 Remove head restraints See Operating Instructions 2 Remove tensioning element (1) from front AR91.10-P-1910FF seat backrest 3 Press in the engagement lugs (arrows) with a Observe installation position of the head screwdriver and pull the head restraint guides restraint guides (2). (2) upward Installation:

Do not let the backrest cover (3) get caught between the head restraint guides (2) and the backrest frame. 4 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.16-p-0050ff, Remove/install headrest guide on front seat MODELS 454.0

AR91.16-P-1775FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4029 · Applies to: 453 · AR: AR91.16-P-1775FF

Remove/install rear seat backrest head restraint guides 3.3.04 MODELS 454.0 Shown on right rear seat backrest with code (S33) Double folding rear bench seat (3 seats) 1 Head rest guide 2 Backrest upholstery 3 Rear seat backrest frame P91.16-2257-06 Remove/Install

1 Remove headrests 2 Open zipper on the rear seat backrest cover AR91.18-P-1820-04FF *454589013700

3 Fold up rear seat backrests 4 Press in catch hooks (arrows) using a suitable Note installation position of head restraint screwdriver and pull head restraint guides (1) guides (1). up and out Installation:

Do not get backrest cover (2) caught between head restraint guides (1) and rear seat backrest frame (3). 5 Install in the reverse order 454 589 01 37 00 Pliers Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.16-p-1775ff, Remove/install rear seat backrest head restraint guides MODELS 454.0

AR91.18-P-1850FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4030 · Applies to: 453 · AR: AR91.18-P-1850FF, AR91.21-P-4000FF, AR91.21-P-4050FF

Remove and install cover on rear seat cushion 2.3.04 MODELS 454.0 P91.18-2202-09 Shown on bench seat with code (S33) Double folding rear bench seat (3 seats) 1 Cap (with code (S33) Double folding 3 Safety strap (with code (S33) Double 9 Zipper rear bench seat (3 seats)) folding rear bench seat (3 seats)) 10 Pliers 2 Adjustment lever (with code (S33) 5 Seat cover 11 Nut (with code (S33) Double folding Double folding rear bench seat (3 6 Hook rear bench seat (3 seats)) seats)) 7 Rear seat backrest 12 Belt end fitting (with code (S33) 8 Rear seat backrest Double folding rear bench seat (3 seats)) 4 Seat cushion frame 5 Seat cover 13 Terminal strip cover 14 Terminal strip covering P91.18-2203-06 Remove/Install

1 Remove rear bench seat AR91.21-P-4000FF 2.1 Remove adjustment lever (2) On vehicles with code (S33) Double folding AR91.21-P-4050FF rear bench seat (3 seats) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.18-p-1850ff, Remove and install cover on rear seat cushion MODELS 454.0

Remove safety strap (3) from bench seat

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4031 · Applies to: 453 · AR: AR91.12-P-1735FF

3.1 Remove safety strap (3) from bench seat On vehicles with code (S33) Double folding rear bench seat (3 seats) 4 Move rear seat backrest (7, 8) to vertical position 5 Remove paneling of release lever from rear AR91.12-P-1735FF seat backrests (7, 8) 6 Separate terminal strip cover (13) and terminal strip covering (14) from each other by twisting 7 Unhook cover (5) on side (arrows) of seat cushion frame (4) 8 Feed terminal strip cover (13) in between rear seat cushion and rear seat backrests (7, 8) 9 Unhook hook (6) on side of seat cushion frame (4) 10 Unzip the zipper (9) Installation:

Fold down rear bench seat and close zipper (9), starting in the middle, moving first to the right and then to the left using the pliers (10). *454589013700

11 Unhook hook of cover (5) from seat frame 12.1 Unscrew nut (11) and remove belt end fitting On vehicles with code (S33) Double folding (12) rear bench seat (3 seats) *BA91.40-P-1007-01J

13 Remove cover (5) with foam section. In doing Installation: Pay attention to installation so, guide seat belt buckles through the position of seat belt buckles. openings in the cover (5) 14 Remove cover (5) from foam section AR91.18-P-1820-03FH *454589023700

15 Install in the reverse order Seat belts/emergency tensioning retractors

Number Designation Model 454.0 BA91.40-P-1007-01J Bolt for belt end fitting to bench seat Nm 45 454 589 01 37 00 454 589 02 37 00 Pliers Pliers Page 2 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.18-p-1850ff, Remove and install cover on rear seat cushion MODELS 454.0

AR91.18-P-1820FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4032 · Applies to: 453 · AR: AR91.18-P-1820FF, AR91.16-P-0050FF, AR91.60-P-0695FF, AR91.10-P-6620FF

Remove front seat backrest cover 2.3.04 MODEL 454.0 except CODE (S17) Heated seats (FFO) Shown on right front seat 1 Foam part 2 Backrest frame 3 Cover P91.18-2160-01 Remove/Install

1 Remove head restraint guide from front seat AR91.16-P-0050FF 2 Removing front seat sidebag unit AR91.60-P-0695FF 3.1 Remove lumbar support thumb wheel In vehicles with code (S21) Lumbar support AR91.10-P-6620FF (FFO) 4 Push foam part (1) out of backrest frame (2) at bottom (arrows) 5 Pull cover (3) with foam part (1) out of backrest frame (2) from above 6 Detach cover (3) from foam part (1) AR91.18-P-1820-03FF *454589023700

7 Install in the reverse order 454 589 02 37 00 Pliers Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.18-p-1820ff, Remove front seat backrest cover MODEL 454.0 except CODE (S17) Heated seats (FFO)

AR91.18-P-1820FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4033 · Applies to: 453 · AR: AR91.18-P-1820FG, AR91.16-P-0050FF, AR91.60-P-0695FF

Remove front seat backrest cover 6.8.04 MODEL 454.0 with CODE (S17) Heated seats (FFO) Shown on removed right front seat with code (S20) Seat height adjustment (FFO) and code (S21) Lumbar support (FFO) 1 Cover 2 Heated seats wiring harness 3 Foam part 4 Backrest frame 5 Loop P91.10-2778-06 Removal/installation

1 Remove head restraint guide from front seat AR91.16-P-0050FF 2 Removing front seat sidebag unit AR91.60-P-0695FF 3 Push foam part (3) out of backrest frame (4) at bottom (arrows) 4 Detach cover (1) with foam part (3) from Handle heated seats wiring harness (2) backrest frame (4), pull off from above and with care. place on seat cushion 5 Open loop (5) on cover (1) and expose heated Installation: Close loop (5) with suitable

seats wiring harness (2) fabric adhesive tape. 6 Detach cover (1) from foam part (3) AR91.18-P-1820-03FF *454589023700

7 Install in the reverse order 454 589 02 37 00 Pliers Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.18-p-1820fg, Remove front seat backrest cover MODEL 454.0 with CODE (S17) Heated seats (FFO)

AR91.18-P-1800FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4034 · Applies to: 453 · AR: AR91.18-P-1800FF, AR91.10-P-1056FF, AR91.10-P-1056FH, AR91.10-P-1056FG, AR91.10-P-1910FF

Remove/install front seat cushion cover 2.3.04 MODEL 454.0 except CODE (S17) Heated seats (FFO) P91.18-2163-09 1 Terminal strip 3 Clip 5 Cover 2 Seat cushion frame 4 Seat cushion Remove/Install

1.1 Remove outer paneling from seat frame In vehicles without code (S20) Seat height AR91.10-P-1056FF adjustment (FFO) 1.2 Remove seat height adjustment paneling from In vehicles with code (S20) Seat height AR91.10-P-1056FH seat frame adjustment (FFO) 2 Remove seat backrest unlocking mechanism AR91.10-P-1056FG paneling from seat frame 3 Remove tensioning element from front seat AR91.10-P-1910FF backrest 4 Push down seat cushion (4) at rear and detach terminal strip (1) from seat cushion frame (2) 5 Run cover (5) with terminal strip (1) between seat cushion (4) and seat backrest 6 Remove clips (3) 7 Push down seat cushion (4) and detach remaining terminal strips (arrows) from seat cushion frame (2) 8 Remove seat cushion (4) 9 Detach cover (5) from foam part AR91.18-P-1820-03FG *454589023700

10 Install in the reverse order 454 589 02 37 00 Pliers Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.18-p-1800ff, Remove/install front seat cushion cover MODEL 454.0 except CODE (S17) Heated seats (FFO)

AR91.18-P-1800FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4035 · Applies to: 453 · AR: AR91.18-P-1800FG, AR91.10-P-3290FF

Remove/install front seat cushion cover 6.8.04 MODEL 454.0 with CODE (S17) Heated seats (FFO) Shown on removed right front seat with code (S20) Seat height adjustment (FFO) and code (S21) Lumbar support (FFO) 1 Cover P91.10-2777-03 Remove/Install

1 Remove front seat padding AR91.10-P-3290FF 2 Detach cover (1) from front seat cushion AR91.18-P-1820-03FG *454589023700

3 Install in the reverse order 454 589 02 37 00 Pliers Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.18-p-1800fg, Remove/install front seat cushion cover MODEL 454.0 with CODE (S17) Heated seats (FFO)

AZ91.20-P-0001FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4036 · Applies to: 453 · AR: AZ91.20-P-0001FF, AR91.18-P-1850FF

Retrofit bracket for child-seat anchorage 17.1.06 MODEL 454.0 Retrofit ISO-fix without new rear seat cushion Shown on rear bench seat with code (S33) Double folding rear bench seat (3 seats) 1 ISO-fix mounting 2 Frame P91.20-2129-11 3 Rear seat cushion 4 Cutout P91.20-2152-05 Removing

1 Remove cover from rear seat cushion Remove and install cover on rear seat AR91.18-P-1850FF

cushion Install

2 Slide ISO-fix mountings (1) onto frame mounting (2) 3 Cut rear seat cushion (3) along the perforation (arrows) and remove cutouts (4) 4 Install new seat cover with ISO-fix cutout onto Check that ISO-fix mountings (1) are processed rear seat cushion (3) correctly positioned in openings of seat cover. Remove and install cover on rear seat AR91.18-P-1850FF

cushion 5.1 Enter special equipment in the vehicle data At workshops without DMS Autoline 8.0 card and in the vehicle's online data card dealer system. Add code (S22) ISO-fix (child seat fastening system). Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, az91.20-p-0001ff, Retrofit bracket for child-seat anchorage MODEL 454.0 Retrofit ISO-fix without new rear seat cushion

AZ91.20-P-0001FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4037 · Applies to: 453 · AR: AZ91.20-P-0001FG, AR91.18-P-1850FF

Retrofit bracket for child-seat anchorage 17.1.06 MODEL 454.0 Retrofit ISO-fix with new rear seat cushion Shown on rear bench seat with code (S33) Double folding rear bench seat (3 seats) 1 ISO-fix mounting 2 Frame P91.20-2129-11 Removing

1 Remove cover from rear seat cushion Remove and install cover on rear seat AR91.18-P-1850FF

cushion Install

2 Slide ISO-fix mountings (1) onto frame mounting (2) 3 Install new seat cover with ISO-fix cutout onto Check that ISO-fix mountings (1) are new rear seat cushion with ISO-fix cutout correctly positioned in openings of seat cover. Remove and install cover on rear seat AR91.18-P-1850FF

cushion 4.1 Enter special equipment in the vehicle data At workshops without DMS Autoline 8.0 card and in the vehicle's online data card dealer system. Add code (S22) ISO-fix (child seat fastening system). Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, az91.20-p-0001fg, Retrofit bracket for child-seat anchorage MODEL 454.0 Retrofit ISO-fix with new rear seat cushion

AR91.21-P-4000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4039 · Applies to: 453 · AR: AR91.21-P-4000FF

Remove and install bench 2.3.05 MODELS 454.0 Shown on vehicle with code (S33) Double folding rear bench seat (3 seats) 1 Rear bench seat 2 Nut 3 Lock 4 Release lever (for code (S33) Double folding rear bench seat (3 seats)) 5 Cover 6 Release lever (for code (S33) Double folding rear bench seat (3 seats)) 7 Self-locking bolt (for code (S33) Double folding rear bench seat (3 seats)) 8 Bolts P91.12-2679-06 Remove

1 Move rear bench seat (1) as far to the rear as possible. 2 Remove covers (5) 3 Fold down rear bench seat (1) Model 454.0 without code (S33) Double AR91.21-P-4000-01FF folding rear bench seat (3 seats) With model 454.0 with code (S33) Double folding rear bench seat (3 seats): release rear bench seat (1) at the release lever (4) and move as far forward as possible. Retract head restraints and fold down rear seat backrests. Then release rear bench seat (1) at the release lever (6) and set to vertical position. 4 Unscrew nuts (2) 5 Fold back rear bench seat (1) and move as far Do not fold back rear seat backrests. to the rear as possible 6.1 Screw in self-locking bolts (7) For vehicles with code (S33) Double folding rear bench seat (3 seats) Use commercially available bolts M10 25. 7 Move rear bench seat (1) as far forward as possible. 8 Remove bolts (8) 9.1 Release rear bench seat (1) at the release For vehicles with code (S33) Double folding lever (6) and remove to the rear of the vehicle rear bench seat (3 seats) Helper required 9.2 Release rear bench seat (1) and remove to For vehicles without code (S33) Double the rear out of the vehicle folding rear bench seat (3 seats) Helper required See Fold down bench seat AR91.21-P-4000-01FF Install

10 Position rear bench seat (1) in the vehicle Helper required Both locks (3) must be engaged in the body. 11 Tighten screws (8) Replace screws (8). *BA91.22-P-1001-01A

12 Move rear bench seat (1) as far to the rear as possible. 13.1 Remove self-locking bolts (7) For vehicles with code (S33) Double folding rear bench seat (3 seats) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.21-p-4000ff, Remove and install bench MODELS 454.0

AR91.21-P-4050FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4041 · Applies to: 453 · AR: AR91.21-P-4050FF

Remove/install bench seat adjustment lever 10.5.04 MODELS 454.0 with CODE (S33) Double folding rear bench seat (3 seats) 1 Rear bench seat 2 Release lever 3 Lock 4 Release lever 5 Fish-plate 6 Rail 7 Edge guard P91.21-2029-06 Remove/install

1 Fold back the rear bench seat (1) Release rear bench seat (1) on release lever (4) and move to the frontmost position. Retract head restraints and fold down rear seat backrests. Next, release rear bench seat (1) on release lever (2) and move into the vertical position. 2 Release both locking mechanisms (3) by Installation:

Release both locking pressing the spring mechanisms (3) by operating the release lever (2). 3 Operate release lever (4) and move rear Helper required bench seat (1) up vertically 4 Bend tab (5) toward inside Installation:

Bend tab (5) toward the outside by approx. 30°. If tab (5) is bent too far toward the outside, a grinding noise can be heard when the rear bench seat (1) is moved. 5 Compress release lever (2) using a suitable Installation: On vehicles up to the

screwdriver (arrows) and pull out of the rail (6) production date 13.1.05, the edge guard (7) has to be modified when the release lever (2) is replaced. 6 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.21-p-4050ff, Remove/install bench seat adjustment lever MODELS 454.0 with CODE (S33) Double folding rear bench seat (3 seats)

AR91.21-P-4050FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4042 · Applies to: 453 · AR: AR91.21-P-4050FG

Remove/install bench seat adjustment lever 10.8.04 MODELS 454.0 with CODE (S33) Double folding rear bench seat (3 seats) Adjustment lever on side of luggage compartment P91.21-2030-07 1 Adjustment lever 3 Screwdriver 4 Catch hook 2 Cover Remove/install

1 Unclip cover (2) using suitable screwdriver (3) Note installation position for cover (2). and remove 2 Release catch hook (4) using a suitable screwdriver (3) and detach adjustment lever (1) toward the rear 3 Install in the reverse order Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.21-p-4050fg, Remove/install bench seat adjustment lever MODELS 454.0 with CODE (S33) Double folding rear bench seat (3 seats) Adjustment lever on side of luggage compartment

AR91.21-P-4050FH

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4043 · Applies to: 453 · AR: AR91.21-P-4050FH

Remove/install bench seat adjustment lever 21.2.05 MODELS 454.0 Front adjustment lever P91.21-2033-08 1 Rear bench seat 2 Adjustment lever 4 Front guide 3 Locks 5 Rear guide 1 Rear bench seat 6 Screwdriver 7 Guide rail 8 Lever P91.21-2032-03 Remove/install

1 Fold back the rear bench seat (1) Model 454.0 without code (S33) Double AR91.21-P-4000-01FF folding rear bench seat (3 seats) On model 454.0 with code (S33) Double folding rear bench seat (3 seats): move rear bench seat (1) into the frontmost position. Retract head restraints and fold down rear seat backrests. Next, release rear bench seat (1) and move into vertical position. 2 Release both locking mechanisms (3) by Installation:

On vehicles with code (S33) pressing the spring Double folding rear bench seat (3 seats): release both locking mechanisms (3) by operating the release lever. On vehicles without code (S33) Double folding rear bench seat (3 seats) Carefully fold back the rear bench seat (1) Guide a screwdriver (6) on left and right into the guide rails (7), lift up the levers (8) thus releasing the locking mechanisms (3). Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.21-p-4050fh, Remove/install bench seat adjustment lever MODELS 454.0 Front adjustment lever

PE91.30-P-2001ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4045 · Applies to: 453 · AR: PE91.30-P-2001ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Block diagram of heated seats (HS) 8.3.04 MODELS 454 PE91.30-P-2001-99ZA Block diagram of heated seats (HS) PE91.30-P-2001-99ZA PE91.30-P-2001-60ZA Legend for block diagram of heated seats PE91.30-P-2001-60ZA (HS) OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Arrangement and assignment of the wiring GF00.19-P-1000ZA and plug connectors GF00.19-P-2000ZA Arrangement and assignment of ground GF00.19-P-2000ZA points GF00.19-P-3000ZA Arrangement and assignment of Z connector GF00.19-P-3000ZA sleeves (wiring connections in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE91.00-P-1100ZA Further wiring diagrams PE91.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe91.30-p-2001za, Block diagram of heated seats (HS) MODELS 454

PE91.30-P-2050BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4046 · Applies to: 453 · AR: PE91.30-P-2050BBA

Electrical function schematic, seat heater (SIH) 05.09.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) with code 873 (Left and right driver's seat heating) Model 453.091/391/491 with code 873 (Left and right driver's seat heating) except code U14 (Climate package) Electrical function schematic, seat heater PE91.30-P-2050-97BBA (SIH) Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe91.30-p-2050bba, Electrical function schematic, seat heater (SIH) Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) with code 873 (Left and right driver's seat heating) Model 453.091/391/491 with code 873 (Left and right driver's ...

GF91.30-P-9990KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4047 · Applies to: 453 · AR: GF91.30-P-9990KJ, GF91.30-P-0999KJ

Overview of system components of comfort heating systems 28.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) with code 873 (Left and right driver's seat heating) Model 453.091/391/491 with code 873 (Left and right driver's seat heating) except code U14 (Climate package) P91.30-2633-79 Shown on model 453.3 left-hand drive vehicle 1 Driver seat N25/5b1 Driver seat heater temperature sensor 2 Passenger seat R13/1 Left front seat cushion heater pad F2 Vehicle interior fuse and relay module R13/2 Left front seat backrest heater pad K59/2 Left seat heater power supply solenoid switch R13/3 Right front seat cushion heater pad K59/3 Right seat heater power supply solenoid switch R13/4 Right front seat backrest heater pad N25/4 Front passenger seat heater control unit S2 Ignition lock N25/4b1 Front passenger seat heater temperature sensor S51/1 Left front seat heater switch N25/5 Driver seat heater control unit S51/2 Right front seat heater switch The respective seat heater control unit and the respective seat heater power supply solenoid switch are part of the respective front seat cushion heater pad or the respective wiring harness in the front seat cushion heater pad. The seat heater control unit and the seat heater power supply solenoid switch cannot be exchanged separately. Table of contents for function description of GF91.30-P-0999KJ comfort heating systems Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf91.30-p-9990kj, Overview of system components of comfort heating systems Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) with code 873 (Left and right driver's seat heating) Model 453.091/391/491 with code 873 (Left and right driver's ...

AR91.30-P-0005FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4048 · Applies to: 453 · AR: AR91.30-P-0005FF, AR91.10-P-3290FF

Remove/install heated cushion at front seat cushion 10.8.04 MODEL 454.0 with CODE (S17) Heated seats (FFO) 1 Foam part 2 Adhesive strips 3 Adhesive strips 4 Adhesive strips 5 Heated seats wiring harness R13/1 Left seat heated cushion R13/3 Right seat heated cushion P91.30-2197-06 Remove

1 Remove foam part (1) from front seat AR91.10-P-3290FF 2 Detach cover from foam part (1) AR91.18-P-1820-03FG The left seat heated cushion (R13/1) and the right seat heated cushion (R13/3) cannot be removed from the foam part (1). Both parts must always be replaced. *454589023700

Install

3 Align left seat heated cushion (R13/1) or right seat heated cushion (R13/3) on foam part (1) 4 Pull off adhesive strip (2) and stick left seat heated cushion (R13/1) or right seat heated cushion (R13/3) to foam part (1) 5 Push areas (C) of left seat heated cushion If the areas (C) of the left seat heated (R13/1) or right seat heated cushion (R13/3) cushion (R13/1) or the right seat heated into recesses (arrows A) in foam part (1) cushion (R13/3) do not sit properly in the recesses (arrows A), this may prevent the seat cushion cover from being installed properly. 6 Pull off adhesive strip (3) and stick left seat heated cushion (R13/1) or right seat heated cushion (R13/3) to foam part (1) 7 Push areas (D) of left seat heated cushion If the areas (D) of the left seat heated (R13/1) or right seat heated cushion (R13/3) cushion (R13/1) or the right seat heated into recesses (arrows B) in foam part (1) cushion (R13/3) do not sit properly in the recesses (arrows B), this may prevent the seat cushion cover from being installed properly. 8 Pull off adhesive strip (4) and stick left seat heated cushion (R13/1) or right seat heated cushion (R13/3) to foam part (1) 9 Route heated seats wiring harness (5) in guide (arrow E) of foam part (1) 10 Fit cover to foam part (1) AR91.18-P-1820-03FG *454589023700

11 Fit foam part (1) with cover to front seat AR91.10-P-3290FF Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.30-p-0005ff, Remove/install heated cushion at front seat cushion MODEL 454.0 with CODE (S17) Heated seats (FFO)

AR91.30-P-0030FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4050 · Applies to: 453 · AR: AR91.30-P-0030FF, AR68.10-P-1400FF

Remove/install heated seats control unit 7.9.04 MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle with CODE (S17) Heated seats (FFO) P91.30-2199-07 1 Bolts 2 Housing N25/5 Front HS control unit Remove/Install

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

components due to electrostatic discharge 1 Remove glove compartment AR68.10-P-1400FF 2 Remove bolts (1) 3 Turn housing (2) until the front HS control unit (N25/5) is accessible 4 Pull out front heated seats (HS) control unit (N25/5) 5 Install in the reverse order 6 Check heated seats for proper function Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.30-p-0030ff, Remove/install heated seats control unit MODEL 454.0## 1# with CODE (LHD) Left-hand drive vehicle with CODE (S17) Heated seats (FFO)

AR91.30-P-0030FG

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4051 · Applies to: 453 · AR: AR91.30-P-0030FG, AR68.10-P-1520FF

Remove/install heated seats control unit 9.9.04 MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle with CODE (S17) Heated seats (FFO) P91.30-2200-07 1 Support base N25/5 Front HS control unit Remove/Install

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

components due to electrostatic discharge 1 Remove cover below right instrument panel AR68.10-P-1520FF 2 Pull out front heated seats (HS) control unit The front HS control unit (N25/5) is (N25/5) located on the front side of the base (1). 3 Install in the reverse order 4 Check heated seats for proper function Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.30-p-0030fg, Remove/install heated seats control unit MODEL 454.0## 2# with CODE (RHD) Right-hand drive vehicle with CODE (S17) Heated seats (FFO)

AR91.30-P-0006FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4052 · Applies to: 453 · AR: AR91.30-P-0006FF, AR91.10-P-1120FF

Removing and installing front seat backrest heated cushion 10.8.04 MODEL 454.0 with CODE (S17) Heated seats (FFO) Shown on foam part of right front seat 1 Foam part 2 Adhesive strips 4 Adhesive strips R13/1 Left seat heated cushion R13/3 Right seat heated cushion P91.30-2196-06 Remove

1 Remove foam part (1) from front seat backrest AR91.10-P-1120FF 2 Remove cover from foam part (1) of front seat AR91.18-P-1820-03FF The left seat heated cushion (R13/1) and backrest the right seat heated cushion (R13/3) cannot be removed from the foam part (1). Both parts must always be replaced. *454589023700

Install

3 Align left seat heated cushion (R13/1) or right seat heated cushion (R13/3) on foam part (1), so that the openings (arrows C) on the left seat heated cushion (R13/1) or the right seat heated cushion (R13/3) are in exact alignment with the openings (arrows A) in the foam part (1) 4 Pull off adhesive strip (2) and stick left seat Ensure that the openings (arrows C) on heated cushion (R13/1) or right seat heated the left seat heated cushion (R13/1) or the cushion (R13/3) to foam part (1) right seat heated cushion (R13/3) are in exact alignment with the openings (arrows A) in the foam part (1). 5 Push areas (D) of left seat heated cushion If the areas (D) of the left seat heated (R13/1) or right seat heated cushion (R13/3) cushion (R13/1) or the right seat heated into recesses (arrows B) in foam part (1) cushion (R13/3) do not sit properly in the recesses (arrows B), this may prevent the seat backrest cover from being installed properly. 6 Pull off adhesive strip (4) and stick left seat heated cushion (R13/1) or right seat heated cushion (R13/3) to foam part (1) 7 Fit cover to foam part (1) AR91.18-P-1820-03FF *454589023700

8 Fit foam part (1) with cover to front seat AR91.10-P-1120FF backrest Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.30-p-0006ff, Removing and installing front seat backrest heated cushion MODEL 454.0 with CODE (S17) Heated seats (FFO)

GF91.30-P-0999KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4054 · Applies to: 453 · AR: GF91.30-P-0999KJ, GF91.30-P-0001KJ, GF91.30-P-0004KJ, GF91.30-P-9990KJ

Table of contents for function description of comfort heating systems 28.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) with code 873 (Left and right driver's seat heating) Model 453.091/391/491 with code 873 (Left and right driver's seat heating) except code U14 (Climate package) Comfort heating function GF91.30-P-0001KJ Front heated seats function GF91.30-P-0004KJ Overview of system components of comfort GF91.30-P-9990KJ heating systems Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf91.30-p-0999kj, Table of contents for function description of comfort heating systems Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) with code 873 (Left and right driver's seat heating) Model 453.091/391/491 with code 873 (Left and right driver's ...

PE91.30-P-2000BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4060 · Applies to: 453 · AR: PE91.30-P-2000BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram of heated seats (HS) 12.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code 873 (Left and right driver's seat heating) Wiring diagram of seat heater (SIH) PE91.30-P-2000-97BBA Location and assignment of line and plug GF00.19-P-1000BBA connectors Location and assignment of ground points GF00.19-P-2000BBA Location and assignment of Z connector GF00.19-P-3000BBA sleeves (wiring and plug connectors in wiring harness) Abbreviations of signal and circuit OV00.01-P-1001-28BBA designations for wiring diagrams Use of wiring diagrams OV00.01-P-1901-03BBA Search aid for all electrical components OV00.01-P-1909BBA Fuse and relay box, as-built configuration GF54.15-P-0800KJ Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, pe91.30-p-2000bba, Wiring diagram of heated seats (HS) Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 with code 873 (Left and right driver's seat heating)

PE91.30-P-2000ZA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4061 · Applies to: 453 · AR: PE91.30-P-2000ZA, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+1 more)

Wiring diagram of heated seats (HS) 16.12.03 MODEL 454 up to 2.4.06 PE91.30-P-2000-99ZA Wiring diagram of heated seats (HS) PE91.30-P-2000-99ZA PE91.30-P-2000-60ZA Legend of wiring diagram heated seats (HS) PE91.30-P-2000-60ZA OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Arrangement and assignment of the wiring GF00.19-P-1000ZA and plug connectors GF00.19-P-2000ZA Arrangement and assignment of ground GF00.19-P-2000ZA points GF00.19-P-3000ZA Arrangement and assignment of Z connector GF00.19-P-3000ZA sleeves (wiring connections in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe91.30-p-2000za, Wiring diagram of heated seats (HS) MODEL 454 up to 2.4.06

PE91.30-P-2000ZB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4062 · Applies to: 453 · AR: PE91.30-P-2000ZB, OV00.01-P-1901ZA, GF00.19-P-1000ZA, GF00.19-P-2000ZA, GF00.19-P-3000ZA (+2 more)

Wiring diagram of heated seats (HS) 8.3.06 MODEL 454 as from 3.4.06 PE91.30-P-2000-99ZB Wiring diagram of heated seats (HS) PE91.30-P-2000-99ZB PE91.30-P-2000-60ZB Legend of wiring diagram heated seats (HS) PE91.30-P-2000-60ZB OV00.01-P-1901-03ZA Use of wiring diagrams OV00.01-P-1901-03ZA OV00.01-P-1901ZA Search aid for all wiring diagram groups OV00.01-P-1901ZA OV00.01-P-1001-27ZA Abbreviations for wiring diagrams OV00.01-P-1001-27ZA OV00.01-P-1001-28ZA Abbreviations of signal and circuit OV00.01-P-1001-28ZA designations for wiring diagrams GF00.19-P-1000ZA Location and assignment of line and plug GF00.19-P-1000ZA connectors GF00.19-P-2000ZA Location and assignment of ground points GF00.19-P-2000ZA GF00.19-P-3000ZA Location and assignment of Z connector GF00.19-P-3000ZA sleeves (line connectors in wiring harness) PE54.00-P-1100ZA Further wiring diagrams PE54.00-P-1100ZA PE80.00-P-1100ZA Further wiring diagrams PE80.00-P-1100ZA Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe91.30-p-2000zb, Wiring diagram of heated seats (HS) MODEL 454 as from 3.4.06

AR91.40-P-0612CW

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4063 · Applies to: 453 · AR: AR91.40-P-0612CW

Checking recognition of actuation state of emergency/compact tensioning 13.8.14 retractors MODEL 117, 156, 176, 204, 205, 212, 242, 246, 453 Check

1 Connect diagnostic system and read out fault memory MODEL 453 AD00.00-P-2000-06SR

MODEL 205 AD00.00-P-2000-04B

MODEL 117, 156, 176, 204, 212, 242, 246 AD00.00-P-2000-04A

Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.40-p-0612cw, Checking recognition of actuation state of emergency/compact tensioning retractors MODEL 117, 156, 176, 204, 205, 212, 242, 246, 453

AP91.40-P-9150FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4064 · Applies to: 453 · AR: AP91.40-P-9150FF, AR91.40-P-0630FF, AR91.40-P-0681FF, AR91.40-P-0683FF, AR91.40-P-1515FF (+1 more)

Inspect seat belts and seat belt buckles for external damage and operation 7.10.03 MODELS 454.0 Check

1 Pull out seat belt webbing fully, inspect for Cut fibers, chafing marks and other damage damage If damage is present: Replace seat belt - subject to separate repair order. Remove/install seat belt with emergency AR91.40-P-0630FF

tensioning retractor Remove/install rear seat belts AR91.40-P-0681FF

Remove/install rear center safety belt AR91.40-P-0683FF

If a customer refuses replacement of a damaged seat belt, an appropriate endorsement must be made on the repair order. 2 Inspect lock function of inertia reel by pulling If damage present: sharply on belt webbing Replace seat belt - subject to separate repair order. Remove/install seat belt with emergency AR91.40-P-0630FF

tensioning retractor Remove/install seat belt in rear AR91.40-P-0681FF

Remove/install rear center safety belt AR91.40-P-0683FF

If a customer refuses replacement of a damaged seat belt, an appropriate endorsement must be made on the repair order. 3 Inspect proper operation of seat belt buckle If damage present: Replace seat belt buckle - subject to separate repair order. Removing and installing seat belt buckle (front AR91.40-P-1515FF

seat) Removing and installing rear seat belt buckle AR91.40-P-1516FF

If a customer refuses replacement of a damaged seat belt buckle , an appropriate endorsement must be made on the repair order. Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap91.40-p-9150ff, Inspect seat belts and seat belt buckles for external damage and operation MODELS 454.0

AR91.40-P-0683FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4065 · Applies to: 453 · AR: AR91.40-P-0683FF, AR91.12-P-8457FF

Remove/install rear center seat belt 7.12.03 MODELS 454.0 with CODE (S33) rear bench seat folds down in two sections (3-person seat) 1 Screw 2 Automatic belt retractor P91.40-2510-04 Remove/Install

1 Remove the cover and upholstery from right AR91.12-P-8457FF rear seat backrest 2 Unscrew bolt (1) Installation:

Replace bolt (1). *BA91.40-P-1008-01J

Risk of injury. Danger! Injury may result when the Never disassemble automatic belt retractors. AS91.00-Z-0002-01A

tension in the spring in the automatic belt retractor is released. 3 Detach automatic belt retractor (2) 4 Install in the reverse order Seat belts/emergency tensioning retractors

Number Designation Model 454.0 BA91.40-P-1008-01J Bolt for automatic belt retractor to bench Nm 40 seat Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.40-p-0683ff, Remove/install rear center seat belt MODELS 454.0 with CODE (S33) rear bench seat folds down in two sections (3-person seat)

AR91.40-P-1516FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4066 · Applies to: 453 · AR: AR91.40-P-1516FF

Remove/install rear seat belt buckle 7.12.03 MODELS 454.0 1 Seatbelt buckle 2 Nut P91.40-2509-04 Remove/Install

1 Unscrew nut (2) and remove seat belt buckle Note correct installation positions. (1) *BA91.40-P-1006-01J

2 Install in the reverse order 3 Perform function test of the seat belt buckle (1) Seat belts/emergency tensioning retractors

Number Designation Model 454.0 BA91.40-P-1006-01J Bolt for seat belt buckle to bench seat Nm 45 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.40-p-1516ff, Remove/install rear seat belt buckle MODELS 454.0

AR91.40-P-0681FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4067 · Applies to: 453 · AR: AR91.40-P-0681FF

Remove/install rear seat belts 16.10.03 MODELS 454.0 P91.40-2480-08 1 Cap 5 Bottom C-pillar paneling 8 Bolt 2 Bolt 6 Bolt 9 Seat belt end fitting 3 Seat belt guide bracket 7 Automatic belt retractor 10 Floor mat 4 Edge guard Remove/Install

Risk of injury Danger! caused by release of spring in Never disassemble automatic belt retractors. AS91.00-Z-0002-01A

the automatic belt retractor is released. 1 Pull off edge guard (4) on C-pillar in area of Installation:

Ensure that edge guard (4) is bottom C-pillar paneling (5) downwards properly seated. 2 Remove cap (1) from seat belt guide bracket (3) 3 Detach seat belt guide bracket (3) from C- Installation:

Ensure that seat belt is pillar correctly routed. *BA91.40-P-1002-01J

4 Fold back rear bench seat For model 454.0 with code (S33) Double folding rear bench seat (3 seats): move rear bench seat as far forward as possible, retract head restraints and fold down rear seat backrests. Then release rear bench seat and set in vertical position. For model 454.0 without code (S33) Double folding rear bench seat (3 seats), Refer to: Fold down bench seat AR91.21-P-4000-01FF 5 Fold floor covering (10) to side in trunk 6 Unclip bottom C-pillar paneling (5) Installation:

Check clips on the back of the bottom C-pillar paneling (5), replace if necessary. *452589016300

7 Detach belt end fitting (9) from body and *BA91.40-P-1001-01J

remove belt end fitting (9) 8 Detach automatic belt retractor (7) from C- *BA91.40-P-1003-01J

pillar 9 Remove automatic belt reel (7) Installation:

The seat belt can only be pulled out of the automatic belt retractor (7) if the automatic belt retractor (7) is in the installation position. 10 Install in the reverse order Seat belts/emergency tensioning retractors

Number Designation Model 454.0 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.40-p-0681ff, Remove/install rear seat belts MODELS 454.0

AR91.40-P-1515FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4069 · Applies to: 453 · AR: AR91.40-P-1515FF

Remove/install seat belt buckle (front seat) 7.12.03 MODELS 454.0 1 Cap 2 Screw 3 Seatbelt buckle 4 Electrical line 5 Front seat 6 Plug connection 7 Plug connection P91.40-2508-06 Remove/Install

1 Remove the cover cap (1) 2 Unscrew screw (2) *BA91.40-P-1005-01J

3.1 Disconnect the electrical line (4) and Only when removing the driver-side seat belt connector (6, 7) at the front seat (5) buckle (3). Carefully detach connector (6, 7) to prevent damage to the connector engagement lugs (arrows). Ensure that the electrical line (4) is correctly routed. 4.1 Disconnect connector (7) Only when removing the driver-side seat belt buckle (3). 5 Remove belt buckle (3) 6 Install in the reverse order 7 Perform function test of the seat belt buckle (3) Seat belts/emergency tensioning retractors

Number Designation Model 454.0 BA91.40-P-1005-01J Bolt for seat belt buckle to seat frame Nm 45 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.40-p-1515ff, Remove/install seat belt buckle (front seat) MODELS 454.0

AR91.40-P-1515SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4070 · Applies to: 453 · AR: AR91.40-P-1515SR

Remove/install seat belt buckle (front seat) 13.08.2014 MODEL 453 1 Cup holder 2 Electrical connector 3 Screw P68.20-4772-06 4 Front seat 5 Electrical connector 6 Screw 7 Belt buckle 8 Bracket 9 Electrical wiring harness for seat belt buckle X55/3 Driver seat connector block X55/4 Front passenger seat connector block P91.40-3449-06 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Remove/install

1 Switch off ignition and remove transmitter key from electronic ignition lock control unit 2 Unscrew bolt (3) 3 Unclip cup holder (1) Pull cup holder (1) far enough upwards

until electrical connector (2) is accessible. *110589035900 Mounting wedge 4 Disconnect electrical connector (2) and remove cup holder (1) Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.40-p-1515sr, Remove/install seat belt buckle (front seat) MODEL 453

AR91.40-P-0630FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4072 · Applies to: 453 · AR: AR91.40-P-0630FF, AR54.10-P-0003FF, AR68.30-P-4100FF, AR68.30-P-4700FF

Remove/install seat belt with emergency tensioning retractor 18.03.2019 Model 454.0 P91.40-2483-09 1 Automatic belt retractor 6 Cover 11 Bracket 2 Door sill 7 Screw 12 Locking pin 3 B-pillar paneling 8 Seat belt guide bracket 13 Connector 4 Screw 9 Screw R12/1 Driver ETR [GUS] squib 5 Belt end fitting 10 Seat belt guide R12/2 Front passenger ETR [GUS] squib Remove/install

Risk of injury. Injury may result when the Never disassemble automatic belt retractors. AS91.00-Z-0002-01A Caution

tension in the spring in the automatic belt retractor is released. Risk of injury Warning caused by performing testing or Store airbag units with deployment side facing AS91.00-Z-0001-01A

repair work on airbag or emergency tensioning up; do not expose to temperatures greater retractor units. than 100 °C. When working on these units, disconnect the power supply. Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Legal requirements on handling and storing AH91.00-P-0004-01A airbags and emergency tensioning retractor units 1 Disconnect battery ground line AR54.10-P-0003FF 2 Remove door sill molding (2) AR68.30-P-4100FF 3 Remove B-pillar trim (3) downwards AR68.30-P-4700FF 4 Remove screw (4) from seat belt end fitting (5) BA91.40-P-1001-01J Bolt, belt end fitting to body 5 Remove cover (6) and remove screw (7) BA91.40-P-1002-01J Bolt, belt guide bracket underneath from seat belt guide bracket (8) 6 Remove screw (9) and unhook seat belt guide BA91.40-P-1004-01J Torx bolt, belt guide to B-pillar (10) 7 Remove seat belt retractor (1) at bracket (11) BA91.40-P-1003-01J Bolt, automatic belt retractor to body and fold outwards 8 Pull out locking pin (12) and detach plug (13) at driver seat belt tensioner squib (R12/1) or front passenger seat belt tensioner squib (R12/2) 9 Remove seat belt retractor (1) If the seat belt retractor (1) is replaced, the

defective seat belt retractor (1) must be disposed of properly. 10 Install in the reverse order Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.40-p-0630ff, Remove/install seat belt with emergency tensioning retractor Model 454.0

AR91.40-P-0630SRA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4074 · Applies to: 453 · AR: AR91.40-P-0630SRA, AR54.10-P-0003SR, AR68.30-P-4800SRA, AR68.30-P-4800SRC

Remove/install seat belt with emergency tensioning retractor 02.11.2017 Model 453.3/4 Modification notes 02.11.2017 Remove seat belt end fitting from front seat, added. Operation step variant 3.2 Shown on vehicle except code 460 (Canada version) and except code 494 (USA version) 1 Screw 2 Screw 3 Seat belt with emergency tensioning retractor 4 Electrical connector 5 Screw R12/53 Left front emergency tensioning retractor squib R12/54 Right front emergency tensioning retractor squib P91.40-3468-05 Risk of injury Warning during testing and repair Do not expose pyrotechnical components to AS91.00-Z-0008-01A

operations related to pyrotechnical temperatures above 100 °C or 212 ℉. components Disconnect current supply when working on such components. Risk of injury. Injury may result when the Never disassemble automatic belt retractors. AS91.00-Z-0002-01A Caution

tension in the spring in the automatic belt retractor is released. Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Information, assessment and legal AH91.00-Z-0000-10A requirements when working with, handling and storing pyrotechnical components Remove/install

1 Disconnect battery ground line AR54.10-P-0003SR 2 Remove left and right side paneling in trunk Model 453.3 AR68.30-P-4800SRA Model 453.4 AR68.30-P-4800SRC 3.1 Remove screw/bolt (1) from belt end fitting Model 453.3/4 except code 460 (Canada version) except code 494 (US version) *BA91.40-P-1004-01SR Bolt, belt end fitting to B-pillar 3.2 Remove belt end fitting from front seat Model 453.3/4 with code 460 (Canada version) Model 453.3/4 with code 494 (US version) AR91.40-P-1030-02SR Installation: Check for correct routing of

seat belt (3) and seat belt end fitting. Check lock of buckle in seat belt end fitting. 4 Remove screw/bolt (2) from belt guide bracket BA91.40-P-1005-01SR Bolt, belt guide bracket to B-pillar 5 Disconnect electrical connector (4) at left front emergency tensioning retractor squib (R12/53) or right front emergency tensioning retractor squib (R12/54) 6 Remove screw/bolt (5) and take out seat belt BA91.40-P-1001-01SR Bolt, seat belt retractor to B-pillar with emergency tensioning retractor (3) 7 Install in the reverse order Check

Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.40-p-0630sra, Remove/install seat belt with emergency tensioning retractor Model 453.3/4

AR91.45-P-0500SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4077 · Applies to: 453 · AR: AR91.45-P-0500SR, AR91.10-P-8656SR

Remove/install seat belt guide 15.03.2018 Model 453.3/4 with code 460 (Canada version) Model 453.3/4 with code 494 (US version) P91.45-2046-09 Shown on left front seat 1 Seat belt guide 4 Guide 2 Screw 5 Nuts 3 Cover 6 Bracket Remove/install

1 Fold respective seat backrest in forward direction. 2 Unscrew bolts (2). *BA91.10-P-1009-01K Bolt, cover to seat belt guide 3 Remove cover (3). Installation: Make sure that the cover (3)

is seated correctly. The guide (4) on the seat belt guide (1) must retract into the opening (arrow) of the cover (3). 4 Unscrew nuts (5). BA91.10-P-1008-01K Nut, seat belt guide to holder 5 Remove seat belt guide (1) from holder (6). 6 Remove front seat and detach cover of seat AR91.10-P-8656SR backrest far enough until holder (6) on seat backrest frame is accessible. 7 Detach holder (6) from seat backrest frame. BA91.10-P-1007-01K Nut, holder for seat belt guide to seat backrest 8 Install in the reverse order. Front seats Number Designation Model 453 except code 866 (Pre-installation for iPad cradle) BA91.10-P-1007-01K Nut, holder for seat belt guide to seat backrest Nm 6 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.45-p-0500sr, Remove/install seat belt guide Model 453.3/4 with code 460 (Canada version) Model 453.3/4 with code 494 (US version)

Seat belt guide

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4080 · Applies to: 453 · AR: AR91.10-P-1000SR, AR91.10-P-8656SR, AN91.45-P-0001SR

6 Seat belt guide 9 Guide 7 Nuts 10 Cover 8 Bracket 11 Screw Modify 1 Remove driver seat. AR91.10-P-1000SR

2 Cut off push button upper part (2) with suitable tool. 3 Cut off belt loop (1) below the mount (3) carefully using a suitable tool. 4 Transfer dimensions (a, b, c) for cutout of Lower reference line (arrow A) for

holder (8) to seat backrest cover and mark. dimension (a) is the impression of sidebag unit. 5 Make cutout for holder (8) according to markings. 6 Remove cover for seat backrest far enough from seat backrest frame (5) until the mounts (4) are accessible. AR91.10-P-8656SR

7 Remove residue of push button. 8 Position holder (8) from parts kit at mounts (4) *BA91.10-P-1007-01K Nut, holder for seat belt guide to seat and tighten. backrest 9 Slip cover for seat backrest over holder (8) and install. AR91.10-P-8656SR

10 Position seat belt guide (6) at holder (8) and *BA91.10-P-1008-01K Nut, seat belt guide to holder tighten nuts (7). 11 Position cover (10) and tighten screws (11). Check cover (10) is correctly seated.

The guide (9) at the seat belt guide (6) must insert into opening (arrow B) of cover (10). *BA91.10-P-1009-01K Bolt, cover to seat belt guide 12 Install driver seat. AR91.10-P-1000SR

Update Vehicle Documentation (VeDoc) 13 Attach note seat belt guide retrofitted as per AN91.45-P-0001SR under field organization texts for DG 91. Front seats Number Designation Model 453 Model 453 with code 866 (Pre- except code 866 installation for iPad (Pre-installation for cradle) iPad cradle) BA91.10-P-1007-01K Nut, holder for seat belt guide to seat backrest Nm 6 6 Front seats Number Designation Model 453 Model 453 with code 866 (Pre- except code 866 installation for iPad (Pre-installation for cradle) iPad cradle) BA91.10-P-1008-01K Nut, seat belt guide to holder Nm 6 6 Front seats Number Designation Model 453 Model 453 with code 866 (Pre- except code 866 installation for iPad (Pre-installation for cradle) iPad cradle) BA91.10-P-1009-01K Bolt, cover to seat belt guide Nm 1 1 Page 2 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, an91.45-p-0001sr, Transfer seat belt guide Model 453.3/4

PE91.60-P-2055BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4082 · Applies to: 453 · AR: PE91.60-P-2055BBA

Actuate supplemental restraint system, electrical function schematic 11.05.2016 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) except code 494 (US version) Electrical function schematic for deployment of PE91.60-P-2055-97BBA supplemental restraint system Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe91.60-p-2055bba, Actuate supplemental restraint system, electrical function schematic Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) except code 494 (US version)

PE91.60-P-2055BBU

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4083 · Applies to: 453 · AR: PE91.60-P-2055BBU

Actuate supplemental restraint system, electrical function schematic 29.03.2016 Model 453.3 (except 453.391), 453.4 (except 453.491) with code 494 (US version) Electrical function schematic for deployment of PE91.60-P-2055-97BBU supplemental restraint system Use of electrical function schematics OV00.01-P-1901-09A Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, pe91.60-p-2055bbu, Actuate supplemental restraint system, electrical function schematic Model 453.3 (except 453.391), 453.4 (except 453.491) with code 494 (US version)

GF91.60-P-9996KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4084 · Applies to: 453 · AR: GF91.60-P-9996KJ

Overview of system components for supplemental restraint system 19.09.2016 Model 453.0/3/4 except code 494 (US version) P91.60-4698-79 Shown on model 453.0 with engine 281 (valid for all except model 453.091/391/491) A1 Instrument cluster N2/10 Supplemental restraint system control unit A1e9 Seat belt warning lamp N3/10 ME-SFI [ME] control unit A1e15 Supplemental restraint system indicator lamp N10/10 Center SAM control unit A45/1 Steering wheel clock spring contact N30/4 Electronic Stability Program control unit A53 Left sidebag sensor R12/3 Driver airbag squib A54 Right sidebag sensor R12/6 Left rear emergency tensioning retractor squib (model 453.0) A71 Front passenger airbag warning indicator R12/7 Right rear emergency tensioning retractor squib (model 453.0) A71e1 Front passenger airbag OFF indicator lamp R12/8 Front passenger airbag squib A71e2 Front passenger airbag ON indicator lamp R12/25 Driver kneebag squib (only with code 294 (Kneebag)) B41/1 Front passenger seat occupied recognition R12/39 Left front sidebag B48/7 Left front door pressure sensor R12/40 Right front sidebag B48/8 Right front door pressure sensor R12/53 Left front emergency tensioning retractor squib F2 Vehicle interior fuse and relay module R12/54 Right front emergency tensioning retractor squib F11k1 Engine function circuit 87 relay S2 Ignition lock F11K3 Ignition coils/fuel pump actuation relay S68/1 Left front seat belt buckle switch M3/3 Fuel pump with fill level sensor and temperature sensor S68/2 Right front seat belt buckle switch M14/5 Front passenger door central locking system actuator S68/11 Left rear seat belt buckle switch (model 453.0) M14/6 Driver door central locking system actuator S68/12 Right rear belt buckle switch (model 453.0) M14/7 Rear-end door central locking motor S68/15 Front passenger airbag shutoff switch M14/8 Left rear central locking actuator (model 453.0 only) T1/1 Cylinder 1 ignition coil M14/9 Right rear central locking actuator (model 453.0 only) T1/2 Cylinder 2 ignition coil M14/10 Tank cap central locking actuator T1/3 Cylinder 3 ignition coil Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, gf91.60-p-9996kj, Overview of system components for supplemental restraint system Model 453.0/3/4 except code 494 (US version)

GF91.60-P-9996KJU

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4087 · Applies to: 453 · AR: GF91.60-P-9996KJU

Overview of system components for supplemental restraint system 19.09.2016 Model 453.3/4 with code 494 (US version) P91.60-4832-79 Shown on model 453.3 with engine 281 (valid for all except model 453.391/491) 1 Front passenger seat occupied recognition seat mat N10/10 Center SAM control unit A1 Instrument cluster N30/4 Electronic Stability Program control unit A1e9 Seat belt warning lamp N110 Weight Sensing System (WSS) control unit A1e15 Supplemental restraint system indicator lamp R12/4 Front passenger airbag squib 1 A45/1 Steering wheel clock spring contact R12/5 Front passenger airbag squib 2 A53 Left sidebag sensor R12/13 Driver airbag squib 1 A54 Right sidebag sensor R12/14 Driver airbag squib 2 A71 Front passenger airbag warning indicator R12/22 Left windowbag squib A71e1 Front passenger airbag OFF indicator lamp R12/23 Right windowbag squib A71e2 Front passenger airbag ON indicator lamp R12/24 Front passenger kneebag squib B3 Left front seat position sensor R12/25 Driver kneebag squib B3/1 Right front seat position sensor R12/26 Right front belt force limiter B48/1 Left frontal acceleration sensor R12/27 Left front belt force limiter B48/2 Right frontal acceleration sensor R12/37 Left front belt fitting tensioner squib B48/7 Left front door pressure sensor R12/38 Right front belt fitting tensioner squib B48/8 Right front door pressure sensor R12/39 Left front sidebag F2 Vehicle interior fuse and relay module R12/40 Right front sidebag F11k1 Engine function circuit 87 relay R12/44 Front passenger airbag bleed valve squib F11k3 Ignition coils/fuel pump actuation relay R12/53 Left front emergency tensioning retractor squib M3/3 Fuel pump with fill level sensor and temperature sensor R12/54 Right front emergency tensioning retractor squib M14/5 Front passenger door central locking system actuator S2 Ignition lock M14/6 Driver door central locking system actuator S68/1 Left front seat belt buckle switch M14/7 Rear-end door central locking motor S68/2 Right front seat belt buckle switch M14/10 Tank cap central locking actuator T1/1 Cylinder 1 ignition coil N2/10 Supplemental restraint system control unit T1/2 Cylinder 2 ignition coil N3/10 ME-SFI [ME] control unit T1/3 Cylinder 3 ignition coil Page 1 of 3 © Mercedes-Benz AG, 5/21/18, L/07/20, gf91.60-p-9996kju, Overview of system components for supplemental restraint system Model 453.3/4 with code 494 (US version)

AR91.60-P-0681FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4092 · Applies to: 453 · AR: AR91.60-P-0681FF, AR68.10-P-1400FF

Remove/install airbag cutout switch 11.9.09 MODEL 454.0 P91.60-2748-09 1 Electrical connector S68/15 Front passenger airbag cutout switch Modification notes 3.8.09 Replace front passenger airbag cutout switch (S68/15) with Step 3 airbag unit deployed Remove/install

1 Remove glove compartment AR68.10-P-1400FF 2 Unclip catch hook of front passenger airbag cutout switch (S68/15) and remove front passenger airbag cutout switch (S68/15) toward the inside 3 Disconnect electrical connector (1) at front With the airbag unit deployed, the front passenger airbag cutout switch (S68/15) passenger airbag cutout switch (S68/15) must be replaced. 4 Install in the reverse order 5 Carry out function check Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.60-p-0681ff, Remove/install airbag cutout switch MODEL 454.0

AR91.60-P-0660FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4093 · Applies to: 453 · AR: AR91.60-P-0660FF, AR54.10-P-0003FF

Remove/install airbag unit on steering wheel 18.03.2019 Model 454.0 P91.60-2687-08 1 Steering wheel 3 Airbag unit 4 Electrical connector 2 Screw Remove/install

Risk of injury Warning caused by performing testing or Store airbag units with deployment side facing AS91.00-Z-0001-01A

repair work on airbag or emergency tensioning up; do not expose to temperatures greater retractor units. than 100 °C. When working on these units, disconnect the power supply. Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Legal requirements on handling and storing AH91.00-P-0004-01A airbags and emergency tensioning retractor units 1 Disconnect battery ground line AR54.10-P-0003FF 2 Remove screw (2) on left and right in rear area *BA91.60-P-1001-01D Torx bolt, airbag to steering wheel of steering wheel (1) up to end stop 3 Lift off airbag unit (3) until the electrical connector (4) is accessible 4 Lift yellow retainer of electrical connector (4)

using suitable tool and disconnect electrical Do not damage yellow retainer, connector (4) otherwise the electrical connector (4) will no longer be locked. Installation: Ensure that the electrical

connector (4) locks. 5 Remove airbag unit (3) When replacing the airbag unit (3), dispose

of it properly and in an environmentally- appropriate way. 6 Install in the reverse order 7 Read out fault memory AD00.00-P-2000-04FF

If necessary, rectify faults in control units.

STAR DIAGNOSIS diagnosis system

Airbag Number Designation Model 454.0 BA91.60-P-1001-01D Torx bolt, airbag to steering wheel Nm 9 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.60-p-0660ff, Remove/install airbag unit on steering wheel Model 454.0

AR91.60-P-0660SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4094 · Applies to: 453 · AR: AR91.60-P-0660SR, AR54.10-P-0003SR

Remove/install airbag unit on steering wheel 19.9.14 MODEL 453 P91.60-4722-07 1 Airbag unit on steering wheel 4 Steering wheel cover 2 Steering wheel 5 Electrical connector 3 Marking 6 Retaining clips Risk of injury Danger ! caused by performing testing or Store airbag units with deployment side facing AS91.00-Z-0001-01A

repair work on airbag or emergency tensioning up; do not expose to temperatures greater retractor units. than 100 °C. When working on these units, disconnect the power supply. Notes on performing repair, body work and AH91.00-P-0002-01M

welding on vehicles with airbags and RTE units Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Legal requirements on handling and storing AH91.00-P-0004-01A

airbags and emergency tensioning retractor units Assessment of airbag and belt tensioner units AH91.00-P-0006-01B

in accident vehicles Remove/install

1 Place steering column in the central height MODEL 453 position with CODE J37 (Steering column) 2 Disconnect ground line at the on-board AR54.10-P-0003SR electrical system battery 3 Insert suitable tool into opening at markings The opening at the markings (3) of the

(3) at left and right on steering wheel cover (4) steering wheel cover (4) must be pierced the and the push retaining clips (6) inward first time the airbag unit on the steering wheel (1) is removed. Installation: The retaining clips (6) of the

airbag unit on the steering wheel (1) must latch audibly into the steering wheel (2). 4 Remove airbag unit on steering wheel (1) far enough from steering wheel (2) until electrical connector (5) is accessible 5 Disconnect electrical connector (5) and If the airbag unit on the steering wheel (1)

remove airbag unit (1) from steering wheel (2) is replaced, the defective airbag unit (1) must be properly disposed of. 6 Install in the reverse order Check

7 Connect diagnostic unit and check supplemental restraint system (SRS) AD00.00-P-2000-06SR

Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar91.60-p-0660sr, Remove/install airbag unit on steering wheel MODEL 453

AR91.60-P-0623SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4095 · Applies to: 453 · AR: AR91.60-P-0623SR, AR68.20-P-2000SR, AR68.20-P-2340SR, AR54.10-P-0003SR

Remove/install airbag, sidebag and emergency tensioning retractor control unit 12.04.2016 Model 453 2 Bracket 3 Nut 4 Electrical connector 5 Electrical connector 6 Nut 7 Nut N2/10 Supplemental restraint system control unit P91.60-5087-06 Information on preventing damage to AH54.00-P-0001-01A

electronic components due to electrostatic discharge Information, assessment and legal AH91.00-Z-0000-10A

requirements when working with, handling and storing pyrotechnical components Remove/install

1 Perform initial startup of supplemental restraint When replacing supplemental restraint system system control unit (N2/10) control unit (N2/10). AD00.00-P-2000-06SR

2 Remove center console AR68.20-P-2000SR 3.1 Remove center mounting console Model 453 with code J58 (Center console with drawer) reinforcement Model 453 with code J59 (Center armrest) AR68.20-P-2340SR 3.2 Remove front part of center console above the Model 453 supplemental restraint system control unit with code J56 (Centre console) (N2/10) 4 Disconnect battery ground line AR54.10-P-0003SR 5 Unscrew nuts (3) 6 Remove bracket (2) 7 Disconnect electrical connectors (4, 5) and place outside of the working area 8 Unscrew nut (6) BA91.60-P-1015-01C Nut, restraint systems control unit to vehicle floor 9 Loosen nuts (7) until the supplemental BA91.60-P-1015-01C Nut, restraint systems control unit to restraint system control unit (N2/10) can be vehicle floor swiveled with the threaded pins of the nut (6) 10 Remove supplemental restraint system control unit (N2/10) 11 Install in the reverse order 12 Clear fault memory When reusing supplemental restraint system control unit (N2/10). AD00.00-P-2000-06SR

Airbag Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.60-p-0623sr, Remove/install airbag, sidebag and emergency tensioning retractor control unit Model 453

AR91.60-P-0200SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4097 · Applies to: 453 · AR: AR91.60-P-0200SR, AR54.10-P-0003SR, AR68.10-P-1500SR

Remove/install driver knee airbag 25.11.2019 Model 453 1 Driver kneebag 2 Cover below dashboard 8 Bolts R12/25 Driver kneebag squib P91.60-4702-06 Risk of injury Warning during testing and repair Do not expose pyrotechnical component parts AS91.00-Z-0008-01A

operations related to pyrotechnical to temperatures above 100 °C or 212 °F. components Disconnect current supply when working on such component parts. Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Information, assessment and legal AH91.00-Z-0000-10A requirements when working with, handling and storing pyrotechnical components Remove/install

1 Disconnect battery ground line AR54.10-P-0003SR 2 Remove left cover under instrument panel (2) AR68.10-P-1500SR with electrical lines connected and set down in footwell

Do not put electrical connector of driver kneebag squib (R12/25) under tension. Otherwise, damage may occur to the electrical connector of the driver kneebag squib (R12/25). Ensure that the driver kneebag (1) does

not fall. 3 Disconnect electrical connector at driver kneebag squib (R12/25) 4 Remove screws/bolts (8) and remove driver *BA91.60-P-1011-01C Bolt/nut, bracket to kneebag kneebag (1) from left cover under instrument panel (2) 5 Properly dispose of driver kneebag (1) When replacing driver kneebag (1). 6 Install in the reverse order Check

7 Check Supplemental Restraint System (SRS) When replacing driver kneebag (1). with diagnostic system AD00.00-P-2000-06SR

Airbag Number Designation Model 453.0 Model 453.3/4 BA91.60-P-1011-01C Bolt/nut, bracket to kneebag Nm 8 8 Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar91.60-p-0200sr, Remove/install driver knee airbag Model 453

AR91.60-P-0695FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4098 · Applies to: 453 · AR: AR91.60-P-0695FF, AR54.10-P-0003FF

Remove/install front seat sidebag unit 03.04.2019 Model 454.0 1 Nut 2 Side airbag unit 3 Electrical lines 4 Bracket 5 Lock 6 Backrest frame R12/20x1 Left front sidebag squib connector R12/21x1 Right front sidebag squib connector P91.60-2822-06 Remove/install

Risk of injury Warning caused by performing testing or Store airbag units with deployment side facing AS91.00-Z-0001-01A

repair work on airbag or emergency tensioning up; do not expose to temperatures greater retractor units. than 100 °C. When working on these units, disconnect the power supply. Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Legal requirements on handling and storing AH91.00-P-0004-01A airbags and emergency tensioning retractor units 1 Disconnect ground line of battery AR54.10-P-0003FF 2 Open zipper on outer cover of front seat AR91.18-P-1820-01FF backrest 454589013700 Pliers 3 Unscrew nut (1) BA91.60-P-1006-01D Nut, sidebag to backrest frame 4 Slide sidebag unit (2) downward and unhook Installation: Electric lines (3) must run

from seat backrest frame (6) between the holder (4) and sidebag unit (2). 5 Pull out lock (5) and disconnect connector coupling for front left side airbag squib (R12/20x1) or connector coupling for front right side airbag squib (R12/21x1) 6 Remove sidebag unit (2) Dispose of defective airbag unit and seat

belt tensioner properly and in an environmentally-appropriate way. 7 Install in the reverse order 8 Read out fault memory and delete errors AD00.00-P-2000-04FF

Airbag Number Designation Model 454.0 BA91.60-P-1006-01D Nut, sidebag to backrest frame Nm 6 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.60-p-0695ff, Remove/install front seat sidebag unit Model 454.0

AR91.60-P-0695SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4100 · Applies to: 453 · AR: AR91.60-P-0695SR, AR54.10-P-0003SR

Remove/install front seat sidebag unit 25.04.2018 Model 453 Shown on removed driver seat 1 Seat backrest 2 Backrest cover 3 Sidebag unit 7 Nuts 8 Ground cable 9 Electrical connector P91.60-4719-06 Risk of injury Warning during testing and repair Do not expose pyrotechnical component parts AS91.00-Z-0008-01A

operations related to pyrotechnical to temperatures above 100 °C or 212 °F. components Disconnect current supply when working on such component parts. Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Information, assessment and legal AH91.00-Z-0000-10A requirements when working with, handling and storing pyrotechnical components Remove/install

1 Move front seat and backrest (1) forward 2 Disconnect battery ground line AR54.10-P-0003SR 3 Unhook tabs for backrest cover (2) from backrest frame and under seat cushion 4 Loosen backrest cover (2) until nuts (7) are accessible 5 Unscrew nuts (7) and remove ground line (8) *BA91.60-P-1007-01C Nut, sidebag to backrest 6 Detach sidebag unit (3), as shown, from

backrest frame Do not tug on cover of sidebag unit (3). Otherwise, the cover of the sidebag unit (3) may become damaged. *110589035900 Mounting wedge 7 Disconnect Electrical connection (9) 8 Remove sidebag unit (3) 9 Dispose of sidebag unit (3) properly When replacing sidebag unit (3). 10 Install in the reverse order Check

11 Check Supplemental Restraint System (SRS) When replacing sidebag unit (3). with diagnostic system AD00.00-P-2000-06SR

Airbag Number Designation Model 453.0 Model 453.3/4 BA91.60-P-1007-01C Nut, sidebag to backrest Nm 7 7 Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.60-p-0695sr, Remove/install front seat sidebag unit Model 453

AR91.60-P-0680FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4102 · Applies to: 453 · AR: AR91.60-P-0680FF, AR68.10-P-1020FF, AR91.60-P-0681FF

Remove/install passenger airbag unit 18.03.2019 Model 454.0 Modification notes 03.08.2009 Replace switch for front passenger airbag actuation for Step 4 triggered airbag unit 1 Upper part of instrument panel 2 Airbag unit 3 Screw P91.60-2688-05 Remove/install

Risk of injury Warning caused by performing testing or Store airbag units with deployment side facing AS91.00-Z-0001-01A

repair work on airbag or emergency tensioning up; do not expose to temperatures greater retractor units. than 100 °C. When working on these units, disconnect the power supply. Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Legal requirements on handling and storing AH91.00-P-0004-01A airbags and emergency tensioning retractor units 1 Remove upper part of instrument panel (1) AR68.10-P-1020FF 2 Remove screws (3) of airbag unit (2) *BA91.60-P-1005-01D Torx bolt, front passenger airbag to instrument panel 3 Remove airbag unit (2) When replacing the airbag unit (2), dispose

of it properly and in an environmentally- appropriate way. 4 Replace front passenger airbag actuation For triggered airbag unit (2). switch AR91.60-P-0681FF 5 Install in the reverse order Airbag Number Designation Model 454.0 BA91.60-P-1005-01D Torx bolt, front passenger airbag to instrument panel Nm 3 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.60-p-0680ff, Remove/install passenger airbag unit Model 454.0

AR91.60-P-0680SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4103 · Applies to: 453 · AR: AR91.60-P-0680SR, AR54.10-P-0003SR, AR68.10-P-1000SR

Remove/install passenger airbag unit 25.04.2018 Model 453 1 Front passenger airbag 2 Instrument panel 12 Nuts P91.60-4707-11 Risk of injury Warning during testing and repair Do not expose pyrotechnical component parts AS91.00-Z-0008-01A

operations related to pyrotechnical to temperatures above 100 °C or 212 °F. components Disconnect current supply when working on such component parts. Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge Information, assessment and legal AH91.00-Z-0000-10A requirements when working with, handling and storing pyrotechnical components Remove/install

1 Disconnect battery ground line AR54.10-P-0003SR 2 Remove instrument panel (2) AR68.10-P-1000SR 3 Remove nuts (12) and remove front passenger *BA91.60-P-1004-01C Nut, front passenger airbag unit to airbag (1) from instrument panel instrument panel 4 Properly dispose of front passenger airbag (1) When replacing the front passenger airbag (1). 5 Install in the reverse order Check

6 Check Supplemental Restraint System (SRS) When replacing the front passenger airbag (1). with diagnostic system AD00.00-P-2000-06SR

Airbag Number Designation Model 453.0 Model 453.3/4 BA91.60-P-1004-01C Nut, front passenger airbag unit to instrument panel Nm 7 7 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.60-p-0680sr, Remove/install passenger airbag unit Model 453

AR91.60-P-0624FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4104 · Applies to: 453 · AR: AR91.60-P-0624FF, AR54.10-P-0003FF, AR68.30-P-4010FF

Remove/install restraint systems control unit 18.03.2019 Model 454.0 P91.60-2824-09 1 Cover 4 Door sill 7 Electrical connector 2 Screw 5 Floor covering N2/7 Restraint systems control unit 3 Cover 6 Release lever Remove/install

Risk of injury Warning caused by performing testing or Store airbag units with deployment side facing AS91.00-Z-0001-01A

repair work on airbag or emergency tensioning up; do not expose to temperatures greater retractor units. than 100 °C. When working on these units, disconnect the power supply. Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Topical note Information on preventing damage to AH54.00-P-0001-01A electronic components due to electrostatic discharge 1 Disconnect battery ground line AR54.10-P-0003FF 2 Remove paneling in right footwell AR68.30-P-4010FF 3 Move front seat to foremost position 4 Remove cover (1) toward rear Installation: Make sure that the cover (1)

is seated correctly. 5 Remove screw (2) 6 Move front seat to rearmost position 7 Remove trim (3) forward carefully Installation: Ensure that the trim (3) is

seated correctly. 8 Unclip and lift door sill (4) in front area Installation: Ensure that the door sill (4) is

seated correctly. 9 Turn floor covering (5) of front passenger footwell until the control unit of the restraint systems (N2/7) is accessible 10 Open release lever (6) and disconnect electrical connector (7) 11 Remove nuts from control unit of restraint Installation: The control unit of the

systems (N2/7) at body restraint systems (N2/7) must generally be replaced after an airbag deployment. 12 Install in the reverse order 13 Read out fault memory Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.60-p-0624ff, Remove/install restraint systems control unit Model 454.0

AR91.60-P-0720SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4106 · Applies to: 453 · AR: AR91.60-P-0720SR, AR91.10-P-3310SR

Remove/install seat occupancy recognition sensor 13.08.2014 MODEL 453 1 Seat frame B41/1 Front passenger seat occupied recognition P91.60-4723-06 Remove/install

1 Remove seat cushion from front passenger AR91.10-P-3310SR seat 2 Unclip electric subharness for front *452589016300 Clip remover passenger seat occupancy recognition (B41/1) from seat frame (1) (arrow A) 3 Unclip front passenger seat occupancy recognition (B41/1) from seat frame (1) (arrows B) and remove 4 Install in the reverse order 452 589 01 63 00 Clip remover Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar91.60-p-0720sr, Remove/install seat occupancy recognition sensor MODEL 453

AR91.60-P-0730FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4107 · Applies to: 453 · AR: AR91.60-P-0730FF, AR54.10-P-0003FF, AR68.30-P-4100FF

Remove/install sensor for sidebag/windowbag 6.6.03 MODEL 454.0 1 Connector 2 Nuts A53 Left side airbag sensor A54 Right side airbag sensor P91.60-2691-06 Remove/Install

1 Disconnect ground cable of battery AR54.10-P-0003FF 2 Removing left and right door sill molding AR68.30-P-4100FF 3 Unplug connector (1) 4 Unscrew nuts (2) *BA91.60-P-1003-01D

5 Remove left sidebag sensor (A53) and right Installation:

The arrows on the left sidebag sensor (A54) sidebag sensor (A53) and the right sidebag sensor (A54) must point outwards. 6 Install in the reverse order 7 Read out DTC memory Connect STAR DIAGNOSIS, interrogate fault AD00.00-P-2000-04FF

memory Diagnosis system STAR DIAGNOSIS *WH58.30-Z-1048-13A Airbag Number Designation Model 454.0 BA91.60-P-1003-01D Nut, lateral acceleration sensor to B-pillar Nm 8 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, ar91.60-p-0730ff, Remove/install sensor for sidebag/windowbag MODEL 454.0

AR91.60-P-0750FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4108 · Applies to: 453 · AR: AR91.60-P-0750FF, AR54.10-P-0003FF, AR88.00-P-1010FF

Removing and installing frontal acceleration sensor 23.9.03 MODEL 454.0 P91.60-2690-09 1 Bolts B48/1 Left frontal acceleration sensor B48/2 Right frontal acceleration sensor 2 Bolts Remove/Install

1 Disconnect ground cable of battery AR54.10-P-0003FF 2 Remove front CBS AR88.00-P-1010FF 3 Disconnect plugs on left frontal acceleration sensor (B48/1) and right frontal acceleration sensor (B48/2) 4 Unscrew screws (1) and screws (2) and Pay attention to installation position of left remove left frontal acceleration sensor frontal acceleration sensor (B48/1) and right (B48/1) and right frontal acceleration sensor frontal acceleration sensor (B48/2). (B48/2) *BA91.60-P-1002-01D

5 Install in the reverse order 6 Read out DTC memory Connect STAR DIAGNOSIS, interrogate fault AD00.00-P-2000-04FF

memory Diagnosis system STAR DIAGNOSIS *WH58.30-Z-1048-13A Airbag Number Designation Model 454.0 BA91.60-P-1002-01D Torx bolt, frontal acceleration sensor to front module Nm 7 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, ar91.60-p-0750ff, Removing and installing frontal acceleration sensor MODEL 454.0

AR91.60-P-0693FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4109 · Applies to: 453 · AR: AR91.60-P-0693FF, AR54.10-P-0003FF, AR68.30-P-4300FF

Removing, installing windowbag 18.03.2019 Model 454.0 with code I55 (Head airbag (FFO)) P91.60-2983-09 1 Bracket 5 Bracket 8 Screw 2 Bracket 6 Retaining strap 9 Lugs 3 Clip 7 Connector 10 Window airbag 4 Bracket Remove/install

Risk of injury Warning caused by performing testing or Store airbag units with deployment side facing AS91.00-Z-0001-01A

repair work on airbag or emergency tensioning up; do not expose to temperatures greater retractor units. than 100 °C. When working on these units, disconnect the power supply. Topical note Notes on self-locking nuts and bolts AH00.00-N-0001-01A Topical note Notes on performing repair, body work and AH91.00-P-0002-01M welding on vehicles with airbags and RTE units Legal requirements on handling and storing AH91.00-P-0004-01A airbags and emergency tensioning retractor units 1 Disconnect battery ground line AR54.10-P-0003FF 2 Remove headliner AR68.30-P-4300FF 3 Remove screws of brackets (1, 2) The brackets (1, 2) are each fastened with

three screws. Installation: After tightening the brackets

(1, 2), the shackles (9), for checking the correct assembly of the window airbag (10), are torn off. *BA91.60-P-1007-01D Bolt, windowbag to roof frame 4 Push window airbag (10) to side until the This causes damage to the window airbag

clamps (3) are accessible (10). 5 Bend shackle (arrow) of clamp (3) downwards using a suitable screwdriver and unclip clamp (3) 6 Turn retaining clips on check strap (6) by 90° The check strap (6) is fastened with two

and remove retaining clips retaining clips on the A-pillar. 7 Unhook end of check strap (6) from bore at A- Installation: Bend ends of check strap (6)

pillar together and insert into bore on A-pillar. Page 1 of 2 © Mercedes-Benz AG, 5/21/18, L/07/20, ar91.60-p-0693ff, Removing, installing windowbag Model 454.0 with code I55 (Head airbag (FFO))

GF91.60-P-0996KJ

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4112 · Applies to: 453 · AR: GF91.60-P-0996KJ, GF91.60-P-0003KJ, GF91.60-P-1100KJ, GF91.60-P-2012KJ, GF91.60-P-9996KJ

Table of contents for function description of supplemental restraint system 12.09.2016 function Model 453.0/3/4 except code 494 (US version) Supplemental restraint system function GF91.60-P-0003KJ Passenger-side seat occupied recognition GF91.60-P-1100KJ function Actuate supplemental restraint system, GF91.60-P-2012KJ function Overview of system components for GF91.60-P-9996KJ supplemental restraint system Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf91.60-p-0996kj, Table of contents for function description of supplemental restraint system function Model 453.0/3/4 except code 494 (US version)

GF91.60-P-0996KJU

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4113 · Applies to: 453 · AR: GF91.60-P-0996KJU, GF91.60-P-0003KJU, GF91.60-P-1100KJU, GF91.60-P-2012KJU, GF91.60-P-9996KJU

Table of contents for function description of supplemental restraint system 12.09.2016 function Model 453.3/4 with code 494 (US version) Supplemental restraint system function GF91.60-P-0003KJU Passenger-side seat occupied recognition GF91.60-P-1100KJU function Actuate supplemental restraint system, GF91.60-P-2012KJU function Overview of system components for GF91.60-P-9996KJU supplemental restraint system Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, gf91.60-p-0996kju, Table of contents for function description of supplemental restraint system function Model 453.3/4 with code 494 (US version)

PE91.60-P-2105BBA

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4126 · Applies to: 453 · AR: PE91.60-P-2105BBA, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram for airbag control unit 12.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 BB plug Wiring diagram for airbag control unit PE91.60-P-2105-97BBA 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, pe91.60-p-2105bba, Wiring diagram for airbag control unit Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 BB plug

PE91.60-P-2105BBB

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4127 · Applies to: 453 · AR: PE91.60-P-2105BBB, GF00.19-P-1000BBA, GF00.19-P-2000BBA, GF00.19-P-3000BBA, OV00.01-P-1909BBA (+1 more)

Wiring diagram for airbag control unit 12.08.2019 Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 BA-BC plug Wiring diagram for airbag control unit PE91.60-P-2105-97BBB 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, pe91.60-p-2105bbb, Wiring diagram for airbag control unit Model 453.0 (except 453.091), 453.3 (except 453.391), 453.4 (except 453.491) up to model year 2020 BA-BC plug

AR97.10-P-4000FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4131 · Applies to: 453 · AR: AR97.10-P-4000FF, AR97.20-P-1500FF

Seam sealing following repair 29.04.2019 Model 454.0 Picture no., etc. Work notes Risk of explosion Danger and poisoning caused by Never spray corrosion protection on flames or AS97.00-Z-0001-01A

solvent vapors and gasses. Risk of injury to hot, glowing objects and keep them well away skin and eyes when working with anticorrosion from all potential sources of ignition. Use them agents only in well-ventilated rooms; wear respiratory protection. Topical note Underfloor preservation AH97.20-P-2000-01A Topical note Notes on sprayable joint sealant AH97.10-P-0002-01A Cavity preservation following repair work AR97.20-P-1500FF

Processing of body sealant (paintable) before AR97.10-P-0500-02FF

painting Seam sealing following repair, front end AR97.10-P-4000-01FF

damage Seam sealing following repair, rear end AR97.10-P-4000-02FF

damage Seam sealing following repair, side damage AR97.10-P-4000-03FF

Seam sealing following repair, detachable AR97.10-P-4000-04FF

body components Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar97.10-p-4000ff, Seam sealing following repair Model 454.0

AR97.10-P-4000SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4132 · Applies to: 453 · AR: AR97.10-P-4000SR

Seam sealing following repair 18.04.2019 Model 453 Risk of explosion Danger and poisoning caused by Never spray corrosion protection on flames or AS97.00-Z-0001-01A

solvent vapors and gasses. Risk of injury to hot, glowing objects and keep them well away skin and eyes when working with anticorrosion from all potential sources of ignition. Use them agents only in well-ventilated rooms; wear respiratory protection. Topical note Notes on sprayable joint sealant AH97.10-P-0002-01A Notes on seam seal AH97.10-P-0003-01A Seal 1 Perform seam sealing after repair In the event of front end damage AR97.10-P-4000-01SR In the event of rear end damage AR97.10-P-4000-02SR In the event of side damage AR97.10-P-4000-03SR In the event of roof damage AR97.10-P-4000-05SR Seam sealant, sprayable 310 ml BR00.45-Z-1041-01A White sealing compound, 310 ml, DBL BR00.45-Z-1003-01A 6069.20 Repair materials Number Designation Order number BR00.45-Z-1003-01A White sealing compound, 310 ml, DBL 6069.20 A 001 989 63 20 BR00.45-Z-1041-01A Seam sealant, sprayable 310 ml A 002 989 84 20 Page 1 of 1 © Mercedes-Benz AG, 5/22/18, L/07/20, ar97.10-p-4000sr, Seam sealing following repair Model 453

AR97.20-P-1500FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4133 · Applies to: 453 · AR: AR97.20-P-1500FF

Cavity preservation following repair work 24.09.2019 Model 450.3/4, 451.3/4, 452.3/4, 454.0 Risk of explosion Danger and poisoning caused by Never spray corrosion protection on flames or AS97.00-Z-0001-01A

solvent vapors and gasses. Risk of injury to hot, glowing objects and keep them well away skin and eyes when working with anticorrosion from all potential sources of ignition. Use them agents only in well-ventilated rooms; wear respiratory protection. Topical note Notes on cavity preservation AH97.20-P-0001-01B 1 Perform repair preservation Processing instructions for cavity preservation AP97.20-P-0640-01SM

agent Apply cavity sealant only after sealing and

painting work are completed – but before assembly work – from the inside in the repair area . The processing temperature should not be lower than 15 °C. Carry out cavity preservation twice successively with a flash-off time of 5 min between the processes. The spraying hose should be stiff and the

nozzles should spray at angle to the front and rear. The cavities should be dry. Insert the spray hose as far as possible

into the cavities. Spray while inserting and pulling out slowly. 2 Remove cavity sealant from drain holes Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar97.20-p-1500ff, Cavity preservation following repair work Model 450.3/4, 451.3/4, 452.3/4, 454.0

AR97.20-P-1500SR

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4134 · Applies to: 453 · AR: AR97.20-P-1500SR

Cavity preservation following repair work 09.03.2020 Model 453 Shown on model 453.3, front longitudinal member P97.20-2675-05 P97.20-2680-09 Shown on model 453.0, upper front longitudinal member, A-pillar, B-pillar, C-pillar, side wall paneling and bottom side longitudinal member Page 1 of 4 © Mercedes-Benz AG, 5/22/18, L/07/20, ar97.20-p-1500sr, Cavity preservation following repair work Model 453

AP97.20-P-0640FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4138 · Applies to: 453 · AR: AP97.20-P-0640FF, AR97.10-P-4000SM, AR97.10-P-4000RR, AR97.10-P-4000FF, AR97.20-P-1500FF

Preservation 17.04.2019 Model 450, 452, 454 Application 1 Apply seam seal Model 450 AR97.10-P-4000SM

Model 452 AR97.10-P-4000RR

Model 454 AR97.10-P-4000FF

2 Apply hollow cavity preservation AR97.20-P-1500FF

Shake or stir cavity sealant thoroughly

before use. 3 Attach underbody preservation Topical note Instructions for processing permanent AH97.20-P-9409-01A underbody protection Topical note Underfloor preservation AH97.20-P-2000-01A AR97.20-P-0500-03FF

Brake parts such as brake disks and brake hoses must be appropriately covered during corrosion protection work on the underbody, to avoid spraying and subsequent time- consuming cleaning. 4 Remove wax fog residues on outer surface with silicon remover 5 Treat outer surface with polish and gloss Polish, silicone-free 5 l, DB supply BR00.45-Z-1013-04A preservation agent specification 7545.00 Gloss preservation, 500 ml, DB supply BR00.45-Z-1014-04A specification 7551.10 Repair materials Number Designation Order number BR00.45-Z-1013-04A Polish, silicone-free 5 l, DB supply specification 7545.00 A 000 986 45 74 BR00.45-Z-1014-04A Gloss preservation, 500 ml, DB supply specification 7551.10 A 000 986 44 74 Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ap97.20-p-0640ff, Preservation Model 450, 452, 454

AR97.20-P-0500FF

2014-2024 Smart Fortwo 453 Workshop Manual.pdf · p. 4139 · Applies to: 453 · AR: AR97.20-P-0500FF

Processing corrosion protection materials before painting 29.04.2019 Model 450, 451, 452, 454 Application 1 Apply anti-corrosion materials in the repair Processing zinc dust paint before painting AR97.20-P-0500-01FF areas Topical note Instructions for processing permanent AH97.20-P-9409-01A underbody protection Processing of body sealant (paintable) before AR97.10-P-0500-02FF painting Processing permanent underbody protection AR97.20-P-0500-03FF for painting Page 1 of 1 © Mercedes-Benz AG, 5/21/18, L/07/20, ar97.20-p-0500ff, Processing corrosion protection materials before painting Model 450, 451, 452, 454