2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf

359 excerpts.

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 716 · Applies to: 450, 451, 452, 454 · AR: AR88.10-P-1400MCC, AR88.10-P-1400MCU, AR88.20-P-1900MCC, AR01.00-P-3050MCC, AR01.00-P-3050MCU (+2 more)

1 Remove fender liner in the left and right rear fender * not for USA AR88.10-P-1400MCC

• for USA only AR88.10-P-1400MCU 2 Remove rear CBS

AR88.20-P-1900MCC 3 Release rear drive module * not for USA AR01.00-P-3050MCC

• for USA only AR01.00-P-3050MCU 4 Remove intake camshaft and exhaust camshaft

• not for USA AR05.20-P-6992MCC

• for USA only AR05.20-P-6992MCU 5.1 Remove starter Model 451.3/4 (except

Fig 2: Identifying Valve Spring, Retainer, Collet And Special Tools Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Replacing Valve Stem Seal Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Unscrew bolts (1) and remove bracket (2)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 951 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2000MCU

3 Unscrew bolts (1) and remove bracket (2)

4 Guide rear-end door CL motor (M14/7) upward, unhook Bowden cable (5) or connection piece (4) on rear-end door CL motor (M14/7) and remove rear-end door CL motor (M14/7)

5 Install in the reverse order

6 Check rear-end door CL motor (M14/7) for proper function

TESTING & REPAIR INDEX > REMOVE/INSTALL TRANSPONDER COIL - AR80.35-P- 4515MCU > MODEL 451.3 /4

Remove/install

1 Remove center console

AR68.20-P-2000MCU 2 Disconnect electrical connector (1) from transponder coil (L11)

3 Unclip transponder coil (L11) and remove upward

4 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL MICROWAVE SENSOR - AR80.50-P- 1100MCU > MODEL 451.3 /4 with CODE (V01) Antitheft alarm system (FFO) Shown on model 451.4 Fig 1: Identifying Transponder Coil And Electrical Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

* for USA only

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 999 · Applies to: 450, 451, 452, 454 · AR: AR68.40-P-0001MCU, AR68.30-P-4450MCC, AR68.30-P-4450MCU, AR68.30-P-4450MCO, AR68.30-P-4450MCV (+4 more)

AR68.40-P-0001MCU 4 Remove front roof frame paneling Model 451.3 not for USA AR68.30-P-4450MCC Model 451.3 for USA only AR68.30-P-4450MCU Model 451.4 not for USA AR68.30-P-4450MCO Model 451.4 for USA only AR68.30-P-4450MCV 5 Remove longitudinal member panels

AR88.80-P-6000MCC 6 Remove front CBS

AR88.00-P-1010MCC 7 Remove left front headlamp unit * not for USA AR82.10-P-4730MCC * for USA only AR82.10-P-4730MCU Install

8 Prepare longitudinal member panel for installation of BRABUS longitudinal member panel illumination On vehicles without BRABUS longitudinal member panel AN82.10-P-0008- 01MCC Graduated drillHand drill gotis://G_58.0_00.1 450589002800 On vehicles with BRABUS longitudinal member panel AN82.10-P-0008- 01MCB Graduated drillHand drill gotis://G_58.0_00.1 450589002800 9 Retrofit BRABUS longitudinal member panel lamp unit (3) Ensure that the wiring harnesses are not damaged by chafing or being trapped otherwise the appropriate wiring harness must be replaced. AN82.10-P-0008- 03MCC 10 Retrofit BRABUS longitudinal member panel illumination wiring harness Ensure that the wiring harnesses are not damaged by chafing or being trapped otherwise the appropriate wiring harness must be replaced. AN82.10-P-0008- 02MCC 11 Install remaining parts When installing longitudinal member panels, connect wiring harness of lamp units (3) with wiring harness (6).

12 Perform function test of BRABUS longitudinal member panel illumination The following functions must be present: Vehicle is unlocked: Lamp units (3) light up.

MODEL 451.3/4

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1033 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1010MCC, AP82.10-P-8260MCU, AR82.10-P-4905MCC

Remove/install

1 Remove front CBS AR88.00-P-1010MCC 2 Disconnect electrical connector (1) from left front lamp unit (E1) or right front lamp unit (E2)

3 Disconnect electrical connector (2) from left standing light or right standing light

4 Remove bolts (3) from left front lamp unit (E1) or right front lamp unit (E2)

5 Remove left front lamp unit (E1) and right front lamp unit (E2)

6 Install in the reverse order

7 Check adjustment of left front lamp unit (E1) or right front lamp unit (E2) and correct if necessary

Check and correct the adjustment of the headlamps AP82.10-P-8260MCU TESTING & REPAIR > REMOVE/INSTALL TAILLAMP - AR82.10-P-4905MCC > MODEL 451.3/4 Fig 1: Identifying Front Headlamp Units, Electrical Connectors And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Modification Notes

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1051 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2350MCC, AR68.20-P-2350MCF, AR68.10-P-1620MCC

13.1.11 Information on required radio code on vehicles with code (527) High-Line radio, added

Adaptation of audio settings added Operation step 10

Remove/install

The work procedure is described for the smart Radio 9 (A2/1) (with code (C57) smart radio 9). The removal/installation for the other equipment variants is done in the same manner, with the exception of the denoted deviations.

1 Remove transponder key and refueling and parking card from the smart radio car2go In vehicles with code)P02) car2go

2 Remove cover (1) on center console Vehicles up to 30.8.10 and vehicles with code (P02) car2go with an instrument panel up to production date 30.8.10 AR68.20-P-2350MCC Vehicles as of 31.8.10 without code (P02) car2go AR68.20-P-2350MCF 3 Remove center stowage compartment. In vehicles as of 31.8.10 with code (516) RADIO AR68.10-P-1620MCC Fig 1: Identifying Smart Radio 9 (with code (C57)) Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

system 2

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1096 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4050MCC, AR68.30-P-4050MCU, AR68.30-P-4450MCC, AR68.30-P-4450MCU, AR68.30-P-4450MCO (+2 more)

9 Install trim at right A-pillar * not for USA AR68.30-P-4050MCC * for USA only AR68.30-P-4050MCU 10 Install front roof frame paneling Model 451.3

• not for USA AR68.30-P-4450MCC

• for USA only AR68.30-P-4450MCU Model 451.4

• not for USA AR68.30-P-4450MCO

• for USA only AR68.30-P-4450MCV 11 Retrofit footwell ambiance illumination (2) and footwell entrance illumination (3)

AZ82.20-P-0010- 02MCC 12 Connect ground cable to battery

AR54.10-P-0003MCC 13 Perform function test of ambiance illumination When opening a front door, footwell entrance illumination (3) lights up.With circuit 58 On, footwell ambiance illumination (2) and inside rearview mirror ambiance illumination (1) light up.

Fig 2: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Parts scope for external USB connector connecting point (X115) and external audio source

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1104 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2350MCF, AR68.10-P-1502MCC, AR68.10-P-1502MCU

connecting point (X39/45) Remove

1 Remove center console cover (1)

AR68.20-P-2350MCF 2 Remove radio recess cover (2) The radio recess cover (2) is screwed down with four screws/bolts.

3 Remove cable tie (4) and expose smart Entry radio wiring harness (3)

4 Remove dashboard bottom section on passenger side (9) Only if the wiring harness (8) is to be installed with the external USB connector connecting point (X115) and external audio source connecting point (X39/45).

• not for USA AR68.10-P-1502MCC
• for USA only AR68.10-P-1502MCU Install

5 Insert wiring harness (8) with the external connector connecting point (X115) and the external audio source connecting point (X39/45) into the cutout at the passenger-side instrument panel lower section (9) and install the passenger-side instrument panel lower Only if the wiring harness (8) is to be installed with the external USB connector connecting point (X115) and external audio source connecting point (X39/45). Route the wiring harness (8) with the external USB connector connecting point (X115) and the external

Fig 3: Identifying External USB Connector Connecting Point, Glove Compartment And Wiring Harness Courtesy of MERCEDES BENZ OF NORTH AMERICA

section (9)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1105 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1502MCC, AR68.10-P-1502MCU, AR82.60-P-7502MCC, AR82.60-P-7502MCU, AR68.20-P-2350MCF (+1 more)

audio source connecting point (X39/45) in the slot of the smart Entry radio (A2/3).If a glove box (10) is also to be installed in the course of retrofitting the wiring harness (8), a different passenger-side instrument panel lower section (9) must be installed. * not for USA AR68.10-P-1502MCC * for USA only AR68.10-P-1502MCU 6 Install smart Entry radio (A2/3) and center stowage compartment (6) * not for USA AR82.60-P-7502MCC * for USA only AR82.60-P-7502MCU 7 Install center console cover (7)

AR68.20-P-2350MCF 8 Connect Star Diagnosis

AD00.00-P-2000- 04MCC 9 Enter special equipment on the vehicle data card and the online vehicle data card Add code (516) RADIO WITH USB INTERFACE.

10 Disconnect Star Diagnosis

AD00.00-P-2000- 04MCC 11 Document retrofitted equipment using vehicle documentation (VeDoc) Attach note "smart Entry radio (A2/3) retrofitted as per AZ82.60-P-0003MCD " as well as serial number of smart Entry radio (A2/3) under field organization texts to design group 82.

PARTS ORDERING NOTES Part no. Designation Quantity

smart Entry radio retrofit scope

DG 82 (see EPC) smart Entry radio 1 DG 82 (see EPC) Operator's manual for smart Entry radio 1 DG 68 (see EPC) Center console cover 1 DG 68 (see EPC) Center stowage compartment 1

Also for retrofitting external USB connector connecting point and external audio source connecting point

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1138 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1040MCU, AR68.20-P-2000MCU

1 Remove dashboard bottom section (2) and place onto a suitable base

AR68.10-P-1040MCU 2 Remove center console (4) and place onto a suitable base

AR68.20-P-2000MCU 3 Unclip coin holder (13) from center console (4) and remove. in case of model 451.3

Install

4 Cut template (1) included in delivery contents along broken lines (arrows A, B)

5 Position template (1), as illustrated, on dashboard bottom section (2) and fix in position using suitable adhesive tape (3)

6 Place dashboard bottom section (2) on a suitable wooden support and align

7 Drill holes (6) with a diameter of Rechargeable drill /

Fig 2: Identifying Telephone Console Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

12 mm to match the markings

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1139 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1040MCU, AR68.20-P-2000MCU, AR77.39-P-1000MCU

(arrows C) screwdriver gotis://G_58.0_01.1 8 Remove template (1)

9 Install dashboard bottom section (2)

AR68.10-P-1040MCU 10 Install cockpit switch group

AR54.25-P- 1000MCC 11 Install vertical strut paneling

AR68.00-P- 1500MCC 12 Drill a hole (5) with a diameter of 37 mm in the marked area (arrow D) on the right side of the center console (4). The marking (arrow D) is embossed into the center console (4).

Graduated drillRechargeable drill / screwdriver gotis://G_58.0_01.1 *450589002800 13 Install center console (4)

AR68.20-P-2000MCU 14 Position console top section (9) on console bottom section (10) and tighten with bolts (11)

15 Insert rubber guide (7) into holes (6) in dashboard bottom section (2) Observe installation position.

16 Insert telephone console (12) into rubber guide (7) and clip into hole (5) on center console (4).

17 Clip cover (8) into telephone console (12) Counterhold center console (4) from behind through the opening of coin holder (13) or power soft top switch.

18.1 Clip coin holder (13) into center console (4) in case of model 451.3

18.2 Install power soft top switch On model 451.4 AR77.39-P-1000MCU 19 Add special equipment to the vehicle data card and to the online vehicle data card Enter code (C10) Telephone console (DFO).

* for USA only

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1153 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4450MCV, AR82.60-P-7502MCC, AR82.60-P-7502MCU, AR68.20-P-2350MCC, AR68.20-P-2350MCF

AR68.30-P-4450MCV 8 Retrofit iPhone-kit mount (1) on the cover of the center console (2) Vehicles as of 31.8.10Rechargeable drill / screwdriver gotis://G 58.0 01.1 AZ82.70-P-0013- 04MCD 9 Install smart radio 9 (A2/1), smart radio 10 (A2/2) or smart Entry radio Do not install the cover of the center console (2) yet.

• not for USA AR82.60-P-7502MCC
• for USA only AR82.60-P-7502MCU 10 Retrofit iPhone-kit mount (1) on the cover of the center console (2) Vehicles up to 30.8.10Rechargeable drill / screwdriver gotis://G_58.0_01.1 AZ82.70-P-0013- 04MCC 11 Install center console cover (2) Ensure that the wiring harness of the iPhone kit mount (1) is not damaged by crushing upon installation of the center console cover (2).

Vehicles up to 30.8.10 AR68.20-P-2350MCC Vehicles as of 31.8.10 AR68.20-P-2350MCF 12 Tighten center console cover (2) with the screw/bolt (4) contained in the delivery contents and attach cover (3) Vehicles as of 31.8.10

13 Perform function test by means of a telephone conversation using one iPhone The "smart App" does not have to be installed for the function test of the iPhone kit.Insert iPhone into the iPhone kit fixture (1) as explained in the operating instructions. On vehicles as of 31.8.10, the external audio source connecting point (X39/45) installed as standard is no longer available.

14 Perform commissioning of the iPhone kit with the customer and his/her iPhone Only on customer request. Install Bluetooth connection and "smart app" in accordance with the provided operator's manual.

PARTS ORDERING NOTES Part no. Designation Quantity

Parts scope for external USB connector connecting point (X115) and external audio source

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1155 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2350MCF

connecting point (X39/45) Remove

1 Remove center console cover (1)

AR68.20-P-2350MCF 2 Remove radio recess cover (2) The radio recess cover (2) is screwed down with four screws/bolts.

Fig 2: Identifying Operating Instructions, Smart Premium Radio And GPS Antenna Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Wiring Harness, Dashboard Lower Section On Passenger Side And Glove Compartment Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove cable tie (4) and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1156 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1502MCC, AR68.10-P-1502MCU, AR82.85-P-0002MCC, AR82.60-P-7502MCC, AR82.60-P-7502MCU (+1 more)

3 Remove cable tie (4) and expose smart Entry radio wiring harness (3)

4 Remove dashboard bottom section on passenger side (9) Only if the wiring harness (8) is to be installed with the external USB connector connecting point (X115) and external audio source connecting point (X39/45).

• not for USA AR68.10-P-1502MCC
• for USA only AR68.10-P-1502MCU Install

5 Insert wiring harness (8) with the external connector connecting point (X115) and the external audio source connecting point (X39/45) into the cutout at the passenger- side instrument panel lower section (9) and install the passenger-side instrument panel lower section (9) Only if the wiring harness (8) is to be installed with the external USB connector connecting point (X115) and external audio source connecting point (X39/45). Route the wiring harness (8) with the external USB connector connecting point (X115) and the external audio source connecting point (X39/45) in the slot of the smart Premium radio (A2/4).If a glove box (10) is also to be installed in the course of retrofitting the wiring harness (8), a different passenger-side instrument panel lower section (9) must be installed.

• not for USA AR68.10-P-1502MCC
• for USA only AR68.10-P-1502MCU 6 Install GPS antenna (A2/23)

AR82.85-P-0002MCC 7 Install smart Premium radio (A2/4) * not for USA AR82.60-P-7502MCC * for USA only AR82.60-P-7502MCU 8 Install center console cover (1)

AR68.20-P-2350MCF 9 Connect Star Diagnosis

AD00.00-P-2000- 04MCC 10 Enter special equipment on the vehicle data card and the online vehicle data card Add code (527) High- Line radio.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1306 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1010MCC, AP82.10-P-8260MCU, AR82.10-P-4905MCC

1 Remove front CBS AR88.00-P-1010MCC 2 Disconnect electrical connector (1) from left front lamp unit (E1) or right front lamp unit (E2)

3 Disconnect electrical connector (2) from left standing light or right standing light

4 Remove bolts (3) from left front lamp unit (E1) or right front lamp unit (E2)

5 Remove left front lamp unit (E1) and right front lamp unit (E2)

6 Install in the reverse order

7 Check adjustment of left front lamp unit (E1) or right front lamp unit (E2) and correct if necessary

Check and correct the adjustment of the headlamps AP82.10-P-8260MCU TESTING & REPAIR > REMOVE/INSTALL TAILLAMP - AR82.10-P-4905MCC > MODEL 451.3/4 Fig 1: Identifying Left/Right Front Headlamps Unit, Electrical Connectors And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1307 · Applies to: 450, 451, 452, 454 · AR: AR88.20-P-1900MCC, AR82.10-P-5103MCU

1 Remove CBS rear end (1) AR88.20-P-1900MCC 2 Detach retaining clip in marked area (arrows A) from CBS rear end (1)

3 Carefully fold down left taillamp (E3) or right taillamp (E4), detach from bracket (arrows B) and remove

4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL FOG LAMP - AR82.10-P-5103MCU > MODEL 451.3/4 with CODE (V07) Front fog lamps (FFO) Fig 1: Identifying Left/Right Taillamps And CBS Rear End Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

side with connected hoses (3,

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1322 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-2792MCC

4) correctly seated on washer fluid reservoir (1). 7 Take off washer fluid reservoir (1)

8 Detach hose (3) from windshield washer fluid pump (M5/1) On model 451.3

9 Detach hose (4) from windshield washer fluid pump (M5/1) and remove windshield washer fluid pump (M5/1)

10 Install in the reverse order

11 Fill washer fluid reservoir (1)

Windshield washer system - inspect fluid level, adjust to correct level AP82.35- P- 8210MCC 12 Perform tightness check of washer fluid reservoir (1)

13 Perform function check of windshield washer system

TESTING & REPAIR > REMOVE/INSTALL WINDSHIELD WASHER NOZZLE - AR82.35-P- 6970MCC > MODEL 451.3 /4

Remove/install

1 Remove paneling (1) from center piece in front of windshield AR88.00-P-2792MCC 2 Carefully unclip windshield washer nozzle (2) from paneling (1) from the rear using suitable pliers and take off

Fig 1: Identifying Windshield Washer Nozzle And Trim Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

RADIO WITH USB INTERFACE with CODE (527) High-Line radio

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1326 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2350MCC, AR68.20-P-2350MCF, AR68.10-P-1620MCC

Shown on vehicle with code (C57) smart radio 9

Remove/install

The work procedure is described for the smart Radio 9 (A2/1) (with code (C57) mart radio 9). The removal/installation for the other equipment variants is done in the same manner, with the exception of the denoted deviations.

1 Remove cover (1) on center console Vehicles up to 30.8.10 AR68.20-P-2350MCC Vehicles as of 31.8.10 AR68.20-P-2350MCF 2 Remove center stowage compartment. For vehicles with code (516) RADIO WITH USB INTERFACE AR68.10-P-1620MCC 3 Remove screws (2) from smart radio 9 (A2/1) With code (516) RADIO WITH USB INTERFACE the radio is only screwed on using two screws (2).Rechargeable drill / screwdriver

4 Pull smart radio 9 (A2/1) out of radio recess until electrical connectors (3) and antenna plug (4) are With code (516) RADIO WITH USB INTERFACE the radio is fixed in the upper area into two side brackets.

Fig 1: Identifying Radio Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

(2 tweeters, 2 bass

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1373 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4050MCC, AR68.30-P-4050MCU, AR68.30-P-4450MCC, AR68.30-P-4450MCU, AR68.30-P-4450MCO (+2 more)

reflex boxes and diplexers) (FFO) or with code (C54) Sound system 2 9 Install trim at right A- pillar * not for USA AR68.30-P-4050MCC * for USA only AR68.30-P-4050MCU 10 Install front roof frame paneling Model 451.3

• not for USA AR68.30-P-4450MCC

• for USA only AR68.30-P-4450MCU Model 451.4

• not for USA AR68.30-P-4450MCO

• for USA only AR68.30-P-4450MCV 11 Retrofit footwell ambiance illumination (2) and footwell entrance illumination (3)

AZ82.20-P-0010- 02MCC 12 Connect ground cable to battery

AR54.10-P-0003MCC 13 Perform function test of ambiance illumination When opening a front door, footwell entrance illumination (3) lights up.With circuit 58 On, footwell ambiance illumination (2) and inside rearview mirror ambiance illumination (1) light up.

Fig 2: Identifying Wiring Harness Repair Kit, Basic (000 589 13 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1379 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1620MCC, AR68.20-P-2350MCC, AZ82.60-P-0003MCD

1 Remove center stowage compartment.

AR68.10-P-1620MCC Install

2 Connect electrical connectors (1) and antenna plug (2) to smart radio 9 (A2/1) or smart radio 10 (A2/2)

3 Insert smart radio 9 (A2/1) or smart radio 10 (A2/2) into radio recess

4 Tighten bolts (5) of smart radio 9 (A2/1) or smart radio 10 (A2/2) Cordless drill/driver

5 Fit cover (4) onto center console

AR68.20-P-2350MCC 6 Perform function test of smart radio 9 (A2/1) or smart radio 10 (A2/2)

7 Add special equipment to the vehicle data card and to the online vehicle data card Enter code (C50) smart radio 10 or code (C57) smart radio 9.

RETROFITTING & CONVERSION > RETROFIT RADIO - AZ82.60-P-0003MCD > MODEL 451.3 /4 as of 31.8.10 with CODE (C08) Radio preinstallation incl. rod antenna (FFO) Fig 1: Identifying Smart Radio Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1387 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC

1 Move seats to the rear

2 Remove door paneling from front doors

AR72.18-P-1000MCC Fig 1: Identifying Left/Right Front Speaker, Inner Door Foil, Electrical Connector And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Left/Right Tweeter, Dashboard Top Section And Socket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Carefully cut into inner door foil

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1388 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC, AZ82.62-P-0004MCC

3 Carefully cut into inner door foil (3) with a knife in marked area (arrow) until installation location of left front speaker (H4/9) and right front speaker (H4/10) is accessible

Install

4 Position left front speaker (H4/9) and right front speaker (H4/10) at the respective front door and tighten with the bolts (5)

5 Connect electrical connector (4) to left front speaker (H4/9) and right front peaker (H4/10)

6 Align inner door foil (3) and reseal using a suitable adhesive fabric tape (6)

7 Install door paneling

AR72.18-P-1000MCC 8 Place left tweeter (H4/33) and right tweeter (H4/34) into footwell and connect electrical connector

9 Insert left tweeter (H4/33) and right tweeter (H4/34) from below into bracket (2) on upper section of dashboard (1) The left tweeter (H4/33) and the right tweeter (H4/34) must latch audibly in the bracket (2).

10 Return seats to their starting position

11 Add special equipment to the vehicle data card and to the online vehicle data card Add code (C17) Sound package (2 tweeters, 2 bass reflex boxes and diplexer) (FFO).

RETROFITTING & CONVERSION > RETROFIT SUBWOOFER - AZ82.62-P-0004MCC > MODEL 451.3 /4 except CODE (P02) car2go with CODE (C08) Radio preinstallation incl. rod antenna (FFO) MODEL 451.3 /4 up to 30.8.10 with CODE (C50) smart radio 10 MODEL 451.3 /4 up to 30.8.10 with CODE (C57) smart radio 9 MODEL 451.3 /4 as of 31.8.10 except CODE (P02) car2go with CODE (516) RADIO WITH USB INTERFACE MODEL 451.3 /4 as of 31.8.10 except CODE (P02) car2go with CODE (527) High-Line radio

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1415 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1040MCU, AR68.20-P-2000MCU

1 Remove dashboard bottom section (2) and place onto a suitable base

AR68.10-P-1040MCU 2 Remove center console (4) and place onto a suitable base

AR68.20-P-2000MCU 3 Unclip coin holder (13) from center console (4) and remove. in case of model 451.3

Install

4 Cut template (1) included in delivery contents along broken lines (arrows A, B)

5 Position template (1), as illustrated, on dashboard bottom section (2) and fix in position using suitable adhesive tape (3)

Fig 2: Identifying Telephone Console Sections (Shown On Model 451.3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Place dashboard

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1416 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1040MCU, AR54.25-P-1000MCC, AR68.00-P-1500MCC, AR68.20-P-2000MCU, AR77.39-P-1000MCU

6 Place dashboard bottom section (2) on a suitable wooden support and align

7 Drill holes (6) with a diameter of 12 mm to match the markings (arrows C) Rechargeable drill / screwdriver

8 Remove template (1)

9 Install dashboard bottom section (2)

AR68.10-P-1040MCU 10 Install cockpit switch group

AR54.25-P-1000MCC 11 Install vertical strut paneling

AR68.00-P-1500MCC 12 Drill a hole (5) with a diameter of 37 mm in the marked area (arrow D) on the right side of the center console (4). The marking (arrow D) is embossed into the center console (4).

Graduated drillRechargeable drill / screwdriver *450589002800 13 Install center console (4)

AR68.20-P-2000MCU 14 Position console top section (9) on console bottom section (10) and tighten with bolts (11)

15 Insert rubber guide (7) into holes (6) in dashboard bottom section (2) Observe installation position.

16 Insert telephone console (12) into rubber guide (7) and clip into hole (5) on center console (4).

17 Clip cover (8) into telephone console (12) Counterhold center console (4) from behind through the opening of coin holder (13) or power soft top switch.

18.1 Clip coin holder (13) into center console (4) in case of model 451.3

18.2 Install power soft top On model 451.4 AR77.39-P-1000MCU

* for USA only

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1430 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4450MCV, AR82.60-P-7502MCC, AR82.60-P-7502MCU, AR68.20-P-2350MCC, AR68.20-P-2350MCF

AR68.30-P-4450MCV 8 Retrofit iPhone-kit mount (1) on the cover of the center console (2) Vehicles as of 31.8.10Rechargeable drill / screwdriver AZ82.70-P-0013- 04MCD 9 Install smart radio 9 (A2/1), smart radio 10 (A2/2) or smart Entry radio Do not install the cover of the center console (2) yet.

• not for USA AR82.60-P-7502MCC
• for USA only AR82.60-P-7502MCU 10 Retrofit iPhone-kit mount (1) on the cover of the center console (2) Vehicles up to 30.8.10Rechargeable drill / screwdriver AZ82.70-P-0013- 04MCC 11 In tall center con ole cover (2) En ure that the wiring harness of the iPhone kit mount (1) is not damaged by crushing upon installation of the center console cover (2).

Vehicles up to 30.8.10 AR68.20-P-2350MCC Vehicles as of 31.8.10 AR68.20-P-2350MCF 12 Tighten center console cover (2) with the screw/bolt (4) contained in the delivery contents and attach cover (3) Vehicles as of 31.8.10

13 Perform function test by means of a telephone conversation using one iPhone The "smart App" does not have to be installed for the function test of the iPhone kit.Insert iPhone into the iPhone kit fixture (1) as explained in the operating instructions. On vehicles as of 31.8.10, the external audio source connecting point (X39/45) installed as standard is no longer available.

14 Perform commissioning of the iPhone kit with the customer and his/her iPhone Only on customer request. Install Bluetooth connection and "smart app" in accordance with the provided operator's manual.

PARTS ORDERING NOTES

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1543 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-1340MCC, AR68.30-P-1340MCE

Risk of explosion caused by oxyhydrogen gas. Risk of poisoning and caustic burns caused by swallowing battery acid. Risk of injury caused by burns to skin and eyes from battery acid or when handling damaged lead-acid batteries No fire, sparks, open flames or smoking. Wear acid- resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers. AS54.10-Z-0001-01A Notes on battery

AH54.10-P-0001- 01A Notes on AGM battery Model 451.334/380/480 AH54.10-P-0002- 01MCC 1 Connect STAR DIAGNOSIS then read-out and erase diagnostic trouble code memory

AD00.00-P-2000- 04MCC 2 Close Star Diagnosis

3 Remove foot support on passenger side Left-hand drive vehicles AR68.30-P-1340MCC Right-hand drive vehicles AR68.30-P-1340MCE 4 Measure battery voltage at battery terminals Standard digital multimeter gotis://E_15/54_06.0 If the battery voltage is less than 12.2 V:↓

Charge battery (G1) AR54.10-P- 1130MCC 5 Withdraw ignition key

6 Switch off all consumers on board the vehicle

7 Disconnect all external

Fig 1: Identifying Ground Cable And Battery Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 1726 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2350MCC, AR54.30-P-6341MCC

1 Remove cover (1) on center console

AR68.20-P-2350MCC 2 Separate additional instruments connector (A15x1)

3 Undo bolts (2) and remove additional instruments (A15)

4 Install in the reverse order

5 Set clock of additional instruments (A15)

TESTING & REPAIR > REMOVE/INSTALL OUTSIDE TEMPERATURE INDICATOR SENSOR - AR54.30-P-6341MCC > MODEL 451.3/ 4 Remove/install

Fig 1: Identifying Cover, Screw And Additional Instruments With Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Electrical Connector, Front Module And Outside Temperature Display Temperature Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

injury to skin and eyes

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2435 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1010MCC, AR88.20-P-1900MCC, AR01.00-P-3050MCU

caused by contact with liquid refrigerant. repair work on the air conditioning system circuit only after the system has been discharged. Procedure for a damaged or leaky air conditioning system

AH83.30-N-0004-01A Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A Notes on handling R134a refrigerant Air conditioning with refrigerant R134a AH83.30-N-0003-01A Removing

1 Remove maintenance flap

2 Remove front CBS

AR88.00-P-1010MCC 3 Remove rear CBS

AR88.20-P-1900MCC 4 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill / screwdriver gotis://G_58.0_01.1

5 Release rear drive module

AR01.00-P-3050MCU 6 Pour contrast medium into air conditioning system Follow manufacturer's instructions for air conditioning leak detector and for leak detector agent.Air conditioner leak detector gotis://E_83_04.0

Checking

7 Inspect condenser filling valve with air conditioning leak detector If leaks are found, the condenser filling valve must be replaced.Refer to: ↓

Remove/install condenser filling valve AR83.30-P- 5536MCC 8 Inspect intake manifold filling valve with air conditioning leak detector If leaks are found, the intake manifold filling valve must be replaced.Refer to: ↓

Remove/install intake manifold filling valve AR83.30-P- 5535MCC 9 Inspect condenser with air conditioning leak detector If leaks are found, the condenser must be replaced.Refer to: ↓

Remove/install condenser AR83.30-P- 6540MCU

MODIFICATION NOTES

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2631 · Applies to: 450, 451, 452, 454 · AR: AR88.30-P-0505MCC

22.10.07 Install sealing lip newly included Step 2 Remove

1 Remove front spoiler

AR88.30-P-0505MCC Install

2 Position sealing lip (11) on front module (12) and press on firmly

Fig 1: Locating Front Module And Lip Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying BRABUS Front Spoiler Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2633 · Applies to: 450, 451, 452, 454 · AR: AR88.80-P-6000MCC

1 Remove left and right longitudinal member paneling AR88.80-P-6000MCC Install

2 Insert bracket (5) into left and right BRABUS side skirt (1)

3 Hook bracket (8) on BRABUS side skirt (1) into guide (arrow B) on CBS front end (4)

4 Clip bracket (5) on BRABUS side skirt (1) into threaded pins (3) on longitudinal member

5 Clip bracket (6) on BRABUS side skirt (1) into guides (arrows A) on CBS rear end (2)

6 Clip catch hook (7) on BRABUS side skirt (1) into longitudinal member in marked areas (arrows C).

7 Install expansion clips (9) at rear on BRABUS side skirt (1)

8 Add special equipment to the vehicle data card and to the online vehicle data card

TESTING & REPAIR > PARTIALLY LOOSEN FRONT CBS AND FASTEN. - AR88.00-P-1010- 04MCC > Fig 1: Identifying Brabus Side Skirt Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Work procedure shown on left side of vehicle

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2634 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1010MCC

1. Unscrew bolt (1) on front CBS (2) in area of left front lamp unit.
2. Unscrew bolt (8) on front CBS (2) in area of rocker panel.
3. Remove antenna rod. Only on left-hand side of the vehicle.
4. Open left door.
5. Press edge guard (5) in area of fender covering (3) to side and remove expansion clip (4).
6. Slightly slide fender covering (3) upward and remove from front CBS (2).
7. Unscrew bolts (6, 7) on front CBS (2). Installation: Ensure that bushing is seated correctly in area of bolt (7).
8. Unscrew bolt (9) on front CBS (2) in area of door.
9. Fasten in reverse order TESTING & REPAIR > REMOVE/INSTALL FRONT CBS - AR88.00-P-1010MCC > MODEL 451.3/4 Fig 1: Identifying Edge Guard, Expansion Clip And Bolts On Front CBS Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Un crew bolt (11) from front CBS (1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2637 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1014MCC

10 Un crew bolt (11) from front CBS (1)

11 Loosen catches (12) on CBS front end (1) and remove CBS front end (1) with aid of helper. Lay front CBS (1) down on suitable subsurface.

12 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL COMPANY SIGN - AR88.00-P-1014MCC > MODEL 451.3/4 Front Dimensions: Removal

1 Carefully loosen company sign (1) from maintenance flap with clip remover and remove. Carefully company sign (1) to prevent scratching maintenance flap.

*452589016300 Install

2 Clean maintenance flap in area of company sign (1). The maintenance flap must be free of dust and grease in the area of the company sign (1) to prevent adhesion problems when gluing on company sign (1).

3 Determine position of company sign (1) according to dimensions (a, b) and mark with suitable

Fig 1: Locating Company Sign Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

adhesive tape.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2638 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1100MCC

4 Remove rear protective foil from company sign (1) Ensure that individual parts of company sign (1) are not loosened from front carrier foil

5 Align company sign (1) according to marks and press onto maintenance flap.

6 Press on company sign (1) and remove front carrier foil.

7 Remove tape.

TESTING & REPAIR > REMOVE/INSTALL FRONT CENTER PART - AR88.00-P-1100MCC > MODEL 451.3/4 Shown on front CBS with code (V07) Front fog lamps (FFO) Fig 2: Identifying Snap-Release Tool (45 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2639 · Applies to: 450, 451, 452, 454 · AR: AR88.10-P-1000MCC, AR88.00-P-1200MCC

1 Remove left and right fenders (1). AR88.10-P-1000MCC 2 Unlock catch hook (arrows) on left and right lower lock part (4) and remove upper lock part (3) upward.

3 Remove left and right lower lock part (4) downward.

4 Remove license plate with bracket and remove

5 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL FRESH UP - AR88.00-P-1200MCC > MODEL 451.3/4 Fig 1: Identifying Front Center Part Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2640 · Applies to: 450, 451, 452, 454 · AR: AR88.10-P-1000MCC, AR88.00-P-1100MCC, AR72.18-P-1000MCC, AR88.10-P-1100MCC, AR88.00-P-1300MCC (+1 more)

When installing Fresh Up Exterieur, modify all detachable parts not present on replacement part

1 Remove maintenance flap (1)

2 Remove left front fender (4) and right front fender (3) AR88.10-P-1000MCC 3 Remove front center part (2) AR88.00-P-1100MCC 4 Remove left door paneling (6) and right door paneling (5) AR72.18-P-1000MCC 5 Remove left rear fender (8) and right rear fender (7) AR88.10-P-1100MCC 6 Remove rear center section (10) AR88.00-P-1300MCC 7 Remove door paneling on rear-end door (9) AR72.20-P-1000MCC 8 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL REAR CENTER PART - AR88.00-P-1300MCC > MODEL 451.3/4 Fig 1: Identifying Fresh Up Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install in the reverse order

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2642 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-2792MCC

10 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL TRIM ON CENTER PIECE IN FRONT OF WINDSHIELD - AR88.00-P-2792MCC > MODEL 451.3/4 Remove/install

1 Remove maintenance flap

2 Remove antenna rod

3 Open left and right door, press edge guard (5) to side in area of left and right fender covering (3) on both sides and remove expansion clip (4).

4 Slightly slide left and right fender covering (3) upward and remove.

5 Unscrew bolts (6, 7) Installation: Check whether guide sleeve on bolt (7) is seated correctly.

6 Unscrew bolt (11) in area of left front lamp unit and right front lamp unit.

Fig 1: Identifying Trim Components On Center Piece In Front Of Windshield Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Unscrew bolts (10) from paneling (1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2643 · Applies to: 450, 451, 452, 454 · AR: AR88.00-Z-9451CA, AR88.10-P-1101MCC, AR88.20-P-1950MCC, AR88.00-P-1014MCC, AR88.00-P-1014MCE (+5 more)

7 Unscrew bolts (10) from paneling (1)

8 Carefully remove trim (1) toward front and covering (arrow B) simultaneously toward rear until hose (9) on spray nozzle (8) is accessible. Installation: Observe installation position of hose (9) (arrow A) and covering (arrows B) in paneling (1).

9 Remove hose (9) from spray nozzle (8) and lay trim (1) down to side.

10 Loosen spray nozzle (8) from trim (1) from rear with suitable pliers and remove. When replacing trim (1).

11 Install in the reverse order

12 Adjust spray nozzle (8) on windshield washer system.

AR82.35- P- 6975MCC TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: DETACHABLE BODY COMPONENTS, EXTERIOR FLAPS - AR88.00-Z-9451CA > MODEL 451 Remove/install attachment part on rear fender MODEL 451.3/4 AR88.10-P-1101MCC Remove/install CMS rear end MODEL 451.3/4 AR88.20-P-1950MCC Remove/install company sign MODEL 451.3/4 Front AR88.00-P-1014MCC Remove/install company sign MODEL 451.3/4 Rear AR88.00-P-1014MCE Remove/install complete outside mirror MODEL 451.3/4 AR88.70-P-9000MCC Remove/install C-pillar outer cover MODEL 451.3 AR88.30-P-1200MCC Remove/install fender liner in front fender MODEL 451.3/4 AR88.10-P-1300MCC Remove/install fender liner in front fender MODEL 451.3/4 AR88.10-P-1300MCU Remove/install fender liner in rear fender MODEL 451.3/4 AR88.10-P-1400MCC Remove/install fender liner in rear fender MODEL 451.3/4 AR88.10-P-1400MCU Remove/install fresh up MODEL 451.3/4 AR88.00-P-1200MCC Remove/install front CBS MODEL 451.3/4 AR88.00-P-1010MCC Remove/install front center part MODEL 451.3/4 AR88.00-P-1100MCC Remove/install front CMS foam pad MODEL 451.3/4 AR88.00-P-1013MCC

Remove/install front fenders

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2644 · Applies to: 450, 451, 452, 454 · AR: AR88.10-P-1000MCC, AR88.30-P-0505MCC, AR88.20-P-1925MCC, AR88.80-P-6000MCC, AR88.70-P-9020MCC (+5 more)

MODEL 451.3/4 AR88.10-P-1000MCC Remove/install front spoiler MODEL 451.3/4 AR88.30-P-0505MCC Remove/install heat shield MODEL 451.3/4 with ENGINE 132.930 AR88.20-P-1925MCC Remove/install longitudinal member paneling MODEL 451.3/4 AR88.80-P-6000MCC Remove/install mirror glass MODEL 451.3/4 AR88.70-P-9020MCC Remove/install outside mirror adjustment switch MODEL 451.3/4 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO) AR88.79-P-3470MCC Remove/install outside mirror trim MODEL 451.3/4 AR88.70-P-9040MCC Remove/install radiator paneling MODEL 451.3/4 AR88.40-P-4001MCC Remove/install rear apron MODEL 451.3/4 AR88.30-P-0502MCC Remove/install rear CBS MODEL 451.3/4 AR88.20-P-1900MCC Remove/install rear center part MODEL 451.3/4 AR88.00-P-1300MCC Remove/install rear fender MODEL 451.3/4 AR88.10-P-1100MCC Remove/install rear spoiler MODEL 451.3 AR88.30-P-0500MCC Remove/install tank recess MODEL 451.3/4 AR88.60-P-2000MCC Remove/install trim on center piece in front of windshield MODEL 451.3/4 AR88.00-P-2792MCC TESTING & REPAIR > REMOVE/INSTALL FRONT FENDERS - AR88.10-P-1000MCC > MODEL 451.3/4 Shown on vehicle with code (V07) Front fog lamps (FFO)

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2645 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1010MCC

1 Remove CBS front end and lay down on suitable subsurface AR88.00-P-1010MCC 2 Loosen catches (arrows A) on upper radiator grille (4) and remove upper radiator grille (4).

3 Loosen catches (arrows B) on lower radiator grille (5) and remove lower radiator grille (5).

4 Loosen catches (arrows C) on left and right cover (9) and remove left and right cover (9).

5 Remove expansion clips (8) and loosen catches between left and right fender (1) and front spoiler (2).

6 Remove expansion clips (6) on left and right fender (1).

7 Loosen catches (7) between left and right fender (1) and front center part (3).

8 Remove left and right fender (1) from front center part (3).

9 Install in the reverse order

Fig 1: Identifying Front Fender Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL REAR FENDER - AR88.10-P-1100MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2646 · Applies to: 450, 451, 452, 454 · AR: AR88.10-P-1100MCC

MODEL 451.3/4 Remove/install

1 Remove rear CBS

AR88.20- P- 1900MCC 2 Remove expansion clip (5) on left rear fender (1) and right rear fender (3)

3 Remove expansion clip (4) from left rear fender (1) and right rear fender (3)

4 Loosen catches (9) on rear apron (6).

5 Loosen catches (7) between left rear fender (1) and right rear fender (3) and rear center part (2).

6 Loosen left rear fender (1) and right rear fender (3) from bracket (8) and remove.

7 Remove left taillamp (E3) or right taillamp (E4) When replacing left rear fender (1) and right rear fender (3). AR82.10- P- 4905MCC 8 Unclip tank recess (10) from right rear fender (3) and remove. When replacing right rear fender (3).

Fig 1: Identifying Rear Fender Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Unclip air intake grille (11) from left rear fender

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2647 · Applies to: 450, 451, 452, 454 · AR: AR88.10-P-1101MCC

9 Unclip air intake grille (11) from left rear fender (1) and remove. When replacing left rear fender (1).

10 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL ATTACHMENT PART ON REAR FENDER - AR88.10-P-1101MCC > MODEL 451.3/4

Remove/install

1 Remove retaining clamps (3) from left and right attachment part (2).

2 Detach catch hook (arrows) on attachment part (2) from rear CBS (1) and remove attachment part (2). Installation: Clean contact surfaces on attachment parts (2) and rear CBS (1). 3 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL FENDER LINER IN FRONT FENDER - AR88.10- P-1300MCU > MODEL 451.3/4 Fig 1: Locating Rear CBS, Attachment Part And Retaining Clips Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2654 · Applies to: 450, 451, 452, 454 · AR: AR88.20-P-1900MCC

1 Remove left and right rear wheel AR40.10-P- 1100MCU 2 Remove expansion clips (3) from longitudinal member paneling (2).

3 Unscrew nuts (5) from fender liner (1).

4 Remove expansion clip (4) from fender liner (1).

5 Detach fender liner (1) in area of rear CBS and remove.

6 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL REAR CBS - AR88.20-P-1900MCC > MODEL 451.3/4 Fig 1: Identifying Rear Fender Liner Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL CMS REAR END - AR88.20-P-1950MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2659 · Applies to: 450, 451, 452, 454 · AR: AR88.20-P-1950MCC

MODEL 451.3/4 Vehicles with Motor 660 and code (474) Diesel particulate filter (closed) Fig 7: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying CMS Rear End, Screws And Bracket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODIFICATION NOTES

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2660 · Applies to: 450, 451, 452, 454 · AR: AR88.30-P-0502MCC

7.1.09 Remove, install diesel particulate filter differential pressure sensor Step 2 Remove/install

1 Remove rear CBS

AR88.20- P- 1900MCC 2 Unscrew bolts (4) and lay bracket down to side together with diesel particulate filter differential pressure sensor (B28/8) On vehicles with engine 660 and code (474) Diesel particulate filter (closed)

3 Unscrew bolts (2) from CMS rear-end (1) and remove CMS rear-end (1) The outer four bolts (2) are accessible from the rear and the inner two bolts (2) from the front.

*BA64.20- P-1001- 01B 4 Unscrew bolts on bracket (3) from CMS rear-end (1) and remove bracket (3) When replacing CMS rear-end (1). The brackets (3) are fastened to the CMS rear-end (1) with one bolt each.

5 Install in the reverse order

CMS REAR END Number Designation Model 451.3/4 BA64.20-P-1001- 01B Bolt, CMS rear end to drive module Nm 22 TESTING & REPAIR > REMOVE/INSTALL REAR APRON - AR88.30-P-0502MCC > MODEL 451.3/4 Fig 2: Identifying CMS Rear End, Bolts And Diesel Particulate Filter Differential Pressure Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2661 · Applies to: 450, 451, 452, 454 · AR: AR88.30-P-0505MCC

1 Unscrew bolt (2) from rear apron (1) on left and right. 2 Remove expansion clip (6) on rear apron (1) on left and right. 3 Loosen rear apron (1) from brackets (4). 4 Loosen catches (7) on rear apron (1). 5 Unhook bracket (5) on rear apron (1) from rear CBS (3) and remove rear apron (1). 6 Install in the reverse order TESTING & REPAIR > REMOVE/INSTALL FRONT SPOILER - AR88.30-P-0505MCC > MODEL 451.3/4 Shown on CBS front end with code (V07) Front fog lamp (FFO) Fig 1: Identifying Rear Apron Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

4 Release quick-release coupling (6).

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2664 · Applies to: 450, 451, 452, 454 · AR: AR88.40-P-4001MCC

5 Remove engine compartment cover (5) from vehicle. 6 Install in the reverse order. TESTING & REPAIR > REMOVE/INSTALL RADIATOR PANELING - AR88.40-P-4001MCC > MODEL 451.3/4 Shown on CBS front end with code (V07) Front fog lamps (FFO) Fig 2: Locating Quick-Release Coupling And Engine Compartment Cover Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2665 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1010MCC, AR88.60-P-2000MCC

1 Remove CBS front end and lay down on suitable base AR88.00-P-1010MCC 2 Unclip catch hooks (arrows A) and remove carrier (2) with upper front grille (1).

3 Unclip catch hooks (arrows B) and remove upper front grille (1) from carrier (2).

4 Unclip catch hooks (arrows C) and remove lower front grille (3).

5 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL TANK RECESS - AR88.60-P-2000MCC > MODEL 451.3/4 Fig 1: Identifying Carrier & Upper And Lower Front Grilles Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

right electrically adjustable and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2670 · Applies to: 450, 451, 452, 454 · AR: AR88.70-P-9020MCC

heated outside mirror (M21/2) in upper area (arrow A) and remove seal (7) upward. 6 Disconnect left electrically adjustable and heated outside mirror connector (M21/1x1) or right electrically adjustable and heated outside mirror connector (M21/2x1) On vehicles with code (V21) Electrically adjustable and heated outside mirror (FFO) 7 Unscrew bolts (8) and remove manual outside mirror (1) or left electrically adjustable and heated outside mirror (M21/1) or right electrically adjustable and heated outside mirror (M21/2). Depending on vehicle equipment, guide mirror adjustment lever (5) or electric wiring harness through opening in door body shell toward outside. 8 Install in the reverse order

9 Check manual outside mirror (1) or left electrically adjustable and heated outside mirror (M21/1) or right electrically adjustable and heated outside mirror (M21/2) for proper function.

TESTING & REPAIR > REMOVE/INSTALL MIRROR GLASS - AR88.70-P-9020MCC > MODEL 451.3/4

Remove/install

1 Unclip mirror glass (1) from bracket (2) on outside mirror.

2.1 Remove mirror glass (1) On vehicles without code (V21) Electrically adjustable and heated outside mirrors (FFO) 2.2 Remove mirror glass (1) until electrical connector on mirror glass On vehicles with code (V21) Electrically adjustable and heated Fig 1: Identifying Mirror Glass And Bracket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

(1) is accessible.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2671 · Applies to: 450, 451, 452, 454 · AR: AR88.70-P-9040MCC, AR88.79-P-3470MCC

outside mirrors (FFO) 3 Disconnect electrical connector on mirror glass (1) and remove mirror glass (1). On vehicles with code (V21) Electrically adjustable and heated outside mirrors (FFO) 4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL OUTSIDE MIRROR TRIM - AR88.70-P-9040MCC

MODEL 451.3/4 Shown on vehicle without code (V21) Electrically adjustable and heated outside mirrors (FFO) Remove/install

1 Remove mirror glass (1)

AR88.70- P- 9020MCC 2 Loosen catches (arrows) between outside mirror and outside mirror trim (2). Do not damage outside mirror trim (2), otherwise outside mirror trim (2) must be replaced.

3 Remove outside mirror trim (2)

4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL OUTSIDE MIRROR ADJUSTMENT SWITCH - AR88.79-P-3470MCC > MODEL 451.3/4 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO) Fig 1: Identifying Mirror Glass, Outside Mirror Trim And Catch Hooks Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removal

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2675 · Applies to: 450, 451, 452, 454 · AR: AR88.40-P-4001MCC

1 Remove upper front grille and disassemble

AR88.40-P-4001MCC Install

2 Assemble chrome front grille (1) with carrier of upper front grille and install. Do not reinstall upper front grille. AR88.40-P-4001MCC 3 Clean contact surfaces on chrome mirror caps (2).

4 Remove protective foils from adhesive strips (3), position chrome mirror caps (2) and press on.

5 Clean contact surface on trim strip (4).

6 Position trim strip (4) on rear-end door paneling as shown, center and mark installation position using suitable adhesive tape (5).

7 Carefully cut adhesive tape (5) in marked area (arrow) and remove trim strip (4). Carefully cut adhesive tape (5) to prevent damaging rear- end door panel below.

8 Remove protective foil on adhesive strip from trim strip (4), center trim strip (4) according to the two halves of adhesive strip (5) and press on.

RETROFITTING & CONVERSION > RETROFIT MOUNTS FOR BASIC CARRIER - AZ88.00- P-0005-02MCU > AZ88.00- Fig 2: Identifying Trim Strip And Adhesive Tape Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > ELECTRICALLY ADJUSTABLE OUTSIDE MIRRORS, FUNCTION -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2688 · Applies to: 450, 451, 452, 454 · AR: GF88.79-P-0005MCC

GF88.79-P-0005MCC > MODEL 451.3/4 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO) Fig 1: Locating Electrically Adjustable Outside Mirror Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Electrically adjustable

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2690 · Applies to: 450, 451, 452, 454 · AR: PE88.79-P-2000MCC, PE88.79-P-2000MCD, PE88.79-P-2000MCU, GF54.21-P-4157MCC, GF54.21-P-4157MCU (+4 more)

outside mirrors, location of components

GF88.79-P-0005- 01MCC Wiring diagram of outside mirrors * not for USA PE88.79-P-2000MCC Model 451.3## /4## ## up to 013644

• not for USA PE88.79-P-2000MCD Model 451.3## /4## ## as of 013645

• for USA only PE88.79-P-2000MCU

SAM control unit, component description N10/10 GF54.21-P-4157MCC * not for USA

• for USA only GF54.21-P-4157MCU

Outside mirror adjustment switch, component description S50 GF88.79-P-4110MCC BASIC KNOWLEDGE > TABLE OF CONTENTS FOR FUNCTION DESCRIPTION FOR ELECTRICALLY ADJUSTABLE OUTSIDE MIRROR - GF88.79-P-0999MCC > MODEL 451.3/4 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO) Electrically adjustable outside mirrors, function

GF88.79-P-0005MCC Electrically adjustable outside mirrors, location of components

GF88.79-P-0005- 01MCC Wiring diagram of outside mirrors * not for USA PE88.79-P-2000MCC Model 451.3## /4## ## up to 013644

• not for USA PE88.79-P-2000MCD Model 451.3## /4## ## as of 013645

• for USA only PE88.79-P-2000MCU Overview of system components for electrically adjustable outside mirror

GF88.79-P-9998MCC BASIC KNOWLEDGE > OUTSIDE MIRROR ADJUSTMENT SWITCH, COMPONENT DESCRIPTION - GF88.79-P-4110MCC > MODEL 451.3/4 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO)

Location

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2691 · Applies to: 450, 451, 452, 454 · AR: GF88.79-P-9998MCC, GF54.21-P-4157MCC, GF54.21-P-4157MCU

The outside mirror adjustment switch is located in the driver door panel Task Reading in following requests: Preselecting outside mirror to be adjusted Adjusting mirror lens upward and downward Adjusting mirror lens toward inside and outside Actuating following components: Mirror up/down adjustment motor (M21/1m1, M21/2m1) Mirror in/out adjustment motor (M21/1m2, M21/2m2) BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS FOR ELECTRICALLY ADJUSTABLE OUTSIDE MIRROR - GF88.79-P-9998MCC > MODEL 451.3/4 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO) SAM control unit, component description N10/10 GF54.21-P-4157MCC * not for USA

• for USA only GF54.21-P-4157MCU Outside mirror adjustment switch, component S50 GF88.79-P- Fig 1: View Of Outside Rearview Mirror Adjustment Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

WIRING DIAGRAMS > WIRING DIAGRAM OF OUTSIDE MIRRORS - PE88.79-P-2000MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2694 · Applies to: 450, 451, 452, 454 · AR: PE88.79-P-2000MCU

MODEL 451 Wiring diagram of outside mirrors PE88.79-P-2000-97MCU Use of wiring diagrams OV00.01-P-1901-03MCC Fig 2: Outside Mirrors - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2705 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1010MCC

1 Remove left and right longitudinal member paneling

AR88.80-P- 6000MCC Install

2 Insert bracket (5) into left and right BRABUS side skirt (1)

3 Hook bracket (8) on BRABUS side skirt (1) into guide (arrow B) on CBS front end (4)

4 Clip bracket (5) on BRABUS side skirt (1) into threaded pins (3) on longitudinal member

5 Clip bracket (6) on BRABUS side skirt (1) into guides (arrows A) on CBS rear end (2)

6 Clip catch hook (7) on BRABUS side skirt (1) into longitudinal member in marked areas (arrows C).

7 Install expansion clips (9) at rear on BRABUS side skirt (1)

8 Add special equipment to the vehicle data card and to the online vehicle data card

TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT CBS - AR88.00-P-1010MCC > MODEL 451.3/ 4 Fig 1: Identifying Side Skirts Brabus Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Un crew bolt (11) from front CBS (1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2708 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1014MCC

10 Un crew bolt (11) from front CBS (1)

11 Loosen catches (12) on CBS front end (1) and remove CBS front end (1) with aid of helper. Lay front CBS (1) down on suitable subsurface.

12 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL COMPANY SIGN - AR88.00-P-1014MCC > MODEL 451.3/4 Front Dimensions: Removal

1 Carefully loosen company sign (1) from maintenance flap with clip remover and remove. Carefully company sign (1) to prevent scratching maintenance flap.

Figure Install

2 Clean maintenance flap in area of company sign (1). The maintenance flap must be free of dust and grease in the area of the company sign (1) to prevent adhesion problems when gluing on company sign (1).

3 Determine position of company sign (1) according to dimensions (a, b) and mark with suitable adhesive tape.

4 Remove rear protective foil from Ensure that individual parts of company sign

Fig 1: Identifying Company Sign Dimension Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

company sign (1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2709 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1014MCE

(1) are not loosened from front carrier foil 5 Align company sign (1) according to marks and press onto maintenance flap.

6 Press on company sign (1) and remove front carrier foil.

7 Remove tape.

TESTING & REPAIR INDEX > REMOVE/INSTALL COMPANY SIGN - AR88.00-P-1014MCE > MODEL 451.3/4 Rear Dimensions: Fig 2: Identifying Snap-Release Tool (45 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Company Sign Dimension Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2711 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1200MCC

1 Remove left and right fenders (1).

AR88.10-P- 1000MCC 2 Unlock catch hook (arrows) on left and right lower lock part (4) and remove upper lock part (3) upward.

3 Remove left and right lower lock part (4) downward.

4 Remove license plate with bracket and remove

5 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL FRESH UP - AR88.00-P-1200MCC > MODEL 451.3/4 Fig 1: Identifying Fenders, Front Center Part, Upper And Lower Lock Part Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install in the reverse order

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2714 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-2792MCC

10 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL TRIM ON CENTER PIECE IN FRONT OF WINDSHIELD - AR88.00-P-2792MCC > MODEL 451.3/4 Remove/install

1 Remove maintenance flap

2 Remove antenna rod

3 Open left and right door, press edge guard (5) to side in area of left and right fender covering (3) on both sides and remove expansion clip (4).

4 Slightly slide left and right fender covering (3) upward and remove.

5 Unscrew bolts (6, 7) Installation: Check whether guide sleeve on bolt (7) is seated correctly.

6 Unscrew bolt (11) in area of left front lamp unit and right front lamp unit.

Fig 1: Identifying Trim On Center Piece In Front Of Windshield Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Unscrew bolts (10) from paneling (1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2715 · Applies to: 450, 451, 452, 454 · AR: AR88.00-Z-9451CA

7 Unscrew bolts (10) from paneling (1)

8 Carefully remove trim (1) toward front and covering (arrow B) simultaneously toward rear until hose (9) on spray nozzle (8) is accessible. Installation: Observe installation position of hose (9) (arrow A) and covering (arrows B) in paneling (1).

9 Remove hose (9) from spray nozzle (8) and lay trim (1) down to side.

10 Loosen spray nozzle (8) from trim (1) from rear with suitable pliers and remove. When replacing trim (1).

11 Install in the reverse order

12 Adjust spray nozzle (8) on windshield washer system.

AR82.35- P- 6975MCC TESTING & REPAIR INDEX > TESTING AND REPAIR WORK: SMART: DETACHABLE BODY COMPONENTS, EXTERIOR FLAPS - AR88.00-Z-9451CA > MODEL 451

Remove/install attachment part on rear fender MODEL 451.3 /4 AR88.10- P- 1101MCC

Remove/install CMS rear end MODEL 451.3 /4 AR88.20- P- 1950MCC

Remove/install company sign MODEL 451.3 /4 Front AR88.00- P- 1014MCC

Remove/install company sign MODEL 451.3 /4 Rear AR88.00- P- 1014MCE

Remove/install complete outside mirror MODEL 451.3 /4 AR88.70- P- 9000MCC

Remove/install C-pillar outer cover MODEL 451.3 AR88.30- P- 1200MCC

Remove/install fender liner in front fender MODEL 451.3 /4 AR88.10- P- 1300MCC

Remove/install fender liner in front fender MODEL 451.3 /4 AR88.10- P- 1300MCU

Remove/install fender liner in rear fender MODEL 451.3 /4 AR88.10- P- 1400MCC

Remove/install rear center

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2717 · Applies to: 450, 451, 452, 454 · AR: AR88.10-P-1000MCC

part MODEL 451.3/ 4 AR88.00- P- 1300MCC

Remove/install rear fender MODEL 451.3/ 4 AR88.10- P- 1100MCC

Remove/install rear spoiler MODEL 451.3 AR88.30- P- 0500MCC

Remove/install tank recess MODEL 451.3/ 4 AR88.60- P- 2000MCC

Remove/install trim on center piece in front of windshield MODEL 451.3/ 4 AR88.00- P- 2792MCC TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT FENDERS - AR88.10-P-1000MCC

MODEL 451.3/4 Shown on vehicle with code (V07) Front fog lamps (FFO) Fig 1: Identifying Front Fenders Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2718 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1010MCC, AR88.10-P-1100MCC

1 Remove CBS front end and lay down on suitable subsurface AR88.00-P-1010MCC 2 Loosen catches (arrows A) on upper radiator grille (4) and remove upper radiator grille (4).

3 Loosen catches (arrows B) on lower radiator grille (5) and remove lower radiator grille (5).

4 Loosen catches (arrows C) on left and right cover (9) and remove left and right cover (9).

5 Remove expansion clips (8) and loosen catches between left and right fender (1) and front spoiler (2).

6 Remove expansion clips (6) on left and right fender (1).

7 Loosen catches (7) between left and right fender (1) and front center part (3).

8 Remove left and right fender (1) from front center part (3).

9 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL REAR FENDER - AR88.10-P-1100MCC > MODEL 451.3/4

TESTING & REPAIR INDEX > REMOVE/INSTALL ATTACHMENT PART ON REAR FENDER

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2720 · Applies to: 450, 451, 452, 454 · AR: AR88.10-P-1101MCC, AR88.10-P-1300MCU

• AR88.10-P-1101MCC > MODEL 451.3/4

Remove/install

1 Remove retaining clamps (3) from left and right attachment part (2).

2 Detach catch hook (arrows) on attachment part (2) from rear CBS (1) and remove attachment part (2). Installation: Clean contact surfaces on attachment parts (2) and rear CBS (1). 3 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL FENDER LINER IN FRONT FENDER - AR88.10-P-1300MCU > MODEL 451.3/4 Fig 1: Identifying Rear CBS, Attachment Part And Retaining Clips Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Fender Liner In Front Fender Components (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > REMOVE/INSTALL FENDER LINER IN REAR FENDER -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2725 · Applies to: 450, 451, 452, 454 · AR: AR88.10-P-1400MCU

AR88.10-P-1400MCU > MODEL 451.3/4 Fig 7: Identifying Puller (450 589 01 33 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 8: Identifying Assembly Tool Set (450 589 08 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 9: Identifying Holding Device (451 589 00 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > REMOVE/INSTALL CMS REAR END - AR88.20-P-1950MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2731 · Applies to: 450, 451, 452, 454 · AR: AR88.20-P-1950MCC

MODEL 451.3 /4 Vehicles with Motor 660 and code (474) Diesel particulate filter (closed) Fig 7: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying CMS Rear End, Screw And Bracket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODIFICATION NOTES

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2732 · Applies to: 450, 451, 452, 454 · AR: AR88.30-P-0500MCC

7.1.09 Remove, install diesel particulate filter differential pressure sensor Step 2 Remove/install

1 Remove rear CBS

AR88.20- P- 1900MCC 2 Unscrew bolts (4) and lay bracket down to side together with diesel particulate filter differential pressure sensor (B28/8) On vehicles with engine 660 and code (474) Diesel particulate filter (closed)

3 Unscrew bolts (2) from CMS rear-end (1) and remove CMS rear-end (1) The outer four bolts (2) are accessible from the rear and the inner two bolts (2) from the front.

*BA64.20- P-1001- 01B 4 Unscrew bolts on bracket (3) from CMS rear-end (1) and remove bracket (3) When replacing CMS rear-end (1). The brackets (3) are fastened to the CMS rear-end (1) with one bolt each.

5 Install in the reverse order

CMS REAR END Number Designation Model 451.3/4 BA64.20-P-1001-01B Bolt, CMS rear end to drive module Nm 22 TESTING & REPAIR INDEX > REMOVE/INSTALL REAR SPOILER - AR88.30-P-0500MCC > MODEL 451.3 Fig 2: Identifying CMS Rear End, Bolts And Diesel Particulate Filter Differential Pressure Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Open rear-end door upper

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2734 · Applies to: 450, 451, 452, 454 · AR: AR88.30-P-0502MCC

4 Open rear-end door upper section (4)

5 Mark position left hinge (3) and right hinge (6) in relation to upper rear-end door (4).

6 Unscrew bolts (10) at side on rear spoiler (7).

7 Unscrew bolts (1, 2) from left hinge (3) and bolt (2) from right hinge (6).

8 Loosen bolt (5) on right hinge (6). Do not unscrew bolt (5), otherwise the upper rear-end door (4) can be damaged by folding down. Installation: Align upper rear-end door (4) according to markings made previously and tighten bolts (1, 2, 5).

*BA72.20- P-1006- 02F 9 Carefully lift upper rear-end door (4) in area of left hinge (3) and unscrew bolts (11) on rear spoiler (7). Helper required for unscrewing inner bolt (11).

10 Screw bolt (1) into left hinge (3). Screw in bolt (1) only until upper rear-end door (4) is fastened.

11 Unscrew bolt (5) from right hinge (6). Installation: Screw in bolt (5) only until upper rear-end door (4) is fastened.

12 Carefully lift upper rear-end door (4) in area of right hinge (6), unscrew bolts (12) on rear spoiler (7) and remove rear spoiler (7) with aid of helper. Helper required for unscrewing inner bolt (12).

13 Install in the reverse order

REAR-END DOOR Number Designation Model 451.3 BA72.20-P-1006-02F Bolt, hinge to glass pane Nm 12 TESTING & REPAIR INDEX > REMOVE/INSTALL REAR APRON - AR88.30-P-0502MCC > MODEL 451.3/4

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2735 · Applies to: 450, 451, 452, 454 · AR: AR88.30-P-0505MCC

1 Unscrew bolt (2) from rear apron (1) on left and right. 2 Remove expansion clip (6) on rear apron (1) on left and right. 3 Loosen rear apron (1) from brackets (4). 4 Loosen catches (7) on rear apron (1). 5 Unhook bracket (5) on rear apron (1) from rear CBS (3) and remove rear apron (1). 6 Install in the reverse order TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT SPOILER - AR88.30-P-0505MCC

MODEL 451.3/ 4 Shown on CBS front end with code (V07) Front fog lamp (FFO) Fig 1: Identifying Rear Apron, Bolt, Rear CBS, Brackets, Expansion Clip And Catch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2740 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1010MCC, AR88.60-P-2000MCC

1 Remove CBS front end and lay down on suitable base AR88.00-P-1010MCC 2 Unclip catch hooks (arrows A) and remove carrier (2) with upper front grille (1).

3 Unclip catch hooks (arrows B) and remove upper front grille (1) from carrier (2).

4 Unclip catch hooks (arrows C) and remove lower front grille (3).

5 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL TANK RECESS - AR88.60-P-2000MCC > MODEL 451.3/4 Fig 1: Identifying Carrier, Upper And Lower Front Grille Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Unclip fuel filler flap CL motor (M14/10)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2742 · Applies to: 450, 451, 452, 454 · AR: AR88.70-P-9000MCC

7 Unclip fuel filler flap CL motor (M14/10) on tank recess (1) and remove. When replacing tank recess (1).

8 Remove fuel filler flap (3) from hinge lever (9) in direction of arrow. When replacing tank recess (1).

9 Remove hinge lever (9) from tank recess (1). When replacing tank recess (1).

10 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL COMPLETE OUTSIDE MIRROR - AR88.70-P-9000MCC > MODEL 451.3/4 Shown with code (V21) Electrically adjustable and heated outside mirror (FFO) Fig 2: Identifying Snap-Release Tool (452 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

mirror (1) or left electrically

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2745 · Applies to: 450, 451, 452, 454 · AR: AR88.70-P-9020MCC

adjustable and heated outside mirror (M21/1) or right electrically adjustable and heated outside mirror (M21/2) in upper area (arrow A) and remove seal (7) upward. 6 Disconnect left electrically adjustable and heated outside mirror connector (M21/1x1) or right electrically adjustable and heated outside mirror connector (M21/2x1) On vehicles with code (V21) Electrically adjustable and heated outside mirror (FFO) 7 Unscrew bolts (8) and remove manual outside mirror (1) or left electrically adjustable and heated outside mirror (M21/1) or right electrically adjustable and heated outside mirror (M21/2). Depending on vehicle equipment, guide mirror adjustment lever (5) or electric wiring harness through opening in door body shell toward outside. 8 Install in the reverse order

9 Check manual outside mirror (1) or left electrically adjustable and heated outside mirror (M21/1) or right electrically adjustable and heated outside mirror (M21/2) for proper function.

TESTING & REPAIR INDEX > REMOVE/INSTALL MIRROR GLASS - AR88.70-P-9020MCC > MODEL 451.3/4

Remove/install

1 Unclip mirror glass (1) from bracket (2) on outside mirror.

2.1 Remove mirror glass (1) On vehicles without code (V21) Electrically adjustable and Fig 1: Identifying Mirror Glass And Bracket Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

heated outside mirrors (FFO)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2746 · Applies to: 450, 451, 452, 454 · AR: AR88.79-P-3470MCC

2.2 Remove mirror glass (1) until electrical electrical connector on mirror glass (1) is accessible. On vehicles with code (V21) Electrically adjustable and heated outside mirrors (FFO) 3 Disconnect electrical connector on mirror glass (1) and remove mirror glass (1). On vehicles with code (V21) Electrically adjustable and heated outside mirrors (FFO) 4 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL OUTSIDE MIRROR TRIM - AR88.70-P- 9040MCC > MODEL 451.3/4 Shown on vehicle without code (V21) Electrically adjustable and heated outside mirrors (FFO) Remove/install

1 Remove mirror glass (1)

AR88.70- P- 9020MCC 2 Loosen catches (arrows) between outside mirror and outside mirror trim (2). Do not damage outside mirror trim (2), otherwise outside mirror trim (2) must be replaced.

3 Remove outside mirror trim (2)

4 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL OUTSIDE MIRROR ADJUSTMENT SWITCH - AR88.79-P-3470MCC > MODEL 451.3/4 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO) Fig 1: Identifying Mirror Glass, Outside Mirror Trim And Catch Hook Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > REMOVE/INSTALL LONGITUDINAL MEMBER PANELING -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2748 · Applies to: 450, 451, 452, 454 · AR: AR88.80-P-6000MCC

AR88.80-P-6000MCC > MODEL 451.3/4 Removal 1 Remove expansion clip (2) at front and rear from longitudinal member paneling (1). 2 Unclip catch hook (4) on longitudinal member paneling (1) from longitudinal member (5). Fig 2: Identifying Assembly Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Longitudinal Member Paneling Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > ELECTRICALLY ADJUSTABLE OUTSIDE MIRRORS, FUNCTION -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2763 · Applies to: 450, 451, 452, 454 · AR: GF88.79-P-0005MCC

GF88.79-P-0005MCC > MODEL 451.3 /4 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO) Fig 1: Identifying Electrically Adjustable Outside Mirrors Components Location Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Electrically adjustable outside mirrors,

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2765 · Applies to: 450, 451, 452, 454 · AR: GF88.79-P-0999MCC, GF88.79-P-0005MCC, PE88.79-P-2000MCC, PE88.79-P-2000MCD, PE88.79-P-2000MCU (+2 more)

location of components

GF88.79-P- 0005-01MCC Wiring diagram of outside mirrors * not for USA PE88.79-P- 2000MCC Model 451.3## /4## ## up to 013644

• not for USA PE88.79-P- 2000MCD Model 451.3## /4## ## as of 013645

• for USA only PE88.79-P- 2000MCU

SAM control unit, component description N10/10 GF54.21-P- 4157MCC * not for USA

• for USA only GF54.21-P- 4157MCU

Outside mirror adjustment switch, component description S50 GF88.79-P- 4110MCC BASIC KNOWLEDGE > TABLE OF CONTENTS FOR FUNCTION DESCRIPTION FOR ELECTRICALLY ADJUSTABLE OUTSIDE MIRROR - GF88.79-P-0999MCC > MODEL 451.3 /4 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO) Electrically adjustable outside mirrors, function

GF88.79-P-0005MCC Electrically adjustable outside mirrors, location of components

GF88.79-P-0005-01MCC Wiring diagram of outside mirrors * not for USA PE88.79-P-2000MCC Model 451.3## /4## ## up to 013644

• not for USA PE88.79-P-2000MCD Model 451.3## /4## ## as of 013645

• for USA only PE88.79-P-2000MCU Overview of system components for electrically adjustable outside mirror

GF88.79-P-9998MCC BASIC KNOWLEDGE > OUTSIDE MIRROR ADJUSTMENT SWITCH, COMPONENT DESCRIPTION - GF88.79-P-4110MCC > MODEL 451.3/4 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO)

Location

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2766 · Applies to: 450, 451, 452, 454 · AR: GF88.79-P-9998MCC, GF54.21-P-4157MCC, GF54.21-P-4157MCU, GF88.79-P-4110MCC

The outside mirror adjustment switch is located in the driver door panel Task Reading in following requests: Preselecting outside mirror to be adjusted Adjusting mirror lens upward and downward Adjusting mirror lens toward inside and outside Actuating following components: Mirror up/down adjustment motor (M21/1m1, M21/2m1) Mirror in/out adjustment motor (M21/1m2, M21/2m2) BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS FOR ELECTRICALLY ADJUSTABLE OUTSIDE MIRROR - GF88.79-P-9998MCC > MODEL 451.3/4 except CODE (V21) Electrically adjustable and heated outside mirrors (FFO) SAM control unit, component description N10/10 GF54.21-P-4157MCC * not for USA

• for USA only GF54.21-P-4157MCU Outside mirror adjustment S50 GF88.79-P-4110MCC Fig 1: Identifying Outside Rearview Mirror Adjustment Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

switch, component description

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2767 · Applies to: 450, 451, 452, 454 · AR: GF88.79-P-0999MCC

Table of contents for function description for electrically adjustable outside mirror

GF88.79-P-0999MCC Document number: pe88.79-p-2000-97mcu Document title: Wiring diagram of outside mirrors Code: Designation: Position: M21/1 Left electrically adjustable and heated exterior mirror 10L M21/1m1 Mirror up/down adjustment motor

M21/1m2 Mirror in/out adjustment motor

M21/1r1 Mirror heater

M21/1x1 Left electrically adjustable and heated exterior mirror connector

M21/2 Right electrically adjustable and heated exterior mirror 20L M21/2m1 Mirror up/down adjustment motor

M21/2m2 Mirror in/out adjustment motor

M21/2r1 Mirror heater

M21/2x1 Right electrically adjustable and heated exterior mirror connector

N10/10 SAM control unit 7A N10/10f20 Fuse 20 2A N10/10f37 Fuse 37

S50 Outside rearview mirror adjustment switch 15L W43 Ground (outside left fire wall) 22C W43 Ground (outside left fire wall) 14C X35/1 Left door separation point 8E X35/2 Right door separation point 18E Z3/44 Instrument cluster - radio circuit 15 connector sleeve (fused) 1H Z3/44 Instrument cluster - radio circuit 15 connector sleeve (fused) 17C Z52/12 Mirror adjustment connector sleeve 15H Z52/12 Mirror adjustment connector sleeve 9G Z6/35 Left door ground connector sleeve 14H Z6/35 Left door ground connector sleeve 8G Z6/36 Right door ground connector sleeve 21G

uitable pray lubricant

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2772 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-0550MCC, AR72.10-P-1950MCC, AR72.20-P-3510MCC, AR72.20-P-3510MCD, AR72.20-P-3515MCC (+5 more)

5 Lubricate door locks (arrows D, G) at the bottom of the rear-end door (3) using a suitable spray lubricant The door lock (arrow D) is only fitted on model 451.3.

6 Remove cover on the lock cylinder (arrow A) of the left door (1) and lubricate lock cylinder with lock cylinder grease

*BR00.45-Z-1012- 06A REPAIR MATERIALS Number Designation Order number BR00.45-Z-1012-06A Lock cylinder grease spray 50 ml A 002 989 06 51 TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: DOORS - AR72.00-Z- 9451CA > MODEL 451 Adjust front door MODEL 451.3/4 AR72.10-P-0550MCC Adjust front door crank window MODEL 451.3/4 AR72.10-P-1950MCC Adjust rear-end door MODEL 451.3/4 Bottom rear- end door AR72.20-P-3510MCC Adjust rear-end door MODEL 451.3 AR72.20-P-3510MCD Open tailgate using emergency unlocking feature MODEL 451.3 AR72.20-P-3515MCC Open tailgate using emergency unlocking feature MODEL 451.4 AR72.20-P-3515MCO Remove, install inner cover on rear- end door MODEL 451.3/4 AR72.20-P-0001MCC Remove rear-end door paneling MODEL 451.3/4 AR72.20-P-1000MCC Remove/install actuator of rear-end door lock MODEL 451.3/4 AR72.20-P-2555MCC Remove/install crank window in front door MODEL 451.3/4 AR72.10-P-1900MCC Remove/install door paneling MODEL 451.3/4 AR72.18-P-1000MCC Remove/install door shell MODEL 451.3/4 AR72.10-P-1020MCC Remove/install fixed front door window MODEL 451.3/4 AR72.10-P-1920MCC Remove/install front door MODEL 451.3/4 AR72.10-P-0500MCC Remove/install front door inner actuation MODEL 451.3/4 AR72.10-P-1400MCC Remove/install front door lock MODEL 451.3/4 AR72.10-P-4011MCC

Remove/install front door lock cylinder

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2773 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-4015MCC, AR72.10-P-6575MCC, AR72.10-P-1800MCC, AR72.29-P-1860MCC, AR72.29-P-0100MCC (+5 more)

MODEL 451.3/4 except CODE (L15) United Kingdom AR72.10-P-4015MCC Remove/install front door panel MODEL 451.3/4 AR72.10-P-6575MCC Remove/install front door power window MODEL 451.3/4 AR72.10-P-1800MCC Remove/install front door power window motor MODEL 451.3/4 with CODE (V43) Power window AR72.29-P-1860MCC Remove/install front door power window switch MODEL 451.3/4 with CODE (V43) Power window AR72.29-P-0100MCC Remove/install front outside door opener cable MODEL 451.3/4 AR72.10-P-1410MCC Remove/install gas-operated strut to rear-end door MODEL 451.3 AR72.20-P-3600MCC Remove/install gas-operated strut to rear-end door MODEL 451.3 AR72.20-P-3600MCU Remove/install inside opener cable on front door MODEL 451.3/4 AR72.10-P-1405MCC Remove/install liftgate lock MODEL 451.3 Lower rear-end door AR72.20-P-2550MCD Remove/install outside door handle on front door MODEL 451.3/4 AR72.10-P-2400MCC Remove/install power windows control unit MODEL 451.3/4 with CODE (V43) Power window AR72.29-P-1300MCC Remove/install power windows control unit MODEL 451.3/4 with CODE (V43) Power window AR72.29-P-1300MCU Remove/install rear-end door MODEL 451.3/4 Bottom rear- end door AR72.20-P-3500MCC Remove/install rear-end door MODEL 451.3 AR72.20-P-3500MCE Remove/install rear-end door MODEL 451.3 AR72.20-P-3500MCU Remove/install rear-end door check strap MODEL 451.3/4 AR72.20-P-2570MCC Remove/install rear-end door hinge MODEL 451.3/4 AR72.20-P-2560MCC Remove/install rear-end door hinge MODEL 451.3 AR72.20-P-2560MCD Remove/install rear-end door lock MODEL 451.3 Rear-end door upper section AR72.20-P-2550MCC Remove/install rear-end door lock MODEL 451.4 AR72.20-P-2550MCO Remove/install window crank MODEL 451.3/4 except CODE (V43) Power window AR72.10-P-1100MCC TESTING & REPAIR > REMOVE/INSTALL FRONT DOOR - AR72.10-P-0500MCC >

pillar

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2775 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-0550MCC

8 Unscrew bolts (3) of upper and lower door hinge on A-pillar, open door (1) and remove with aid of helper. Installation: Open door (1) a number of times against stop after tightening bolts (3). Then close door (1) and retighten bolts (3).Check door gaps (1); adjust if necessary: ↓

Adjust front door AR72.10- P- 0550MCC

*BA72.10- P-1002- 01H 9 Install in the reverse order

FRONT DOOR Number Designation Model 451.3/4 BA72.10-P-1002- 01H Screw for hinge on body Nm 40 TESTING & REPAIR > ADJUST FRONT DOOR - AR72.10-P-0550MCC > MODEL 451.3/4 Fig 1: Identifying Front Door Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Checking

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2776 · Applies to: 450, 451, 452, 454 · AR: AR88.80-P-6000MCC, AR72.18-P-1000MCC

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof Keep body parts and limbs well clear of moving parts. AS00.00-Z-0011-01A 1 Check gaps around door (1)

AR60.00-P-0700- 01MCC *BE60.00-P- 1001-01V

*452589012100 Removing

2 Remove maintenance flap

3 Remove left and right longitudinal member paneling

AR88.80-P-6000MCC 4 Partially loosen front CBS (2) to adjust left and right door (1)

AR88.00-P-1010- 04MCC 5 Completely lower crank window

Adjusting gap dimensions

6 Unscrew screws (3) and remove locking eye (4)

7 Loosen A-pillar bolts (5) and adjust corresponding gaps by moving door (1)

AR60.00-P-0700- 01MCC *BE60.00-P- 1001-01V

452589012100 8 Tighten A-pillar screws (5) BA72.10-P-1002-01H

Adjusting contour to front CBS (2) and to lower body

9 Remove door paneling

AR72.18-P-1000MCC 10 Unclip and remove cover (7)

11 Unclip cover (6) and lay down to side with bound wiring harness

12 Install door paneling without covers (6, 7) Do not install door handle and outside mirror. AR72.18-P-1000MCC 13 Loosen bolts on unfinished door (8) and adjust transition between front CBS (2) and door (1) by moving door (1). Avoid damage to paintwork. The contour of the front CBS (2) should be flush with the contour of the door (1) or project by a maximum of 1 mm.

Tighten bolts on unfinished door

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2777 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC, AR72.10-P-1950MCC, AR88.80-P-6000MCC

14 Tighten bolts on unfinished door (8) *BA72.10-P-1001-01H 15 Remove door paneling

AR72.18-P-1000MCC 16 Clip on covers (6, 7) and install door paneling

AR72.18-P-1000MCC

Adjusting contour to rear body

17 Insert locking eye (4) and screw in bolts (3) up to stop

18 Adjust transition between door (1) and body by moving locking eye (4) The door (1) must be flush with the body or should not protrude more than 1 mm.

19 Tighten screws (3) *BA72.10-P-1003-01H 20 Check adjustment of crank window on door (1), correct if necessary

AR72.10-P-1950MCC Install

21 Fasten front CBS (2)

AR88.00-P-1010- 04MCC 22 Install left and right longitudinal member paneling

AR88.80-P-6000MCC 23 Install maintenance flap

CHECK VALUES FOR GAPS Number Designation Model 451.3 Model 451.4 BE60.00- P-1001- 01V Gap dimension Front door to upper CBS front end Dimension "A" mm 5 (+1.5) 5 (+1.5) Front door to lower CBS front end Dimension "A1" mm 4 (+1.5) 4 (+1.5) Front door to entry Dimension "B" mm 7 (±1.5) 7 (±1.5) Front door to B- pillar Dimension "C" mm 7 (±1.5) 7 (±1.5) Door handle to B-pillar Dimension "D" mm 6 (±1.5) 6 (±1.5)

See picture AR60.00-P- 0700-01MCC AR60.00-P- 0700- 01MCC

FRONT DOOR

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2778 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-1020MCC

Number Designation Model 451.3/4 BA72.10-P-1001- 01H Screw for hinge on front door Nm 35 BA72.10-P-1002- 01H Screw for hinge on body Nm 40 BA72.10-P-1003- 01H Screw for striker eye on pillar Nm 32 TESTING & REPAIR > REMOVE/INSTALL DOOR SHELL - AR72.10-P-1020MCC > MODEL 451.3/4 Fig 2: Identifying Feeler Gauge (452 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

1400MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2781 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-6575MCC, AR72.10-P-1405MCC, AR72.10-P-4011MCC

MODEL 451.3/4

Remove/install

1 Remove left or right door panel lining (2). AR72.10-P-6575MCC 2 Unscrew bolts (3) from inner actuation (1).

3 Guide inner actuation (1) out of door panel lining (2) and remove.

4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL INSIDE OPENER CABLE ON FRONT DOOR - AR72.10-P-1405MCC > MODEL 451.3/4

Remove/install

1 Remove left and right door panel lining AR72.10-P-6575MCC 2 Remove right door CL motor (M14/5) or left door CL motor (M14/6) and remove inner actuation cable AR72.10-P-4011MCC Fig 1: Identifying Front Door Inner Actuation, Door Panel Lining And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Inner Actuation Cable And Door Motors Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install in the reverse order

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2782 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-1410MCC, AR72.18-P-1000MCC

(1). 3 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL FRONT OUTSIDE DOOR OPENER CABLE - AR72.10-P-1410MCC > MODEL 451.3/4

Remove/install

1 Remove left or right door paneling AR72.18-P-1000MCC 2 Unclip outer actuation cable (1) from right door CL motor or left door CL motor (arrow A).

3 Press relay lever (2) in direction of arrow with suitable screwdriver, unhook outer actuation cable (1) from relay lever (2) with needle nose pliers (arrow B) and remove

4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL FRONT DOOR POWER WINDOW - AR72.10-P- 1800MCC > MODEL 451.3/4 Fig 1: Removing Outer Actuation Cable Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove window

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2787 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-1950MCC

3 Remove window (3) upward. window seals (3), otherwise the window (3) must be replaced.

4 Install in the reverse order

FRONT DOOR Number Designation Model 451.3/4 BA72.10-P-1005- 01H Bolt, quarter window to upper door frame Nm 10 BA72.10-P-1006- 01H Bolt, quarter window to lower door frame Nm 10 TESTING & REPAIR > ADJUST FRONT DOOR CRANK WINDOW - AR72.10-P-1950MCC > MODEL 451.3/4 Shown on vehicle with code (V43) Power window Fig 2: Identifying Feeler Gauge (452 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Check

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2788 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC

1 Close door, slightly press back seal (2) in area of crank window (1) and measure gap between A- pillar and crank window (1) as well as roof frame and crank window (1). The distance between the crank window (1) and the A- pillar and the roof frame should run parallel over the entire length.

452589012100 2 Measure recess depth of crank window (1) in seal (2). 452589012100 Removing

3 Remove door paneling

AR72.18-P-1000MCC

Adjust height and longitudinal direction

4 Open door and lower crank window (1) approx. 10 cm.

5 Loosen bolts (3)

6 Adjust crank window (1) in vertical and longitudinal direction according to gap dimensions measured previously.

7 Tighten screws (3) *BA72.10-P-1007-01H Fig 1: Identifying Front Door Crank Window Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Clo e crank window (1) and door,

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2789 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC, AR72.10-P-2400MCC

8 Clo e crank window (1) and door, slightly press back seal (2) in area of crank window (1) and measure gap between A-pillar and crank window (1) as well as roof frame and crank window (1). The di tance between the crank window (1) and the A- pillar and the roof frame should run parallel over the entire length.If necessary, repeat adjustment

*452589012100

Adjust recess depth

9 Loosen bolts (4)

10 Adjust recess depth of crank window (1) in seal (2) by moving crank window (5)

11 Tighten bolts (4)

12 Measure recess depth of crank window (1) in seal (2). *452589012100 Install

13 Install door paneling.

AR72.18-P-1000MCC FRONT DOOR Number Designation Model 451.3/4 BA72.10-P-1007- 01H Screw, side window to power window Nm 10 TESTING & REPAIR > REMOVE/INSTALL OUTSIDE DOOR HANDLE ON FRONT DOOR - AR72.10-P-2400MCC > MODEL 451.3/4 Fig 2: Identifying Feeler Gauge (452 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on left side of vehicle on model 451.4

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2790 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-4011MCC

Remove/install

1 Open left and right door and unscrew bolts (3) form door handle (2).

2 Pull door handle (2) toward rear until brackets (arrows A) are exposed.

3 Remove door handle (2) until Bowden cable (5) of door handle (2) is accessible.

4 Unclip Bowden cable (4) on door handle (2) (arrow B) and unhook lock cylinder (6). When removing left door handle (2). 5 Unclip Bowden cable (5) on door handle (2) (arrow C), unhook from relay lever (7) and remove door handle (2).

6 Install in the reverse order

7 Check door handle (2) for proper function.

TESTING & REPAIR > REMOVE/INSTALL FRONT DOOR LOCK - AR72.10-P-4011MCC > MODEL 451.3/4 Fig 1: Identifying Outside Door Handle Components Of Front Door Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Pull lock cylinder (7)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2794 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-6575MCC

7 Pull lock cylinder (7) out of stator (4). Before removing tran mitter key (A) from removed lock cylinder (7), secure locking wedges against falling out with suitable adhesive tape.

8 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL FRONT DOOR PANEL - AR72.10-P-6575MCC > MODEL 451.3/4 Fig 1: Identifying Front Door Panel Components (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL DOOR PANELING - AR72.18-P-1000MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2798 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC

MODEL 451.3/4 Remove/install

1 Remove outside mirror

AR88.70- P- 9000MCC Remove outside door AR72.10- P- Fig 4: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Door Paneling Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

handle on front door

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2799 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-0001MCC

2 handle on front door

2400MCC 3 Mask front CBS (5) in area of door with suitable masking tape.

4 Remove shaft molding (4).

5 Unscrew bolt (3) from door paneling (1) and remove with guide sleeve (2).

6 Open door, carefully slide door paneling (1) toward rear and lift over door panel lining in rear area (arrow A). Handle door paneling (1) carefully to prevent scratching and breakage Installation: Do not damage seal (7) on window (6), otherwise window (6) must be replaced. Installation: Seal (7) on window (6) should run over shaft molding (4).

7 Carefully slide door paneling (1) toward front until brackets (8) are exposed in their guide in the door body shell.

8 Slightly lift door paneling (1) in the front and rear area of the shaft molding (4) and pull toward outside until catches (9) are released.

9 Carefully slide door paneling (1) toward front and remove downward. Installation: Before installing door paneling (1), pull shaft molding (4) from rear onto door paneling (1).

10 Install in the reverse order

TESTING & REPAIR > REMOVE, INSTALL INNER COVER ON REAR-END DOOR - AR72.20-P-0001MCC > MODEL 451.3/4

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2800 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-1000MCC

1 Remove rear-end door paneling

AR72.20- P- 1000MCC 2 Slightly pull left and right pins (2) toward rear, loosen from bracket (arrow) and slide out in direction of arrow (arrow B).

3 Open bottom rear-end door and continue to slide out pin (2) in direction of arrow (arrow C) and remove.

4 Remove inner cover (1) upward.

5 Remove foam insert (4) at inside of inner cover (1). When replacing inner cover (1).

6 Unscrew bolts (5) on handle (3) and remove handle (3) with springs (6). When replacing inner cover (1). Observe installation position of springs (6).

7 Install in the reverse order

TESTING & REPAIR > REMOVE REAR-END DOOR PANELING - AR72.20-P-1000MCC > MODEL 451.3/4 Fig 1: Identifying Inner Cover Components Of Rear-End Door Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

and remove bottom rear-end door

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2802 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-2550MCO

4 and remove bottom rear-end door paneling (1) until electrical connector (4) on rear-end door handle switch is accessible. door paneling (1), loosen wiring harness on rear-end door handle switch from retaining clip (5) on bottom rear-end door.

5 Disconnect electrical connector (4) Installation: Connect electrical connector (4) and check rear-end door handle switch for proper function.

6 Remove bottom rear-end door paneling (1) On vehicles with yellow, red or white bottom rear-end door paneling (1), mask off area above license plate lamps with strips of black textile adhesive tape (6).

7 Remove license plate, if applicable, with bracket. When replacing bottom rear-end door paneling (1).

8 Remove rear-end door handle switch When replacing bottom rear-end door paneling (1). AR72.20- P- 2555MCC 9 Remove company sign from bottom rear-end door paneling (1). When replacing bottom rear-end door paneling (1). AR88.00- P- 1014MCE 10 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL REAR-END DOOR LOCK - AR72.20-P-2550MCO

MODEL 451.4

Remove tapping plate (2) on left and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2804 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-2555MCC, AR72.20-P-1000MCC, AR72.20-P-2560MCC

9 Remove tapping plate (2) on left and right rear-end door lock (8) from stowage compartment.

10 Install in the reverse order

TAILGATE Number Designation Model 451.4 BA72.20-P-1002- 02F Bolt, check strap on bottom rear-end door lock Nm 20 BA72.20-P-1004- 02F Bolt, outer door lock on bottom rear-end door Nm 11 TESTING & REPAIR > REMOVE/INSTALL ACTUATOR OF REAR-END DOOR LOCK - AR72.20-P-2555MCC > MODEL 451.3/4

Remove/install

1 Remove door paneling on rear-end door (1) AR72.20-P-1000MCC 2 Unclip lugs (arrows) with suitable screwdriver and remove rear-end door handle switch (S88/9)

3 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL REAR-END DOOR HINGE - AR72.20-P-2560MCC

MODEL 451.3/4 Fig 1: Identifying Tailgate Handle Switch And Rear-End Door Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

9. Remove rear-end door (1) from trunk and fold floor covering (2) over toward front.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2807 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-3500MCC

Do not break or tear floor covering (2) when folding down. Aid of helper required. 10. Position rear-end door (1) and tighten nut (3) on left and right hinge on rear-end door (1) with specified tightening torque. Observe marking of hinge in relation to body. 11. Tighten bolts (4) on left and right check strap on rear-end door (1) with specified tightening torque. 12. Route rear-end door wiring harness (7) into interior compartment and insert grommet (6) on rear- end wiring harness (7) into body. 13. Clip in retaining clip (8) on rear-end door wiring harness (7). 14. Lay rear-end door wiring harness (7) on left in trunk in loops and fasten to present wiring harness with adhesive tape (9). 15. Install edge guard (5) on rear-end door (1). 16. Close rear-end door (1), check for installation position and correct locking; if necessary, align rear- end door (1). The top of the rear-end door (1) should form a line with the top of the fender. The distance to the fenders should be equal on left and right. TESTING & REPAIR > REMOVE/INSTALL REAR-END DOOR - AR72.20-P-3500MCC > MODEL 451.3/4 Bottom rear-end door Illustrated on model 451.4

Remove foam rubber insert for arresting

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2810 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-3510MCC

13 Remove foam rubber insert for arresting removed side supports from rear-end door (1). When replacing rear-end door (1) on model 451.4.

14 Install in the reverse order

15 Adjust rear-end door (1)

AR72.20- P- 3510MCC TAILGATE Number Designation Model 451.3 Model 451.4 BA72.20-P-1002- 02F Bolt, check strap to lower rear-end door lock Nm 20 20 BA72.20-P-1003- 02F Nut, lower rear-end door hinge to body Nm 43 43 TESTING & REPAIR > ADJUST REAR-END DOOR - AR72.20-P-3510MCC > MODEL 451.3/4 Bottom rear-end door Checking

1 Check dimensions gaps on tailgate (1) The rear-end door (1) should be at the same

Fig 1: Identifying Rear-End Door, Rear Fender, Nut, Bolts And Locking Eye Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TAILGATE

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2812 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-3515MCO

Number Designation Model 451.3 Model 451.4 BA72.20-P-1001- 02F Bolt, lower rear-end door check strap to body Nm 32 32 BA72.20-P-1003- 02F Nut, lower rear-end door hinge to body Nm 43 43 TESTING & REPAIR > OPEN TAILGATE USING EMERGENCY UNLOCKING FEATURE - AR72.20-P-3515MCO > MODEL 451.4 Dimensions: Fig 1: Opening Tailgate Using Emergency Unlocking Feature (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL FRONT DOOR POWER WINDOW SWITCH -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2814 · Applies to: 450, 451, 452, 454 · AR: AR72.29-P-0100MCC

AR72.29-P-0100MCC > MODEL 451.3/4 with CODE (V43) Power window Remove/install

1 Open door and loosen covering (3) in upper area with assembly wedge. *110589035900 2 Unclip paneling (1) in upper area with suitable screwdriver (2) and remove until the electrical connectors (4, 6) are accessible.

Fig 3: Identifying Twist Drill Bit Set (450 589 01 70 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Front Door Power Window Switch Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Disconnect electrical connector (5) from outside

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2815 · Applies to: 450, 451, 452, 454 · AR: AR72.29-P-1860MCC

3 Disconnect electrical connector (5) from outside rearview mirror adjustment switch (S50) On vehicles with code (V21) Electrically adjustable and heated outside mirrors (FFO)

4 Disconnect electrical connector (4) from left power window switch (S21/1) and electrical connector (6) from right power window switch (S21/2) and remove paneling (1).

5 Unclip left power window switch (S21/1) and right power window switch (S21/2) from paneling (1) with suitable screwdriver and remove.

6 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL FRONT DOOR POWER WINDOW MOTOR - AR72.29-P-1860MCC > MODEL 451.3/4 with CODE (V43) Power window Remove/install

Fig 2: Identifying Assembly Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Power Window Motors, Electrical Connector & Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BA72.20-P-1009-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2820 · Applies to: 450, 451, 452, 454 · AR: GF72.29-P-0003MCU

02F Bolt for center door lock on bottom rear-end door Nm 11 - BASIC KNOWLEDGE > POWER WINDOWS (PW [EFH]), FUNCTION - GF72.29-P-0003MCU

MODEL 451.3/4 with CODE (V43) Power window The power window system allows the side windows to be opened and closed. Function requirements Circuit 15 On Operating keys and switches Left power window switch Right power window switch Function To raise or lower the window, actuate and hold down the corresponding power window switch for longer than 420 ms in the opening or closing direction. This request is read in by the power window convenience feature control unit. The power window convenience feature control unit then energizes the corresponding power window motor until the motion request is stopped by the power window switch. The limit stop on the side window to be adjusted is recognized by the power window convenience feature control unit when the power consumption of the power window motor increases (lockup current recognition) Fig 1: Power Windows (EFH) Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

and actuation is then stopped.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2821 · Applies to: 450, 451, 452, 454 · AR: PE72.29-P-2001MCU, GF54.30-P-6000MCU, GF72.29-P-0998MCU, GF72.29-P-0003MCU, GF72.29-P-9997MCU (+1 more)

Switch and controls illumination The switch and controls illumination of the power windows switch is actuated via the instrument cluster. Pinch protection is not available on the electric power window system. Actuation of the corresponding power window motor is interrupted for lockup current recognition only by the power window convenience actuation control unit.

Power windows (PW), location of components

GF72.29-P-0003- 01MCC Wiring diagram for power windows

PE72.29-P-2001MCU

Instrument cluster, component description A1 GF54.30-P-6000MCU

Power window motor, component description M10/3, M10/4 GF72.29-P- 6030MCC

Power window control unit, component description N57/2 GF72.29-P- 6012MCC

Power window switch, component description S21/1, S21/2 GF72.29-P- 6040MCC BASIC KNOWLEDGE > TABLE OF CONTENTS, FUNCTION DESCRIPTION FOR POWER WINDOWS (PW) - GF72.29-P-0998MCU > MODEL 451.3/4 with CODE (V43) Power window

Power windows (PW [EFH]), function GF72.29-P-0003MCU

Power windows (PW), location of components GF72.29-P-0003-01MCU Wiring diagram for power windows PE72.29-P-2001MCU

Overview of system components for power windows (PW) GF72.29-P-9997MCU BASIC KNOWLEDGE > POWER WINDOW CONTROL UNIT, COMPONENT DESCRIPTION - GF72.29-P-6012MCC > MODEL 451.3/4 with CODE (V43) Power window

Location

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2822 · Applies to: 450, 451, 452, 454 · AR: GF72.29-P-6030MCC

The power window convenience feature control unit is located on the left side below the instrument panel on the crossmember. Task The power window convenience feature control unit takes over the control of the side windows. The control unit monitors the power consumption of the connected loads and thereby recognizes lockup or the limit stop of the side window. The following switches are read in: Left power window switch (S21/1) Right power window switch (S21/2) The following loads are switched: Left power window motor (M10/3) Right power window motor (M10/4) BASIC KNOWLEDGE > POWER WINDOW MOTOR, COMPONENT DESCRIPTION - GF72.29-P-6030MCC > MODEL 451.3/4 with CODE (V43) Power window Location The power window motors are screwed below the door paneling on the power window. Task The power window motors are actuated by the power window convenience feature control unit (N57/2) and allow to open and close the side windows. Design The power window motors are DC motors which turn to the right or left depending on the actuation. Fig 1: Locating Power Window Convenience Feature Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > POWER WINDOW SWITCH, COMPONENT DESCRIPTION -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2823 · Applies to: 450, 451, 452, 454 · AR: GF72.29-P-6040MCC

GF72.29-P-6040MCC > MODEL 451.3/4 with CODE (V43) Power window Location The power window switches are installed in the corresponding door paneling on the door handle. Task The left power window switch transfers the adjustment requests for the left power window motor (M10/3) to the power window convenience feature control unit (N57/2). Fig 1: Locating Left And Right Power Window Motors Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Left And Right Power Window Switches Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

The right power window switch transfers the adjustment requests for the right power window motor (M10/4) to

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2824 · Applies to: 450, 451, 452, 454 · AR: GF72.29-P-9997MCU, GF54.30-P-6000MCU, PE72.29-P-2001MCU, PE77.39-P-2200MCU

the power window convenience feature control unit. Design The power window switches are designed as pushbutton switches. Each switch has 2 actuation directions: Push to open window Pull to close window BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS FOR POWER WINDOWS (PW) - GF72.29-P-9997MCU > MODEL 451.3/4 with CODE (V43) Power window Instrument cluster, component description A1 GF54.30-P-6000MCU Power window motor, component description M10/3, M10/4 GF72.29-P- 6030MCC Power window control unit, component description N57/2 GF72.29-P- 6012MCC Power window switch, component description S21/1, S21/2 GF72.29-P- 6040MCC Table of contents, function description for power windows (PW)

GF72.29-P- 0998MCU WIRING DIAGRAMS > OVERVIEW OF WIRING DIAGRAMS FOR DOORS - PE72.00-P- 1100MCU > MODEL 451 Wiring diagram for power windows MODEL 451 PE72.29-P-2001MCU Electric wiring diagram for electric soft top MODEL 451 PE77.39-P-2200MCU WIRING DIAGRAMS > WIRING DIAGRAM FOR POWER WINDOWS - PE72.29-P-2001- 99MCU > Code: Designation: Position: A1 Instrument cluster 7 L M10/3 Left power window motor 17 L M10/4 Right power window motor 19 L N10/10 SAM control unit 3 L N10/10f3 Fuse 3 2 L N57/2 Power window convenience feature control unit 4 A N57/2 Power window convenience feature control unit 12 A N57/2 Power window convenience feature control unit 20 A

WIRING DIAGRAMS > WIRING DIAGRAM FOR POWER WINDOWS - PE72.29-P-2001MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2829 · Applies to: 450, 451, 452, 454 · AR: PE72.29-P-2001MCU

MODEL 451 Wiring diagram for power windows PE72.29-P-2001-99MCU Legend of wiring diagram for power windows PE72.29-P-2001-60MCU Use of wiring diagrams OV00.01-P-1901-03MCC Fig 2: Power Window - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Lubricate hinge

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2834 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-0550MCC, AR72.10-P-1950MCC, AR72.20-P-3510MCC, AR72.20-P-3510MCD, AR72.20-P-3515MCC (+3 more)

3 Lubricate hinge (arrows F) at the bottom of the rear-end door (3) using a suitable spray lubricant

4 Lubricate door lock (arrow B) on the left and right door (1) using a suitable spray lubricant

5 Lubricate door locks (arrows D, G) at the bottom of the rear-end door (3) using a suitable spray lubricant The door lock (arrow D) is only fitted on model 451.3.

6 Remove cover on the lock cylinder (arrow A) of the left door (1) and lubricate lock cylinder with lock cylinder grease

*BR00.45-Z-1012-06A REPAIR MATERIALS Number Designation Order number BR00.45-Z-1012-06A Lock cylinder grease spray 50 ml A 002 989 06 51 TESTING & REPAIR INDEX > TESTING AND REPAIR WORK: SMART: DOORS - AR72.00- Z-9451CA > MODEL 451 Adjust front door MODEL 451.3 /4 AR72.10-P-0550MCC Adjust front door crank window MODEL 451.3/ 4 AR72.10-P-1950MCC Adjust rear-end door MODEL 451.3 /4 Bottom rear- end door AR72.20-P-3510MCC Adjust rear-end door MODEL 451.3 AR72.20-P-3510MCD Open tailgate using emergency unlocking feature MODEL 451.3 AR72.20-P-3515MCC Open tailgate using emergency unlocking feature MODEL 451.4 AR72.20-P-3515MCO Remove, install inner cover on rear-end door MODEL 451.3/ 4 AR72.20-P-0001MCC Remove rear-end door MODEL 451.3 /4 AR72.20-P-1000MCC

paneling

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2835 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-2555MCC, AR72.10-P-1900MCC, AR72.18-P-1000MCC, AR72.10-P-1020MCC, AR72.10-P-1920MCC (+5 more)

Remove/install actuator of rear- end door lock MODEL 451.3/ 4 AR72.20-P-2555MCC Remove/install crank window in front door MODEL 451.3/ 4 AR72.10-P-1900MCC Remove/install door paneling MODEL 451.3/ 4 AR72.18-P-1000MCC Remove/install door shell MODEL 451.3/ 4 AR72.10-P-1020MCC Remove/install fixed front door window MODEL 451.3/ 4 AR72.10-P-1920MCC Remove/install front door MODEL 451.3/ 4 AR72.10-P-0500MCC Remove/install front door inner actuation MODEL 451.3/ 4 AR72.10-P-1400MCC Remove/install front door lock MODEL 451.3/ 4 AR72.10-P-4011MCC Remove/install front door lock cylinder MODEL 451.3 /4 except CODE (L15) United Kingdom AR72.10-P-4015MCC Remove/install front door panel MODEL 451.3 /4 AR72.10-P-6575MCC Remove/install front door power window MODEL 451.3/ 4 AR72.10-P-1800MCC Remove/install front door power window motor MODEL 451.3 /4 with CODE (V43) Power window AR72.29-P-1860MCC Remove/install front door power window switch MODEL 451.3 /4 with CODE (V43) Power window AR72.29-P-0100MCC Remove/install front outside door opener cable MODEL 451.3/ 4 AR72.10-P-1410MCC Remove/install gas-operated strut to rear-end door MODEL 451.3 AR72.20-P-3600MCC Remove/install gas-operated strut to rear-end door MODEL 451.3 AR72.20-P-3600MCU Remove/install inside opener cable on front door MODEL 451.3/ 4 AR72.10-P-1405MCC Remove/install liftgate lock MODEL 451.3 Lower rear-end door AR72.20-P-2550MCD Remove/install outside door handle on front door MODEL 451.3/ 4 AR72.10-P-2400MCC Remove/install power windows control unit MODEL 451.3 /4 with CODE (V43) Power window AR72.29-P-1300MCC Remove/install power windows control unit MODEL 451.3 /4 with CODE (V43) Power window AR72.29-P-1300MCU Remove/install rear-end door MODEL 451.3 /4 Bottom rear- end door AR72.20-P-3500MCC

Remove/in tall rear end door

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2836 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-3500MCU, AR72.20-P-2570MCC, AR72.20-P-2560MCC, AR72.20-P-2560MCD, AR72.20-P-2550MCC (+3 more)

MODEL 451 3 AR72 20 P 3500MCE Remove/install rear-end door MODEL 451.3 AR72.20-P-3500MCU Remove/install rear-end door check strap MODEL 451.3/ 4 AR72.20-P-2570MCC Remove/install rear-end door hinge MODEL 451.3/ 4 AR72.20-P-2560MCC Remove/install rear-end door hinge MODEL 451.3 AR72.20-P-2560MCD Remove/install rear-end door lock MODEL 451.3 Rear-end door upper section AR72.20-P-2550MCC Remove/install rear-end door lock MODEL 451.4 AR72.20-P-2550MCO Remove/install window crank MODEL 451.3 /4 except CODE (V43) Power window AR72.10-P-1100MCC TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT DOOR - AR72.10-P-0500MCC > MODEL 451.3/ 4 Shown on right side of vehicle on model 451.3

Remove/install

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof. Keep body parts and limbs well clear of moving parts. AS00.00-Z-0011-01A Fig 1: Identifying Front Door Components (Right Side - Model 451.3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove service flap

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2837 · Applies to: 450, 451, 452, 454 · AR: AR88.80-P-6000MCC, AR72.10-P-0550MCC

1 Remove service flap

2 Remove left and right longitudinal member paneling.

AR88.80-P-6000MCC 3 Partially loosen front CBS (2) to remove left and right door (1).

AR88.00-P-1010- 04MCC 4 Mark installation position of left and right door (1) in area of door hinge on A-pillar.

5 Mark installation position of left and right door (1) in marked areas (arrows) in relation to body with adhesive tape.

6 Release retainer (4) and disconnect left door separation point (X35/1) or right door separation point (X35/2)

7 Loosen retaining clip (5) on A-pillar.

8 Unscrew bolts (3) of upper and lower door hinge on A-pillar, open door (1) and remove with aid of helper. Installation: Open door (1) a number of times against stop after tightening bolts (3). Then close door (1) and retighten bolts (3).Check door gaps (1); adjust if necessary: ↓

Adjust front door AR72.10-P-0550MCC

*BA72.10-P-1002- 01H 9 Install in the reverse order

FRONT DOOR Number Designation Model 451.3/4 BA72.10-P-1002-01H Screw for hinge on body Nm 40 TESTING & REPAIR INDEX > ADJUST FRONT DOOR - AR72.10-P-0550MCC >

MODEL 451.3 /4

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2838 · Applies to: 450, 451, 452, 454 · AR: AR88.80-P-6000MCC

Checking

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof Keep body parts and limbs well clear of moving parts. AS00.00-Z-0011-01A 1 Check gaps around door (1)

AR60.00-P-0700- 01MCC *BE60.00-P- 1001-01V

Fig 2 Removing

2 Remove maintenance flap

3 Remove left and right longitudinal member paneling

AR88.80-P-6000MCC 4 Partially loosen front CBS (2) to adjust left

AR88.00-P-1010- 04MCC Fig 1: Identifying Front Door Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

and right door (1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2839 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC

5 Completely lower crank window

Adjusting gap dimensions

6 Unscrew screws (3) and remove locking eye (4)

7 Loosen A-pillar bolts (5) and adjust corresponding gaps by moving door (1)

AR60.00-P-0700- 01MCC *BE60.00-P- 1001-01V

Fig 2 8 Tighten A-pillar screws (5) *BA72.10-P-1002-01H

Adjusting contour to front CBS (2) and to lower body

9 Remove door paneling

AR72.18-P-1000MCC 10 Unclip and remove cover (7)

11 Unclip cover (6) and lay down to side with bound wiring harness

12 Install door paneling without covers (6, 7) Do not install door handle and outside mirror. AR72.18-P-1000MCC 13 Loosen bolts on unfinished door (8) and adjust transition between front CBS (2) and door (1) by moving door (1). Avoid damage to paintwork. The contour of the front CBS (2) should be flush with the contour of the door (1) or project by a maximum of 1 mm.

14 Tighten bolts on unfinished door (8) *BA72.10-P-1001-01H 15 Remove door paneling

AR72.18-P-1000MCC 16 Clip on covers (6, 7) and install door paneling

AR72.18-P-1000MCC

Adjusting contour to rear body

17 Insert locking eye (4)

and crew in bolt (3)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2840 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-1950MCC, AR88.80-P-6000MCC

up to stop 18 Adjust transition between door (1) and body by moving locking eye (4) The door (1) must be flush with the body or should not protrude more than 1 mm.

19 Tighten screws (3) *BA72.10-P-1003-01H 20 Check adjustment of crank window on door (1), correct if necessary

AR72.10-P-1950MCC Install

21 Fasten front CBS (2)

AR88.00-P-1010- 04MCC 22 Install left and right longitudinal member paneling

AR88.80-P-6000MCC 23 Install maintenance flap

CHECK VALUES FOR GAPS Number Designation Model 451.3 Model 451.4 BE60.00-P- 1001-01V Gap dimension Front door to upper CBS front end Dimension "A" mm 5 (+1.5) 5 (+1.5) Front door to lower CBS front end Dimension "A1" mm 4 (+1.5) 4 (+1.5) Front door to entry Dimension "B" mm 7 (±1.5) 7 (±1.5) Front door to B-pillar Dimension "C" mm 7 (±1.5) 7 (±1.5) Door handle to B-pillar Dimension "D" mm 6 (±1.5) 6 (±1.5)

See picture AR60.00-P- 0700- 01MCC AR60.00-P- 0700- 01MCC FRONT DOOR Number Designation Model 451.3/4 BA72.10-P-1001-01H Screw for hinge on front door Nm 35

BA72 10 P 1002 01H

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2841 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-1020MCC

Screw for hinge on body Nm 40 BA72.10-P-1003-01H Screw for striker eye on pillar Nm 32 TESTING & REPAIR INDEX > REMOVE/INSTALL DOOR SHELL - AR72.10-P-1020MCC > MODEL 451.3/ 4 Shown on model 451.4 with code (V43) Power window Fig 2: Identifying Feeler Gauge (452 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Door Shell Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2842 · Applies to: 450, 451, 452, 454 · AR: AR88.80-P-6000MCC, AR72.10-P-0550MCC, AR72.10-P-6575MCC, AR72.10-P-1800MCC, AR72.10-P-1920MCC (+1 more)

Risk of injury caused by fingers being pinched or crushed when removing, installing or aligning hoods, doors, trunk lids, tailgates or sliding roof. Keep body parts and limbs well clear of moving parts. AS00.00-Z-0011-01A 1 Remove service flap

2 Remove left and right longitudinal member paneling.

AR88.80-P-6000MCC 3 Partially loosen front CBS to remove door body shell (7). Installation: Adjust front door before fastening front CBS.See: ↓ AR88.00-P-1010- 04MCC

Adjust front door AR72.10-P-0550MCC 4 Remove door panel lining (8).

AR72.10-P-6575MCC 5 Remove power window (6)

AR72.10-P-1800MCC 6 Remove stationary window.

AR72.10-P-1920MCC 7 Unscrew bolts (2, 4) on window guide (3) of crank window and remove window guide.

8 Remove right door CL motor (M14/5) and left door CL motor (M14/6)

AR72.10-P-4011MCC 9 Carefully press front Aid of helper

Fig 2: Identifying Door Shell And Door Hinge Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

CBS to ide, un crew

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2843 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-1100MCC

bolts (1) on door hinge (9) from A-pillar and remove door body shell (7). required

*BA72.10-P-1002- 01H 10 Unscrew bolts on door hinge (9) from door body shell (7) and remove door hinges (9). When replacing door body shell (7).

*BA72.10-P-1001- 01H 11 Install in the reverse order

FRONT DOOR Number Designation Model 451.3/4 BA72.10-P-1001-01H Screw, hinge to front door Nm 35 BA72.10-P-1002-01H Screw, hinge to body Nm 40 TESTING & REPAIR INDEX > REMOVE/INSTALL WINDOW CRANK - AR72.10-P-1100MCC

MODEL 451.3 /4 except CODE (V43) Power window Remove 1 Open front door 2 Insert suitable screwdriver (3) into opening (arrow A) of cover ring (2) on window crank (1) Fig 1: Removing/Installing Window Crank Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Turn window crank (1) clockwise until clamping

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2844 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-1400MCC, AR72.10-P-6575MCC, AR72.10-P-1405MCC

3 Turn window crank (1) clockwise until clamping spring (4) is unlocked 4 Remove window crank (1) 5 Remove cover ring (2) Install 6 Insert clamping spring (4) into crank window guide (1) 7 Position window crank (1) as shown and press onto window lifter shaft TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT DOOR INNER ACTUATION - AR72.10-P-1400MCC > MODEL 451.3/ 4

Remove/install

1 Remove left or right door panel lining (2).

AR72.10-P-6575MCC 2 Unscrew bolts (3) from inner actuation (1).

3 Guide inner actuation (1) out of door panel lining (2) and remove.

4 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL INSIDE OPENER CABLE ON FRONT DOOR - AR72.10-P-1405MCC > MODEL 451.3/ 4 Fig 1: Identifying Front Door Inner Actuation, Door Panel Lining And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2845 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-6575MCC, AR72.10-P-4011MCC, AR72.10-P-1410MCC

1 Remove left and right door panel lining

AR72.10-P-6575MCC 2 Remove right door CL motor (M14/5) or left door CL motor (M14/6) and remove inner actuation cable (1).

AR72.10-P-4011MCC 3 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT OUTSIDE DOOR OPENER CABLE - AR72.10-P-1410MCC > MODEL 451.3/ 4 Fig 1: Identifying Inner Actuation Cable On Front Door Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2846 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC, AR72.10-P-1800MCC

1 Remove left or right door paneling

AR72.18-P-1000MCC 2 Unclip outer actuation cable (1) from right door CL motor or left door CL motor (arrow A).

3 Press relay lever (2) in direction of arrow with suitable screwdriver, unhook outer actuation cable (1) from relay lever (2) with needle nose pliers (arrow B) and remove

4 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT DOOR POWER WINDOW - AR72.10-P-1800MCC > MODEL 451.3/ 4 Fig 1: Identifying Front Outside Door Opener Cable Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2847 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-1900MCC, AR72.10-P-6575MCC, AR72.29-P-1860MCC

1 Remove crank window.

AR72.10-P-1900MCC 2.1 Remove door panel lining. On vehicles without code (V43) Power window AR72.10-P-6575MCC 2.2 Remove left power window motor (M10/3) and right power window motor (M10/4) On vehicles with code (V43) Power window AR72.29-P-1860MCC 3 Mark installation position of power window (3) in area of bolts (1). Only when tubular frame is not replaced.

4 Drill out rivets (2) in power window (3). Use spray adhesive to cement rivet residues in tubular frame.

Fig 3

For cordless drill/driver Fig 2 5 Unscrew bolts (1) on power window (3)

6 Open door, guide power window (3) out of door

Fig 1: Identifying Front Door Power Window Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

and remove

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2848 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-1900MCC

7 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL CRANK WINDOW IN FRONT DOOR - AR72.10-P-1900MCC > MODEL 451.3/ 4 Shown on model 451.4 with code (V43) Power window Fig 2: Identifying Rivet Gun (450 589 00 39 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Nosepiece (450 589 03 39 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2849 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC, AR72.10-P-1950MCC

1 Lower crank window (1) approx. 10 cm.

2 Remove door paneling

AR72.18-P-1000MCC 3 Mark installation position of crank window (1) in area of clamping jaws (2). When reusing crank window (1).

4 Unscrew bolts (3) on clamping jaws (2) on power window *BA72.10-P-1007- 01H

Installation: When installing a new crank window (1)Adjust gaps of crank window (1), see: ↓

Adjust front door crank window AR72.10-P-1950MCC 5 Remove crank window (1) upward from door shaft.

6 Install in the reverse order

FRONT DOOR Fig 1: Identifying Crank Window, Clamping Jaw And Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Number

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2850 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-1920MCC, AR72.10-P-1900MCC

Designation Model 451.3/4 BA72.10-P-1007-01H Screw, side window to power window Nm 10 TESTING & REPAIR INDEX > REMOVE/INSTALL FIXED FRONT DOOR WINDOW - AR72.10-P-1920MCC > MODEL 451.3/ 4 Shown on model 451.4

Remove/install

1 Remove crank window (1) from front door.

AR72.10-P-1900MCC 2 Unscrew bolts (5, 6) on window (3). Installation: Align window (3) before tightening bolts (5, 6).Adjust window (3) in area (arrow A) of roof frame strut seal (2) and in area (arrow B) of seal (4) according to gaps and recess depth.

*BA72.10-P-1005- 01H Fig 1: Identifying Crank Window, Roof Frame Strut Seal, Washer, Seal And Bolts - Shown On Model 451.4 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Check

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2852 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC

1 Close door, slightly press back seal (2) in area of crank window (1) and measure gap between A-pillar and crank window (1) as well as roof frame and crank window (1). The distance between the crank window (1) and the A- pillar and the roof frame should run parallel over the entire length.

Figure 2 Measure recess depth of crank window (1) in seal (2). Figure Removing

3 Remove door paneling

AR72.18-P-1000MCC

Adjust height and longitudinal direction

4 Open door and lower crank window (1) approx. 10 cm.

5 Loosen bolts (3)

6 Adjust crank window (1) in vertical and

Fig 1: Identifying Front Door Crank Window And Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

longitudinal direction

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2853 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC

according to gap dimensions measured previously. 7 Tighten screws (3) *BA72.10-P-1007-01H 8 Close crank window (1) and door, slightly press back seal (2) in area of crank window (1) and measure gap between A-pillar and crank window (1) as well as roof frame and crank window (1). The distance between the crank window (1) and the A- pillar and the roof frame should run parallel over the entire length.If necessary, repeat adjustment

Figure

Adjust recess depth

9 Loosen bolts (4)

10 Adjust recess depth of crank window (1) in seal (2) by moving crank window (5)

11 Tighten bolts (4)

12 Measure recess depth of crank window (1) in seal (2). Figure Install

13 Install door paneling.

AR72.18-P-1000MCC FRONT DOOR Number Designation Model 451.3/4 BA72.10-P-1007-01H Screw, side window to power window Nm 10 Fig 2: Identifying Feeler Gauge (452 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > REMOVE/INSTALL OUTSIDE DOOR HANDLE ON FRONT

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2854 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-2400MCC

DOOR - AR72.10-P-2400MCC > MODEL 451.3/ 4 Shown on left side of vehicle on model 451.4

Remove/install

1 Open left and right door and unscrew bolts (3) form door handle (2).

2 Pull door handle (2) toward rear until brackets (arrows A) are exposed.

3 Remove door handle (2) until Bowden cable (5) of door handle (2) is accessible.

4 Unclip Bowden cable (4) on door handle (2) (arrow B) and unhook lock cylinder (6). When removing left door handle (2). 5 Unclip Bowden cable (5) on door handle (2) (arrow C), unhook from relay lever (7) and remove door handle (2).

6 Install in the reverse order

7 Check door handle (2) for proper function.

TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT DOOR LOCK - AR72.10-P- 4011MCC > Fig 1: Identifying Outside Door Handle Of Front Door Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODEL 451.3/ 4

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2855 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC

Remove/install

1 Close crank window

2 Remove door paneling

AR72.18-P-1000MCC 3 Mark installation position of window (1), unscrew bolts (2) and loosen window (1) on front door. Installation: Do not damage seals on window (1) during installation, otherwise window (1) must be replaced. Installation: Align window (1) according to markings made previously before tightening bolts (2).

*BA72.10-P-1005- 01H

*BA72.10-P-1006- 01H 4 Disconnect electrical connector (3) from right door CL motor (M14/5)

Fig 1: Identifying Front Door Lock Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

or left door CL motor

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2856 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-4015MCC

(M14/6) 5 Unscrew bolts (4) on left right door CL motor (M14/5) or left door CL motor (M14/6) *BA72.10-P-1004- 01H 6 Guide right door CL motor (M14/5) or left door CL motor (M14/6) out of door until cables (5, 7) are accessible.

7 Unclip cable (5) from right door CL motor (M14/5) or left door CL motor (M14/6) (arrow A) and unhook relay lever (6).

8 Unclip cable (7) on right door CL motor (M14/5) or left door CL motor (M14/6) (arrow B), unhook from relay lever (8) and remove right door CL motor (M14/5) or left door CL motor (M14/6). A cable for the lock cylinder in the door handle is additionally installed on the left door CL motor (M14/6). Observe installation position of this cable when removing.

9 Install in the reverse order

FRONT DOOR Number Designation Model 451.3/4 BA72.10-P-1004-01H Bolt, lock to front door Nm 16 BA72.10-P-1005-01H Bolt, quarter window to upper door frame Nm 10 BA72.10-P-1006-01H Bolt, quarter window to lower door frame Nm 10 TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT DOOR LOCK CYLINDER - AR72.10-P-4015MCC > MODEL 451.3 /4 except CODE (L15) United Kingdom

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2857 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-2400MCC

1 Remove left door handle (1).

AR72.10-P-2400MCC 2 Remove retaining spring (5).

3 Remove relay lever (3) Installation: The guide (arrow) of the lock cylinder (7) should be positioned vertically in the stator (4), as shown. Only then it is possible to install the relay lever (3) correctly.Ensure that spring (6) is correctly installed in relay lever (3).

4 Unclip bracket (8) from stator (4) and remove stator (4) with lock cylinder (7) from door handle (1).

5 Insert transmitter key

Fig 1: Identifying Front Door Lock Cylinder Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

"Remove, install window"

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2860 · Applies to: 450, 451, 452, 454 · AR: AR88.80-P-6000MCC, AR72.18-P-1000MCC

17.5.10 "Remove, install window" added Step 11.2

"Code (I53) Head/thoraxbag" inserted Step 9

Remove/install

1 Remove service flap

2 Remove left and right longitudinal member paneling

AR88.80-P-6000MCC 3 Partially loosen front CBS (2) to remove left and right door lining (5)

AR88.00-P-1010- 04MCC 4 Remove door paneling

AR72.18-P-1000MCC 5 Carefully pull front CBS (2) away from vehicle, disconnect left door separation point (X35/1) or right door separation point (X35/2) and loosen retaining clip (1) from A-pillar

6 Mark installation position of quarter window (9), unscrew bolts (8) and detach quarter window (9) on door. Installation: Do not damage seals on quarter window (9) when installing, otherwise quarter window (9) must be replaced. Installation: Before tightening bolts (8), align quarter window (9) according to markings made perviously.

*BA72.10-P-1005- 01H

*BA72.10-P-1006- 01H 7 Unclip upper cover (3) from door lining (5) Only loosen upper cover (3); it is still connected with the wiring harness (13).

8 Unclip lower cover (4) on door lining (5) and remove

Remove spring washers

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2861 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-1100MCC

9 Remove spring washers (19) and remove hip protector (18) For code (I53) Head/thoraxbag Installation: Ensure that hip protector (18) is seated correctly on bracket (20). Replace spring washers (19). Counterhold door paneling (5) when press on spring washers (19). Helper required

10 Disconnect electrical connector (17) from right door CL motor (M14/5) or left door CL motor (M14/6)

11.1 Disconnect electrical connector (7) from left power window motor (M10/3) or right power window motor (M10/4) On vehicles with code (V43) Power window

11.2 Remove window crank Vehicles without code (V43) Power window lifter AR72.10-P-1100MCC 12 Open door and unclip covering (10) in front area with assembly wedge (11) Detach cover (10) only in lower area with assembly wedge (11) as shown.

Mounting wedge Fig 4 13 Slide covering (10) toward front and guide out of door paneling (5) in rear area (arrow A)

14 Unscrew bolt (12) behind covering (10)

15 Remove expansion clip (6)

16 Unclip door trim (5) in lower area, slide upward and remove until cable (16) on inside door opener (14) is accessible Aid of helper required. Installation: Ensure that the wiring harness (13) is not damaged by pinching when installing the door covering (5). Installation: Ensure that the impact protection (15) is

positioned in its guide.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2862 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC

17 Unhook cable (16) from inside door opener (14) (arrow B) and then unhook (arrow C)

18 Remove door liner (5) Aid of helper required.

19 Install in the reverse order

FRONT DOOR Number Designation Model 451.3/4 BA72.10-P-1005-01H Bolt, quarter window to upper door frame Nm 10 BA72.10-P-1006-01H Bolt, quarter window to lower door frame Nm 10 TESTING & REPAIR INDEX > REMOVE/INSTALL DOOR PANELING - AR72.18-P-1000MCC

MODEL 451.3/ 4 Fig 4: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2863 · Applies to: 450, 451, 452, 454 · AR: AR88.70-P-9000MCC, AR72.10-P-2400MCC

1 Remove outside mirror

AR88.70-P-9000MCC 2 Remove outside door handle on front door

AR72.10-P-2400MCC 3 Mask front CBS (5) in area of door with suitable masking tape.

4 Remove shaft molding (4).

5 Unscrew bolt (3) from door paneling (1) and remove with guide sleeve (2).

6 Open door, carefully slide door paneling (1) toward rear and lift over door panel lining in rear area (arrow A). Handle door paneling (1) carefully to prevent scratching and breakage Installation: Do not damage seal (7) on window (6), otherwise window (6) must be replaced. Installation: Seal (7)

Fig 1: Identifying Door Paneling Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

on window (6) should

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2864 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-0001MCC

run over shaft molding (4). 7 Carefully slide door paneling (1) toward front until brackets (8) are exposed in their guide in the door body shell.

8 Slightly lift door paneling (1) in the front and rear area of the shaft molding (4) and pull toward outside until catches (9) are released.

9 Carefully slide door paneling (1) toward front and remove downward. Installation: Before installing door paneling (1), pull shaft molding (4) from rear onto door paneling (1).

10 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE, INSTALL INNER COVER ON REAR-END DOOR - AR72.20-P-0001MCC > MODEL 451.3/ 4

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2865 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-1000MCC

1 Remove rear-end door paneling

AR72.20-P-1000MCC 2 Slightly pull left and right pins (2) toward rear, loosen from bracket (arrow) and slide out in direction of arrow (arrow B).

3 Open bottom rear-end door and continue to slide out pin (2) in direction of arrow (arrow C) and remove.

4 Remove inner cover (1) upward.

5 Remove foam insert (4) at inside of inner cover (1). When replacing inner cover (1).

6 Unscrew bolts (5) on handle (3) and remove handle (3) with springs (6). When replacing inner cover (1). Observe installation position of springs (6).

Fig 1: Identifying Inner Cover Of Rear-End Door Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

door and inner cover

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2867 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-2555MCC, AR88.00-P-1014MCE

(2) on bottom rear-end door. 3 Unscrew bolts (3) on rear-end door at bottom. Rechargeable drill / screwdriver

4 Carefully close bottom rear-end door and remove bottom rear-end door paneling (1) until electrical connector (4) on rear-end door handle switch is accessible. When removing bottom rear-end door paneling (1), loosen wiring harness on rear- end door handle switch from retaining clip (5) on bottom rear-end door.

5 Disconnect electrical connector (4) Installation: Connect electrical connector (4) and check rear-end door handle switch for proper function.

6 Remove bottom rear- end door paneling (1) On vehicles with yellow, red or white bottom rear-end door paneling (1), mask off area above license plate lamps with strips of black textile adhesive tape (6).

7 Remove license plate, if applicable, with bracket. When replacing bottom rear-end door paneling (1).

8 Remove rear-end door handle switch When replacing bottom rear-end door paneling (1). AR72.20-P-2555MCC 9 Remove company sign from bottom rear-end door paneling (1). When replacing bottom rear-end door paneling (1). AR88.00-P-1014MCE 10 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL REAR-END DOOR LOCK - AR72.20-P- 2550MCC > MODEL 451.3 Rear-end door upper section

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2868 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-1000MCC, AR72.20-P-2550MCD

1 Remove bottom rear-end door paneling AR72.20-P-1000MCC 2 Remove seal (1) on bottom rear- end door

3 Remove bolt (2) and remove cover (3)

4 Detach electrical connector (6) from rear-end door and disconnect

5 Unscrew bolts (5) and remove rear-end door upper section lock (4) until Bowden cable (7) is accessible

6 Unclip Bowden cable (7) from brackets (arrows A, B) and remove rear-end door upper section lock (4)

7 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL LIFTGATE LOCK - AR72.20-P-2550MCD > MODEL 451.3 Lower rear-end door Fig 1: Identifying Upper Rear-End Door Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

As of 31.8.10 on left side of vehicle

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2869 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-1000MCC

Remove/install

1 Remove bottom rear- end door paneling

AR72.20-P-1000MCC Fig 1: Identifying Lower Rear-End Door Liftgate Lock Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Left Side Liftgate Lock Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

REAR-END DOOR

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2871 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-2555MCC, AR72.20-P-1000MCC

Number Designation Model 451.3 BA72.20-P-1002-02F Bolt, check strap to lower rear-end door lock Nm 20 BA72.20-P-1004-02F Bolt, outer door lock to lower rear-end door Nm 11 TESTING & REPAIR INDEX > REMOVE/INSTALL ACTUATOR OF REAR-END DOOR LOCK - AR72.20-P-2555MCC > MODEL 451.3/ 4

Remove/install

1 Remove door paneling on rear- end door (1) AR72.20-P-1000MCC 2 Unclip lugs (arrows) with suitable screwdriver and remove rear- end door handle switch (S88/9)

3 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL REAR-END DOOR HINGE - AR72.20-P- 2560MCC > MODEL 451.3/ 4 Fig 1: Identifying Tailgate Handle Switch And Rear-End Door Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2872 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-3500MCC

1 Remove bottom rear- end door (1).

AR72.20-P-3500MCC 2 Cut left and right bolt (2) off flush in marked area (arrow) on rear- end door hinges (3). Cut off outer section of left and right bolt (2).Cutting discs and angle grinder (electric/ pneumatic)

3 Slide both bolts (2) out of rear-end door hinges (3) and remove rear-end door hinges (3).

Install

4 Position rear-end door hinges (3) on bottom rear-end door (1) and insert both bolts (2) from inside into bottom rear-end door (1). Use new bolts (2).

5 Spread both bolts (2) flush at rear-end door hinges (3) in marked area (arrow) with suitable tool. Spread bolt (2) so that it cannot be pushed out.

6 Install bottom rear-end door (1).

AR72.20-P-3500MCC TESTING & REPAIR INDEX > REMOVE/INSTALL REAR-END DOOR HINGE - AR72.20-P- 2560MCD > MODEL 451.3 Fig 1: Identifying Rear-End Door Bottom, Pin And Door Hinge For Tailgate Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2873 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4470MCC

1 Open rear-end door (4)

2 Remove rear roof frame trim

AR68.30-P-4470MCC 3 Mark position of door hinges (3, 6) in relation to rear-end door (4) and to body Do not remove both door hinges (3, 6) simultaneously; reinstall removed door hinge (3 or 6) before removing second door hinge (3 or 6)

4 Center punch bolts (5, 7) from bottom and drill out carefully When drilling out do not damage roof paneling, otherwise it must be replaced. Aid of helper required when drilling out second bolt (5, 7).Only drill out bolts (5, 7) until bolt head can be taken off from top.

Cordless drill/driver and wet/dry vacuum Fig 2 Fig 1: Identifying Rear-End Door Hinge Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

cleaner

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2874 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-3510MCD, AR68.30-P-4470MCC

5 Remove bolts (1, 2) from door hinge (3, 6) and take off door hinge (3, 6) Helper required for holding rear-end door (4).

Install

6 Instead of bolts (5, 7) fix two M6 nuts in place on door hinge (3, 6) from the top Use, for example, instant adhesive to fix the two M6 nuts in place.

7 Align door hinge (3, 6) and screw in suitable M6 bolts up to stop from bottom Observe length of M6 bolts; if M6 bolts are too long, they can hit against the roof paneling and damage it. Aid of helper required for holding rear-end door (4)Counterhold M6 nuts with open end wrench from top (A arrows).

8 Align rear-end door (4) on door hinge (3, 6) and screw in bolts (1, 2) yo to stop Aid of helper required for holding rear-end door (4)

9 Align door hinge (3, 6) to markings previously made and screw in M6 bolts and bolts (1, 2) Installation: Check gaps on rear-end door (4), adjust if necessary. Refer to: ↓

Adjust rear-end door AR72.20-P-3510MCD

*BA72.20-P-1005-02F

*BA72.20-P-1006-02F 10 Install rear roof frame trim

AR68.30-P-4470MCC REAR-END DOOR Number Designation Model 451.3 BA72.20-P-1005-02F Bolt, hinge of rear-end door upper section to body Nm 12 BA72.20-P-1006-02F Bolt, hinge to glass pane Nm 12

TESTING & REPAIR INDEX > REMOVE/INSTALL REAR-END DOOR CHECK STRAP -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2875 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-2570MCC, AR68.30-P-4800MCC

AR72.20-P-2570MCC > MODEL 451.3/ 4 Shown on right side of vehicle on model 451.4

Remove/install

1 Remove left and right side paneling in trunk

AR68.30-P-4800MCC 2 Unscrew bolts (3) and remove door check strap (1). The locking eye (4) is firmly connected to the door check strap (1). Secure rear-end door against folding down when removing both door check straps (1). Installation: Align locking eye (4);

Fig 2: Identifying Twist Drill Bit Set (450 589 01 70 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Door Check Strap, Bolts And Locking Eye - Shown On Model 451.4 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

specified tightening torque.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2878 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-3500MCC

Observe marking of hinge in relation to body. 11. Tighten bolts (4) on left and right check strap on rear-end door (1) with specified tightening torque. 12. Route rear-end door wiring harness (7) into interior compartment and insert grommet (6) on rear- end wiring harness (7) into body. 13. Clip in retaining clip (8) on rear-end door wiring harness (7). 14. Lay rear-end door wiring harness (7) on left in trunk in loops and fasten to present wiring harness with adhesive tape (9). 15. Install edge guard (5) on rear-end door (1). 16. Close rear-end door (1), check for installation position and correct locking; if necessary, align rear- end door (1). The top of the rear-end door (1) should form a line with the top of the fender. The distance to the fenders should be equal on left and right. TESTING & REPAIR INDEX > REMOVE/INSTALL REAR-END DOOR - AR72.20-P-3500MCC

MODEL 451.3 /4 Bottom rear-end door Illustrated on model 451.4 Illustrated on model 451.4 Fig 1: Identifying Rear-End Door Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2879 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-1000MCC

1 Remove door paneling from rear-end door (1).

AR72.20-P-1000MCC 2 Remove covers (4) from left and right door lock on rear-end door (1).

3 Separate electrical connector (5) On model 451.3 the electrical connector (5) is located in the marked area (arrow).

4 Disconnect electrical connector from rear- end door CL motor (M14/7)

5 Loosen retaining clamp (2) from rear-end door wiring harness (3) and expose rear-end door wiring harness (3) on rear-end door (1).

6 Loosen grommet (6) on rear-end door (1)

7 Open rear-end door (1) and loosen bolt (8) on left and right door check The bolt (8) remains on the corresponding door check strap.

Fig 2: Identifying Rear-End Door Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > REMOVE/INSTALL REAR-END DOOR - AR72.20-P-3500MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2881 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-3500MCU

MODEL 451.3

Remove/install

1 Remove cover on left side luggage compartment paneling (2).

2 Guide rear-end door wiring harness (1) out of body opening

3 Push back foam rubber jacketing (arrow) and disconnect all electrical connectors as well as water fluid hose on rear-end door wiring harness (1).

4 Loosen grommet (9) on rear-end door wiring harness (1) in area of left door hinge (4). Installation: Arrow on grommet (9) should coincide with marking on body.

Fig 1: Identifying Rear-End Door Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Fasten suitable pulling

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2882 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-3510MCD, AR82.30-P-6900MCC, AR82.10-P-5375MCC, AR88.30-P-0500MCC

5 Fasten suitable pulling out (3) on rear-end door wiring harness (1) and guide rear-end door (1) upward out of vehicle.

Risk of injury Gas pressure struts are under high pressure and can pinch and crush body parts during work Remove and install gas pressure struts only in relaxed position and on components properly secured. AS00.00-Z-0012-01A 6 Lift retainers (6) with suitable screwdriver and unclip gas- operated strut (7) on rear-end door (8). Ensure that rear- end door (8) does not close unintentionally to prevent damage. Do not remove retainers (6) because otherwise tension on retainers (6) is lost. Installation: Clip gas-operated strut (7) to ball heads on rear-end door (8) using retainers (6) clipped in.

7 Remove bolts (5) from door hinges (4) and take off rear-end door (8). Aid of helper required. Installation: Adjust gaps on rear-end door (8), adjust if necessary.$ Refer to: ↓

Adjust rear-end door (8) AR72.20-P-3510MCD

*BA72.20-P-1006- 02F 8 Remove rear-end door wiper motor When replacing rear- end door (8). AR82.30-P-6900MCC 9 Remove center high- mounted brake lamp When replacing rear- end door (8). AR82.10-P-5375MCC 10 Remove rear spoiler When replacing rear- end door (8). AR88.30-P-0500MCC 11 Remove ball heads from gas-operated struts (7). When replacing rear- end door (8).

*BA72.20-P-1008- 02F 12 Expose rear-end door wiring harness (1) on When replacing rear- end door (8).

rear-end door (8) and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2883 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-3510MCC

remove. 13 Install in the reverse order

14 Check rear window heater, rear wiper system and center high- mounted brake lamp for proper function

REAR-END DOOR Number Designation Model 451.3 BA72.20-P-1006-02F Bolt, hinge to glass pane Nm 12 BA72.20-P-1008-02F Gas-operated spring ball head to upper rear-end door Nm 12 TESTING & REPAIR INDEX > ADJUST REAR-END DOOR - AR72.20-P-3510MCC > MODEL 451.3 /4 Bottom rear-end door Checking

Fig 1: Identifying Rear-End Door, Rear Fender, Nut, Bolts And Locking Eye Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Check dimensions

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2884 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4800MCC

1 Check dimensions gaps on tailgate (1) The rear-end door (1) should be at the same height as the rear fenders (2) in the marked areas (arrows A) and the gap dimension (arrows B) should be equal on both sides.

Removing

2 Remove and left and right paneling in trunk

AR68.30-P-4800MCC

Adjust

3 Loosen bolts (4) on left and right locking eye (5).

4 Lift load compartment floor covering and loosen nuts (3) on left and right hinge on rear-end door (1) so that rear-end door (1) can still be moved.

5 Close rear-end door (1) and check gap dimensions on rear- end door (1), adjust if necessary. The rear-end door (1) should be at the same height as the rear fenders (2) in the marked areas (arrows A) and the gap dimension (arrows B) should be equal on both sides.

6 Open tailgate (1) Ensure that the adjusted position of the rear-end door (1) does not change.

7 Lift load compartment floor covering and tighten nuts (3) on left and right hinge on rear-end door (1). *BA72.20-P-1003-02F 8 Close rear-end door (1).

9 Align locking eyes (5) with rear-end door (1) closed and tighten bolts (4). The rear-end door (1) should be flush with the rear fenders (2).The door lock on the rear-end door (1)

should engage in the

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2885 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4800MCC, AR72.20-P-3510MCD

locking eye (5) without canting.

*BA72.20-P-1001-02F Install

10 Install left and right paneling in trunk

AR68.30-P-4800MCC TAILGATE Number Designation Model 451.3 Model 451.4 BA72.20-P-1001- 02F Bolt, lower rear- end door check strap to body Nm 32 32 BA72.20-P-1003- 02F Nut, lower rear- end door hinge to body Nm 43 43 TESTING & REPAIR INDEX > ADJUST REAR-END DOOR - AR72.20-P-3510MCD > MODEL 451.3 Fig 1: Adjusting Rear-End Door (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > OPEN TAILGATE USING EMERGENCY UNLOCKING

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2889 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-3515MCC

FEATURE - AR72.20-P-3515MCC > MODEL 451.3 Shown with door paneling removed Fig 3: Identifying Feeler Gauge (452 589 01 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Trim, Lug And Hook Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Move left seat forward

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2890 · Applies to: 450, 451, 452, 454 · AR: AR72.10-P-1410MCC

1 Move left seat forward and fold backrest forward

2 Bend lug (2) on paneling (1) toward outside with suitable screwdriver

3 Carefully guide hook (3) in area of lug (2) behind paneling (1) and position above relay lever (4) (arrow A).

Hook for emergency unlocking of rear-end door

WF58.50-P-7205- 01MCC 4 Unlock rear-end door by moving hook (3) in direction of arrow The hook (3) must press down the relay lever (4).

5 Bend lug (2) on paneling (1) back to its original position.

6 Move left seat back to its default position.

TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT OUTSIDE DOOR OPENER CABLE - AR72.10-P-1410MCC > MODEL 451.3/ 4 Fig 2: Identifying Hook And Relay Lever Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2891 · Applies to: 450, 451, 452, 454 · AR: AR72.18-P-1000MCC, AR72.29-P-0100MCC

1 Remove left or right door paneling

AR72.18-P-1000MCC 2 Unclip outer actuation cable (1) from right door CL motor or left door CL motor (arrow A).

3 Press relay lever (2) in direction of arrow with suitable screwdriver, unhook outer actuation cable (1) from relay lever (2) with needle nose pliers (arrow B) and remove

4 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT DOOR POWER WINDOW SWITCH - AR72.29-P-0100MCC > MODEL 451.3 /4 with CODE (V43) Power window Fig 1: Identifying Outer Actuation Cable And Relay Lever Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

(S21/2) from paneling

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2893 · Applies to: 450, 451, 452, 454 · AR: AR72.29-P-1300MCU

(1) with suitable screwdriver and remove. 6 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL POWER WINDOWS CONTROL UNIT - AR72.29-P-1300MCU > MODEL 451.3 /4 with CODE (V43) Power window

Remove/install

Notes on avoiding damage to electronic components due to electrostatic discharge AH54.00-P-0001-01A 1 Move right seat toward rear

2 Disconnect electrical connectors (2) from power window convenience feature control unit (N57/2)

Fig 2: Identifying Assembly Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Power Window Convenience Feature Control Unit, Electrical Connectors And Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove bolts (1) from power

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2894 · Applies to: 450, 451, 452, 454 · AR: AR72.29-P-1860MCC, AR72.18-P-1000MCC

3 Remove bolts (1) from power window convenience feature control unit (N57/2) and remove power window convenience feature control unit (N57/2)

4 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL FRONT DOOR POWER WINDOW MOTOR - AR72.29-P-1860MCC > MODEL 451.3 /4 with CODE (V43) Power window

Remove/install

1 Close crank window

2 Remove door paneling

AR72.18-P-1000MCC 3 Disconnect electrical connector (1) from left power window motor (M10/3) or right power window motor (M10/4)

4 Unscrew bolts (2) on left power window motor (M10/3) or right power window motor (M10/4)

5 Remove left power window motor (M10/3) or right power window motor (M10/4) Installation: The splines (arrow) on the left power window motor (M10/3) or right power window motor (M10/4) should engage in the power window.

6 Install in the reverse order

Fig 1: Identifying Left And Right Power Window Motor And Electrical Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > REMOVE/INSTALL GAS-OPERATED STRUT TO REAR-END

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2895 · Applies to: 450, 451, 452, 454 · AR: AR72.20-P-3600MCU

• AR72.20-P-3600MCU > MODEL 451.3

Removal/install

Risk of injuryGas pressure struts are under high pressure and can pinch and crush body parts during work Remove and install gas pressure struts only in relaxed position and on components properly secured. AS00.00-Z-0012-01A 1 Lift retainer (2) using suitable screwdriver and remove left or right gas-operated strut (1) from rear-end door upper section (3) Ensure that rear- end door upper section (3) does not close unintentionally to preven damage.Do not remove (2), otherwise pretension on retainer (2) can be lost.

Fig 1: Identifying Gas-Operated Strut To Rear-End Door Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > POWER WINDOWS (PW [EFH]), FUNCTION - GF72.29-P-0003MCU

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2901 · Applies to: 450, 451, 452, 454 · AR: GF72.29-P-0003MCU

MODEL 451.3 /4 with CODE (V43) Power window Fig 1: Power Windows (PW) Components Location Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Power Windows (EFH) Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

The power window system allows the side windows to be opened and closed.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2902 · Applies to: 450, 451, 452, 454 · AR: PE72.29-P-2001MCU, GF54.30-P-6000MCU, GF72.29-P-6030MCC, GF72.29-P-6012MCC, GF72.29-P-6040MCC (+2 more)

Function requirements Circuit 15 On Operating keys and switches Left power window switch Right power window switch Function To raise or lower the window, actuate and hold down the corresponding power window switch for longer than 420 ms in the opening or closing direction. This request is read in by the power window convenience feature control unit. The power window convenience feature control unit then energizes the corresponding power window motor until the motion request is stopped by the power window switch. The limit stop on the side window to be adjusted is recognized by the power window convenience feature control unit when the power consumption of the power window motor increases (lockup current recognition) and actuation is then stopped. Switch and controls illumination The switch and controls illumination of the power windows switch is actuated via the instrument cluster. Pinch protection is not available on the electric power window system. Actuation of the corresponding power window motor is interrupted for lockup current recognition only by the power window convenience actuation control unit.

Power windows (PW), location of components

GF72.29-P-0003- 01MCC Wiring diagram for power windows

PE72.29-P-2001MCU

Instrument cluster, component description A1 GF54.30-P-6000MCU

Power window motor, component description M10/3, M10/4 GF72.29-P-6030MCC

Power window control unit, component description N57/2 GF72.29-P-6012MCC

Power window switch, component description S21/1, S21/2 GF72.29-P-6040MCC BASIC KNOWLEDGE > TABLE OF CONTENTS, FUNCTION DESCRIPTION FOR POWER WINDOWS (PW) - GF72.29-P-0998MCU > MODEL 451.3 /4 with CODE (V43) Power window

Power windows (PW [EFH]), GF72.29-P-0003MCU

function

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2903 · Applies to: 450, 451, 452, 454 · AR: PE72.29-P-2001MCU, GF72.29-P-9997MCU, GF72.29-P-6012MCC, GF72.29-P-6030MCC

Power windows (PW), location of components GF72.29-P-0003-01MCU Wiring diagram for power windows PE72.29-P-2001MCU

Overview of system components for power windows (PW) GF72.29-P-9997MCU BASIC KNOWLEDGE > POWER WINDOW CONTROL UNIT, COMPONENT DESCRIPTION - GF72.29-P-6012MCC > MODEL 451.3 /4 with CODE (V43) Power window Location The power window convenience feature control unit is located on the left side below the instrument panel on the crossmember. Task The power window convenience feature control unit takes over the control of the side windows. The control unit monitors the power consumption of the connected loads and thereby recognizes lockup or the limit stop of the side window. The following switches are read in: Left power window switch (S21/1) Right power window switch (S21/2) The following loads are switched: Left power window motor (M10/3) Right power window motor (M10/4) BASIC KNOWLEDGE > POWER WINDOW MOTOR, COMPONENT DESCRIPTION - GF72.29-P-6030MCC > Fig 1: Identifying Power Window Convenience Feature Control Unit Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODEL 451.3 /4 with CODE (V43) Power window

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2904 · Applies to: 450, 451, 452, 454 · AR: GF72.29-P-6040MCC

Location The power window motors are screwed below the door paneling on the power window. Task The power window motors are actuated by the power window convenience feature control unit (N57/2) and allow to open and close the side windows. Design The power window motors are DC motors which turn to the right or left depending on the actuation. BASIC KNOWLEDGE > POWER WINDOW SWITCH, COMPONENT DESCRIPTION - GF72.29-P-6040MCC > MODEL 451.3 /4 with CODE (V43) Power window Fig 1: Identifying Left And Right Power Window Motor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Location

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2905 · Applies to: 450, 451, 452, 454 · AR: GF72.29-P-9997MCU, GF54.30-P-6000MCU, GF72.29-P-6030MCC, GF72.29-P-6012MCC, GF72.29-P-6040MCC (+1 more)

The power window switches are installed in the corresponding door paneling on the door handle. Task The left power window switch transfers the adjustment requests for the left power window motor (M10/3) to the power window convenience feature control unit (N57/2). The right power window switch transfers the adjustment requests for the right power window motor (M10/4) to the power window convenience feature control unit. Design The power window switches are designed as pushbutton switches. Each switch has 2 actuation directions: Push to open window Pull to close window BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS FOR POWER WINDOWS (PW) - GF72.29-P-9997MCU > MODEL 451.3 /4 with CODE (V43) Power window Instrument cluster, component description A1 GF54.30-P-6000MCU Power window motor, component description M10/3, M10/4 GF72.29-P-6030MCC Power window control unit, component description N57/2 GF72.29-P-6012MCC Power window switch, component description S21/1, S21/2 GF72.29-P-6040MCC Table of contents, function description for power windows (PW)

GF72.29-P-0998MCU Fig 1: Identifying Left And Right Power Window Switch Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

WIRING DIAGRAMS > WIRING DIAGRAM FOR POWER WINDOWS - PE72.29-P-2001MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2906 · Applies to: 450, 451, 452, 454 · AR: PE72.29-P-2001MCU, PE77.39-P-2200MCU

MODEL 451 PE72.29-P-2001MCU Wiring diagram for power windows MODEL 451 PE72.29-P-2001MCU PE77.39-P-2200MCU Electric wiring diagram for electric soft top MODEL 451 PE77.39-P-2200MCU WIRING DIAGRAMS > WIRING DIAGRAM FOR POWER WINDOWS - PE72.29-P-2001- 97MCU > Code: Designation: Position: A1 Instrument cluster 7L M10/3 Left power window motor 17L M10/4 Right power window motor 19L N10/10 SAM control unit 3L N10/10f3 Fuse 3 2L N57/2 Power window convenience feature control unit 20A N57/2 Power window convenience feature control unit 12A N57/2 Power window convenience feature control unit 4A S21/1 Left power window switch 11L S21/2 Right power window switch 21L S21/2 Right power window switch 14L W43 Ground (outside left fire wall) 20C W43 Ground (outside left fire wall) 12C W9 Ground (at left headlamp unit) 3H XPE72.29-P-2001-99MCU35/1 Left door separation point 10E X35/2 Right door separation point 18E Z51/6 Circuit 58d connector sleeve 15H Z51/6 Circuit 58d connector sleeve 10H Z6/35 Left door ground connector sleeve 12H Z6/36 Right door ground connector sleeve 20H Z81 Circuit 58d connector sleeve 22C

WIRING DIAGRAMS > WIRING DIAGRAM FOR POWER WINDOWS - PE72.29-P-2001MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2908 · Applies to: 450, 451, 452, 454 · AR: PE72.29-P-2001MCU

MODEL 451 PE72.29-P-2001- 99MCU Wiring diagram for power windows

PE72.29-P-2001- 99MCU PE72.29-P-2001- Legend of wiring

PE72.29-P-2001- Fig 2: Power Windows - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > SEPARATE FRONT AXLE CARRIER CONSOLE - AR62.20-P-1310-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2918 · Applies to: 450, 451, 452, 454 · AR: AR62.00-Z-9451CA, AR62.25-P-1120MCC, AR62.10-P-1020MCC, AR62.10-P-1020MCU, AR62.30-P-1250MCC (+1 more)

01MCC > Shown on model 451.4 1. Expose spot welds on front axle carrier console (1) and cut out (areas A, B, C, D, E and F). 2. Remove damaged front axle carrier console (1). TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: FRONT END AND FIRE WALL - AR62.00-Z-9451CA > MODEL 451 Remove, install windshield crossmember MODEL 451.3/4 Partial replacement AR62.25-P-1120MCC Remove/install CMS front MODEL 451.3/4 AR62.10-P-1020MCC Remove/install CMS front MODEL 451.3/4 AR62.10-P-1020MCU Remove/install crossmember under instrument panel MODEL 451.3## /4## 1# AR62.30-P-1250MCC Remove/install crossmember under instrument panel MODEL 451.3## /4## 2# AR62.30-P-1250MCE Fig 1: Locating Front Axle Carrier Console Spot Welds Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/in tall cro

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2919 · Applies to: 450, 451, 452, 454 · AR: AR62.25-P-5753MCC, AR62.30-P-0001MCC, AR62.20-P-1242MCC, AR62.30-P-1575MCC, AR62.30-P-1575MCU (+5 more)

member under instrument panel MODEL 451 3/4 AR62 30 P 1250MCU Remove/install firewall MODEL 451.3/4 AR62.25-P-5753MCC Remove/install front frame cross member MODEL 451.3/4 AR62.30-P-0001MCC Remove/install front longitudinal member MODEL 451.3/4 AR62.20-P-1242MCC Remove/install front module MODEL 451.3/4 AR62.30-P-1575MCC Remove/install front module MODEL 451.3/4 AR62.30-P-1575MCU Remove/install front module mount MODEL 451.3/4 AR62.30-P-1576MCC Replace complete wheel well MODEL 451.3/4 AR62.20-P-1200MCC Replace consoles on front longitudinal member MODEL 451.3/4 Consoles on bottom front longitudinal member AR62.20-P-1265MCC Replace consoles on front longitudinal member MODEL 451.3/4 Consoles on upper front longitudinal member AR62.20-P-1265MCD Replace crossmember reinforcement MODEL 451.4 AR62.30-P- 1351MCO Replace firewall wall segment side MODEL 451.3/4 AR62.25-P-5754MCC Replace front axle carrier console MODEL 451.3/4 AR62.20-P-1310MCC Replace longitudinal member closing section MODEL 451.3/4 AR62.20-P-1267MCC Replace suspension strut tower MODEL 451.3/4 AR62.20-P-1232MCC Replace tapping plate on front axle carrier console MODEL 451.3/4 AR62.20-P-1315MCC TESTING & REPAIR > REMOVE/INSTALL CMS FRONT - AR62.10-P-1020MCU > MODEL 451.3/4

TESTING & REPAIR > REPLACE COMPLETE WHEEL WELL - AR62.20-P-1200MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2923 · Applies to: 450, 451, 452, 454 · AR: AR62.20-P-1200MCC

MODEL 451.3/4 Shown on model 451.3 Fig 1: Identifying Wheel Well Cutting Area Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: View Of Wheel Well Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 451.3

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2930 · Applies to: 450, 451, 452, 454 · AR: AR62.20-P-1232MCC

1. Fit suspension strut tower (1), wheel well, front longitudinal member, longitudinal member locking lug, console on front longitudinal member, wheel well locking lug, longitudinal member inner shell and section of side wall paneling with straightening tool and fasten with vise grip pliers. Observe set-up plans.
2. Tack suspension strut tower (1) (areas A, B and C).
3. Suspension strut tower (1) (areas A, B and C).
4. Remove wheel well (1), front longitudinal member, longitudinal member locking lug, console on front longitudinal member, wheel well locking lug, longitudinal member inner shell and section of side wall paneling, if required.
5. Grind all weld joints down flat if required.
6. Clean all other weld joints with wire brush. TESTING & REPAIR > REPLACE SUSPENSION STRUT TOWER - AR62.20-P-1232MCC > MODEL 451.3/4 Shown on model 451.3 Fig 1: Fitting Suspension Strut Tower Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Partially remove side wall

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2937 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR63.20-P-1102MCO, AR63.20-P-1114MCC, AR63.20-P-1114MCO (+4 more)

3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC On model 451.4 AR63.10-P-0115MCO 4 Remove lower A-pillar outer section On model 451.4 AR63.20-P-1102MCO 5 Remove lower A-pillar reinforcement On model 451.3 AR63.20-P-1114MCC On model 451.4 AR63.20-P-1114MCO 6 Partially remove side wall reinforcement

AR63.20-P-0862MCC 7 Partially remove longitudinal member reinforcement

AR63.30-P-0818MCC 8 Remove front wheel well locking lug

AR63.20-P-0013MCC 9 Remove longitudinal member locking lug

AR62.20-P- 1267MCC 10 Remove mounting console on bottom front longitudinal member

AR62.20-P- 1265MCC 11 Partially remove outer longitudinal member inner shell on entrance

AR63.30-P-1143MCC 12 Remove front longitudinal member (1)

AR62.20-P-1242- 01MCC 13 Prepare connecting points for front longitudinal member (1) on body

AR62.20-P-1242- 02MCC Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 14 Prepare front longitudinal member (1) for installation

AR62.20-P-1242- 04MCC Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install

15 Install front longitudinal member (1) The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR62.20-P-1242- 03MCC Adhesive BR00.45-Z-1092- 02A Rivet BR00.45-Z-1001-

Partially install longitudinal

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2938 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-1143MCC, AR63.20-P-0013MCC, AR63.30-P-0818MCC, AR63.20-P-0862MCC, AR63.20-P-1114MCC (+5 more)

13A 16 Partially install longitudinal member inner shell on entrance

AR63.30-P-1143MCC 17 Install mounting console on bottom front longitudinal member

AR62.20-P- 1265MCC 18 Install longitudinal member locking lug

AR62.20-P- 1267MCC 19 Install front wheel well locking lug

AR63.20-P-0013MCC 20 Partially install longitudinal member reinforcement

AR63.30-P-0818MCC 21 Partially install side wall reinforcement

AR63.20-P-0862MCC 22 Install lower A-pillar reinforcement On model 451.3 AR63.20-P-1114MCC On model 451.4 AR63.20-P-1114MCO 23 Install lower outer A-pillar On model 451.4 AR63.20-P-1102MCO 24 Partially install side wall paneling On model 451.3 AR63.10-P-0115MCC On model 451.4 AR63.10-P-0115MCO 25 Install front diagonal strut console on longitudinal member On model 451.4 AR61.10-P-5140MCO 26 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

27 Prime area to be repaired using primer filler

28 Supply standard seam seals with body sealant

AR97.10-P-4000MCC Sealant BR00.45-Z-1003- 01A 29 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 30 Paint area repaired and adjacent surfaces

Notes on paintwork repairs AH98.00-P-9408- 02MCC 31 Apply additional cavity preservation

AR97.20-P-1500FF Teroson protective wax *BR00.45-Z-1008- 05A

Reinstall all detachable parts

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2939 · Applies to: 450, 451, 452, 454 · AR: AR62.20-P-1265MCC

32 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1092- 02A Adhesive kit, body, 2-component adhesive A 009 989 36 71 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunichGermanyTel. +49-899268- 0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1001- 13A Blind rivet 6.4x14 A 003 990 35 97 TESTING & REPAIR > REPLACE CONSOLES ON FRONT LONGITUDINAL MEMBER - AR62.20-P-1265MCC > MODEL 451.3/4 Consoles on bottom front longitudinal member Shown on model 451.3

specification 6069.20

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2943 · Applies to: 450, 451, 452, 454 · AR: AR62.20-P-1265MCD

01A specification 6069.20 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunchenGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de TESTING & REPAIR > REPLACE CONSOLES ON FRONT LONGITUDINAL MEMBER - AR62.20-P-1265MCD > MODEL 451.3/4 Consoles on upper front longitudinal member Shown on model 451.3 Fig 1: Identifying Mounting Console And Upper Longitudinal Member Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REPLACE LONGITUDINAL MEMBER CLOSING SECTION -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2950 · Applies to: 450, 451, 452, 454 · AR: AR62.20-P-1267MCC

AR62.20-P-1267MCC > MODEL 451.3/4 Shown on model 451.3 Fig 1: Fitting Longitudinal Member Locking Lug Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Number

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2961 · Applies to: 450, 451, 452, 454 · AR: AR62.20-P-1315MCC

Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunchenGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de TESTING & REPAIR > REPLACE TAPPING PLATE ON FRONT AXLE CARRIER CONSOLE - AR62.20-P-1315MCC > MODEL 451.3/4 Shown on model 451.4 Removing

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. AS00.00-Z-0007- 01A Fig 1: Identifying Front Axle Carrier Tapping Plate With Welding Joints Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 451.3

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2977 · Applies to: 450, 451, 452, 454 · AR: AR62.25-P-5754MCC

1. Fit firewall segment (1), suspension strut tower, wheel well, front longitudinal member, longitudinal member locking lug, console on front longitudinal member, longitudinal member inner shell and section of side wall paneling with straightening tool and fix in place using vise grip pliers. Observe set-up plans.
2. Drill Ø 6.5 mm rivet holes (area A).
3. Remove firewall segment (1), suspension strut tower, wheel well, front longitudinal member, longitudinal member locking lug, console on front longitudinal member, wheel well locking lug, longitudinal member inner shell and section of side wall paneling.
4. Deburr rivet holes on firewall segment (1) and body on both sides.
5. Apply 2-component adhesive to mating surface in cross-hatched area. Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2-component adhesive may be adversely affected. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive.
6. Fit firewall segment (1) and fix in place using manual temporary fasteners and vise grip pliers.
7. Firewall segment (1) (area B).
8. Rivet firewall segment (1) with Polygrip flat round head rivet, 6.4 x 14 (area A). TESTING & REPAIR > REPLACE FIREWALL WALL SEGMENT SIDE - AR62.25-P-5754MCC

   MODEL 451.3/4 Illustrated on model 451.3

Notes on performing repair,

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2979 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR63.20-P-1102MCO, AR63.20-P-1114MCC, AR63.20-P-1114MCO (+3 more)

body work and welding on vehicles with airbags and ETR units

AH91.00-P-0002- 01SM Pretreatment of bonding surfaces

AH60.00-P-0008- 01MCC General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027- 01FF General information on repairs to body

AH60.00-P-0001- 01FF Generally conventional tools are required for body work, additional tools required are listed above. Pneumatic/hydraulic blind rivet tool gotis://K_68-80_06.0

The repair method using riveting described here can be replaced by plug welding if required. Adapt preparatory work accordingly.

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fire-resistant weld protection blanket to prevent damage from flying sparks.

3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC On model 451.4 AR63.10-P-0115MCO 4 Remove lower A-pillar outer section On model 451.4 AR63.20-P-1102MCO 5 Remove lower A-pillar reinforcement On model 451.3 AR63.20-P-1114MCC On model 451.4 AR63.20-P-1114MCO 6 Partially remove side wall reinforcement

AR63.20-P-0862MCC 7 Partially remove side longitudinal member reinforcement

AR63.30-P-0818MCC 8 Remove front wheel well locking lug

AR63.20-P-0013MCC 9 Remove longitudinal member locking lug

AR62.20-P- 1267MCC 10 Remove mounting console

AR62.20-P-

on bottom front longitudinal

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2980 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-1143MCC

member 1265MCC 11 Partially remove outer longitudinal member inner shell on entrance

AR63.30-P-1143MCC 12 Remove front longitudinal member

AR62.20-P- 1242MCC 13 Remove wheel well

AR62.20-P- 1200MCC 14 Remove suspension strut tower

AR62.20-P- 1232MCC 15 Remove firewall segment (1)

AR62.25-P-5754- 01MCC 16 Prepare mating surfaces on vehicle for firewall segment (1).

AR62.25-P-5754- 02MCC Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A 17 Prepare firewall segment (1) for installation

AR62.25-P-5754- 03MCC Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install

18 Install firewall segment (1) The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR62.25-P-5754- 04MCC Adhesive BR00.45-Z-1092- 02A Rivet BR00.45-Z-1001- 13A 19 Install suspension strut tower

AR62.20-P- 1232MCC 20 Install wheel well

AR62.20-P- 1200MCC 21 Install front longitudinal member

AR62.20-P- 1242MCC 22 Partially install longitudinal member inner shell on entrance

AR63.30-P-1143MCC 23 Install mounting console on

AR62.20-P-

bottom front longitudinal

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2981 · Applies to: 450, 451, 452, 454 · AR: AR63.20-P-0013MCC, AR63.30-P-0818MCC, AR63.20-P-0862MCC, AR63.20-P-1114MCC, AR63.20-P-1114MCO (+5 more)

member 1265MCC 24 Install longitudinal member locking lug

AR62.20-P- 1267MCC 25 Install front wheel well locking lug

AR63.20-P-0013MCC 26 Partially install side longitudinal member reinforcement

AR63.30-P-0818MCC 27 Partially install side wall reinforcement

AR63.20-P-0862MCC 28 Install lower A-pillar reinforcement On model 451.3 AR63.20-P-1114MCC On model 451.4 AR63.20-P-1114MCO 29 Install lower outer A-pillar On model 451.4 AR63.20-P-1102MCO 30 Partially install side wall paneling On model 451.3 AR63.10-P-0115MCC On model 451.4 AR63.10-P-0115MCO 31 Install front diagonal strut console on longitudinal member On model 451.4 AR61.10-P-5140MCO 32 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

33 Prime area to be repaired using primer filler

34 Supply standard seam seals with body sealant

AR97.10-P-4000MCC Sealant BR00.45-Z-1003- 01A 35 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 36 Paint area repaired and adjacent surfaces

Notes on paintwork repairs AH98.00-P-9408- 02MCC 37 Apply additional cavity preservation

AR97.20-P-1500FF Teroson protective wax *BR00.45-Z-1008- 05A 38 Reinstall all detachable parts removed

8. Align assembly wedge (12) with

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2994 · Applies to: 450, 451, 452, 454 · AR: AR62.30-P-1250MCU

push-in device (14) by turning knurled screw (13). Aid of helper required If it is not possible to align the crossmember (4) with inserted drift (5) on left and right, remove both drifts (5) if possible. 9. Remove drift (5) on left and right from crossmember (4). Aid of helper required. 10. Tighten bolts (6, 7, 8, 9) with specified tightening torque. Aid of helper required. TESTING & REPAIR > REMOVE/INSTALL CROSSMEMBER UNDER INSTRUMENT PANEL - AR62.30-P-1250MCU > MODEL 451.3/4 Fig 1: Identifying Crossmember Components Under Instrument Panel (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2995 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2340MCU, AR68.10-P-1501MCC

Risk of fire and explosion caused by machining/treating magnesium components Keep away from ignition sources and open flames. AS60.00-Z-0006-01R Notes on bolted connections with self tapping screws

AH00.00-P-0007-01SM 1 Remove center mounting console reinforcement

AR68.20-P-2340MCU 2 Remove bottom section of On vehicles as of AR68.10-P-1501MCC Fig 2: Identifying Crossmember Components Under Instrument Panel (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Crossmember, Control Units & Bolts Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

*BA62.30-P-1001-02B

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2998 · Applies to: 450, 451, 452, 454 · AR: AR88.00-P-1010MCC, AR46.10-P-0400MCU, AR68.10-P-1501MCC, AR68.20-P-2340MCU

Drift 450589021500 Press-in tool 452589012300 24 Loosen knurled screw (9) and remove push-in device (11) Press-in tool *452589012300 25 Open door

26 Tighten bolts (16) on diagonal strut (15) on crossmember (1). BA62.30-P-1010-02B 27 Tighten bolts (13) on vertical strut (12) on crossmember (1). BA62.30-P-1002-02B 28 Route wiring harness along crossmember (1) and fasten

29 Connect electrical connectors (8) to power window convenience feature control unit (N57/2) On vehicles with code (V43) Power window

30 Connect electrical connectors (14 to restraint systems control unit (N2/7)

31 Install protective foils above bolts (4, 5, 6, 7).

32 Position brackets (3) and tighten with nuts (2).

33 Install front CBS

AR88.00-P-1010MCC 34 Install jacket tube

AR46.10-P-0400MCU 35 Install dashboard bottom section on driver side On vehicles as of 31.8.10. AR68.10-P-1501MCC 36 Install center console reinforcement.

AR68.20-P-2340MCU CROSSMEMBER Number Designation Model 451.3/4 BE62.30-P-1001- 01A Outer edge of crossmember (area, lower bearing shell) to firewall mm 230 BE62.30-P-1002- 01A Outer edge of crossmember (area, rear H-profile) to firewall mm 334 BE62.30-P-1003- 01A Lower edge of crossmember (area, lower H-profile) to carrier vehicle floor mm 323 FRONT END ASSEMBLY WITH FRONT REINFORCEMENT Number Designation Model 451.3/4

bare metal in shaded

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3002 · Applies to: 450, 451, 452, 454 · AR: AR62.30-P-1575MCU

areas Install

8 Fit crossmember reinforcement (1) and fasten with vise grip pliers When fitting observe correct distances.

9 Crossmember reinforcement (1) (areas E and F)

10 Level spot welds on crossmember reinforcement (1) if required

11 Clean sheet metal flange with wire brush and clean areas to repaired

12 Prime area to be repaired using primer filler

13 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC

Sealant *BR00.45-Z-1003- 01A 14 Paint area repaired and adjacent surfacesNotes on paintwork repairs

AH98.00-P-9408- 02MCC 15 Apply additional cavity preservation

AR97.20-P- 1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 16 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunchenGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de TESTING & REPAIR > REMOVE/INSTALL FRONT MODULE - AR62.30-P-1575MCU > MODEL 451.3/4

TESTING & REPAIR > REMOVE/INSTALL FRONT MODULE MOUNT - AR62.30-P-1576MCC

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3007 · Applies to: 450, 451, 452, 454 · AR: AR62.30-P-1576MCC

MODEL 451.3/4 Remove/install

1 Remove front module

AR62.30- P- 1575MCC 2 Unscrew bolts (2) on left and right front module mount (1) and remove left and right front module mount (1). Installation: Observe corresponding installation marking (arrows) on front module mount (1).

*BA62.30- P-1009- 02B 3 Install in the reverse order

FRONT END ASSEMBLY WITH FRONT REINFORCEMENT Fig 5: Identifying Support (451 589 01 31 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Front Module Mount & Screws Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

1009-02B

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3009 · Applies to: 450, 451, 452, 454 · AR: BE62.00-Z-9999CZ

BA62.30-P- 1010-02B Bolt for diagonal strut on crossmember Nm - 10 - TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: FRONT END AND FIRE WALL - BE62.00-Z-9999CZ > MODEL all Body shell - Front end MODEL 452 BE62.10-P-1000-01A Crossmember MODEL 451.3/4 BE62.30-P-1000-01A TEST & ADJUSTMENT VALUES > CROSSMEMBER - BE62.30-P-1000-01A > Model 451.3/4 CROSSMEMBER Number Designation Model 451.3/4 BE62.30-P-1001- 01A Outer edge of crossmember (area, lower bearing shell) to firewall mm 230 BE62.30-P-1002- 01A Outer edge of crossmember (area, rear H-profile) to firewall mm 334 BE62.30-P-1003- 01A Lower edge of crossmember (area, lower H-profile) to carrier vehicle floor mm 323 SPECIAL TOOLS > 450 589 02 15 00 PUNCH - WS62.00-P-0045B > FG 62/Set B MODEL 450, 451, 452 Use: Punch for assembly work on CQT. NOTE: CQT alignment punchSmart no. 0009389.

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: FRONT END AND FIRE

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3018 · Applies to: 450, 451, 452, 454 · AR: AR62.00-Z-9451CA

WALL - AR62.00-Z-9451CA > MODEL 451

Remove, install windshield crossmember MODEL 451.3 /4 Partial replacement AR62.25-P- 1120MCC

Remove/install CMS front MODEL 451.3/ 4 AR62.10-P- 1020MCC

Remove/install CMS front MODEL 451.3 /4 AR62.10-P- 1020MCU

Remove/install crossmember under instrument panel MODEL 451.3## /4## 1# AR62.30-P- 1250MCC

Remove/install crossmember under instrument panel MODEL 451.3## /4## 2# AR62.30-P- 1250MCE

Remove/install crossmember under instrument panel MODEL 451.3 /4 AR62.30-P- 1250MCU

Remove/install firewall MODEL 451.3 /4 AR62.25-P- 5753MCC

Remove/install front frame cross member MODEL 451.3 /4 AR62.30-P- 0001MCC

Remove/install front longitudinal member MODEL 451.3 /4 AR62.20-P- 1242MCC

Remove/install front module MODEL 451.3 /4 AR62.30-P- 1575MCC

Remove/install front module MODEL 451.3 /4 AR62.30-P- 1575MCU

Remove/install front module mount MODEL 451.3 /4 AR62.30-P- 1576MCC

Replace complete wheel well MODEL 451.3 /4 AR62.20-P- 1200MCC

Replace consoles on front longitudinal member MODEL 451.3 /4 Consoles on bottom front longitudinal member AR62.20-P- 1265MCC

Replace consoles on front longitudinal member MODEL 451.3 /4 Consoles on upper front longitudinal member AR62.20-P- 1265MCD

Replace crossmember reinforcement MODEL 451.4 AR62.30-P- 1351MCO

Replace firewall wall segment side MODEL 451.3 /4 AR62.25-P- 5754MCC

Replace front axle carrier console MODEL 451.3 /4 AR62.20-P- 1310MCC

Replace longitudinal member closing section MODEL 451.3/ 4 AR62.20-P- 1267MCC

Replace suspension strut tower

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3019 · Applies to: 450, 451, 452, 454 · AR: AR62.10-P-1020MCU

MODEL 451.3 /4 AR62.20-P- 1232MCC

Replace tapping plate on front axle carrier console MODEL 451.3 /4 AR62.20-P- 1315MCC TESTING & REPAIR > REMOVE/INSTALL CMS FRONT - AR62.10-P-1020MCU > MODEL 451.3 /4 Remove/install

1 Remove front CBS

AR88.00- P- 1010MCC 2 Disconnect electrical connector (3) from driver- side frontal acceleration sensor (B48/1) and passenger-side frontal acceleration sensor (B48/2)

3 Remove bolt (4) and lay horn (H2) down to side with electrical lines connected. Only vehicles with code (V55) Twin-tone horn, a horn (H2) is also located on right of vehicle.

4 Unscrew bolts (2) and remove front CMS (1)

Fig 1: Identifying CMS Front Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 451.3

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3028 · Applies to: 450, 451, 452, 454 · AR: AR62.20-P-1232MCC

1. Fit suspension strut tower (1), wheel well, front longitudinal member, longitudinal member locking lug, console on front longitudinal member, wheel well locking lug, longitudinal member inner shell and section of side wall paneling with straightening tool and fasten with vise grip pliers. Observe set-up plans.
2. Tack suspension strut tower (1) (areas A, B and C).
3. Suspension strut tower (1) (areas A, B and C).
4. Remove wheel well (1), front longitudinal member, longitudinal member locking lug, console on front longitudinal member, wheel well locking lug, longitudinal member inner shell and section of side wall paneling, if required.
5. Grind all weld joints down flat if required.
6. Clean all other weld joints with wire brush. TESTING & REPAIR > REPLACE SUSPENSION STRUT TOWER - AR62.20-P-1232MCC > MODEL 451.3 /4 Shown on model 451.3 Fig 1: Identifying Suspension Strut Tower With Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

ealant

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3043 · Applies to: 450, 451, 452, 454 · AR: AR62.20-P-1265MCC

05A 30 Paint area repaired and adjacent surfaces

Notes on paintwork repairs AH98.00- P-9408- 02MCC 31 Apply additional cavity preservation

AR97.20- P-1500FF Teroson protective wax *BR00.45- Z-1008- 05A 32 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45- Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45- Z-1092- 02A Adhesive kit, body, 2- component adhesive A 009 989 36 71 BR00.45- Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45- Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunichGermanyTel. +49-899268-0Fax +49- 899101978www.Loctite.de BR00.45- Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45- Z-1001- 13A Blind rivet 6.4x14 A 003 990 35 97 TESTING & REPAIR > REPLACE CONSOLES ON FRONT LONGITUDINAL MEMBER - AR62.20-P-1265MCC > MODEL 451.3 /4 Consoles on bottom front longitudinal member Shown on model 451.3

TESTING & REPAIR > REPLACE LONGITUDINAL MEMBER CLOSING SECTION -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3050 · Applies to: 450, 451, 452, 454 · AR: AR62.20-P-1267MCC

AR62.20-P-1267MCC > MODEL 451.3/ 4 Shown on model 451.3 Fig 1: Identifying Longitudinal Member Locking Lug Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

1. Attach suitable masking tape (3) on crossmember at positions shown.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3068 · Applies to: 450, 451, 452, 454 · AR: AR62.25-P-5753MCC

1. Install firewall (1) on body flange and align, observe dimension (a). The dimension (a) on the left side of the vehicle should be approx. 5.8 mm; deviations can decrease the leaktightness of the adhesive bead. Ensure that clamps (2) are seated correctly on welding flange on crossmember.
2. Fix in place position of firewall (1) using suitable masking tape (arrows). Masking tape (arrows) serves as positioning aid.
3. Cut masking tape (arrows) on outer side of firewall (1).
4. Remove firewall (1). TESTING & REPAIR > REMOVE/INSTALL FIREWALL - AR62.25-P-5753MCC > MODEL 451.3 /4 Shown on model 451.3 Fig 1: Identifying Firewall, Clamps And Masking Tape On Crossmember Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 451.3

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3074 · Applies to: 450, 451, 452, 454 · AR: AR62.25-P-5754MCC

1. Fit firewall segment (1), suspension strut tower, wheel well, front longitudinal member, longitudinal member locking lug, console on front longitudinal member, longitudinal member inner shell and section of side wall paneling with straightening tool and fix in place using vise grip pliers. Observe set-up plans.
2. Drill Ø 6.5 mm rivet holes (area A).
3. Remove firewall segment (1), suspension strut tower, wheel well, front longitudinal member, longitudinal member locking lug, console on front longitudinal member, wheel well locking lug, longitudinal member inner shell and section of side wall paneling.
4. Deburr rivet holes on firewall segment (1) and body on both sides.
5. Apply 2-component adhesive to mating surface in cross-hatched area. Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2-component adhesive may be adversely affected. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive.
6. Fit firewall segment (1) and fix in place using manual temporary fasteners and vise grip pliers.
7. Firewall segment (1) (area B).
8. Rivet firewall segment (1) with Polygrip flat round head rivet, 6.4 x 14 (area A). TESTING & REPAIR > REPLACE FIREWALL WALL SEGMENT SIDE - AR62.25-P-5754MCC

   MODEL 451.3 /4 Illustrated on model 451.3

8. Align assembly wedge (12) with

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3096 · Applies to: 450, 451, 452, 454 · AR: AR62.30-P-1250MCU

push-in device (14) by turning knurled screw (13). Aid of helper required If it is not possible to align the crossmember (4) with inserted drift (5) on left and right, remove both drifts (5) if possible. 9. Remove drift (5) on left and right from crossmember (4). Aid of helper required. 10. Tighten bolts (6, 7, 8, 9) with specified tightening torque. Aid of helper required. TESTING & REPAIR > REMOVE/INSTALL CROSSMEMBER UNDER INSTRUMENT PANEL - AR62.30-P-1250MCU > MODEL 451.3 /4 Fig 1: Identifying Crossmember Components Under Instrument Panel (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL FRONT MODULE - AR62.30-P-1575MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3101 · Applies to: 450, 451, 452, 454 · AR: AR62.30-P-1575MCU

MODEL 451.3 /4 Shown on model 451.3 with code (I01) Air conditioning Plus Fig 4: Identifying Drift (450 589 02 15 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Installation Tool (452 589 01 23 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL FRONT MODULE MOUNT - AR62.30-P-1576MCC

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3106 · Applies to: 450, 451, 452, 454 · AR: AR62.30-P-1576MCC, BA62.00-Z-9999CZ

MODEL 451.3 /4 Remove/install

1 Remove front module

AR62.30- P- 1575MCC 2 Unscrew bolts (2) on left and right front module mount (1) and remove left and right front module mount (1). Installation: Observe corresponding installation marking (arrows) on front module mount (1).

*BA62.30- P-1009- 02B 3 Install in the reverse order

FRONT END ASSEMBLY WITH FRONT REINFORCEMENT Number Designation Model 451.3/4 BA62.30-P-1009-02B Bolt on CMS front Nm 25 TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: FRONT END AND FIRE WALL - BA62.00-Z-9999CZ > MODEL all

Cross member and front reinforcement MODEL 454.0 BA62.30-P-1000- 01B

Firewall MODEL 454.0 BA62.25-P-1000- 01A Front end with reinforcement at MODEL 450.3 /4, 451.3 /4, 452.3 BA62.30-P-1000- Fig 1: Identifying Front Module Mount & Mounting Screw Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

front

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3107 · Applies to: 450, 451, 452, 454 · AR: BE62.00-Z-9999CZ

/4 02B TORQUE SPECIFICATIONS > FRONT END WITH REINFORCEMENT AT FRONT - BA62.30- P-1000-02B > Model 450, 451, 452 MODIFICATION NOTES 30.5.07 Bolt on CMS front Model 451.3/4

11.6.07 Bolt for vertical strut to crossmember Model 451.3/4

FRONT END ASSEMBLY WITH FRONT REINFORCEMENT Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA62.30-P- 1001-02B Bolt for crossmember on A-pillars Nm 25 25 - BA62.30-P- 1002-02B Bolt for vertical strut to crossmember Nm 8 8 - BA62.30-P- 1003-02B Bolt, vertical strut to center tunnel Nm 25 25 25 BA62.30-P- 1004-02B Bolt, upper crossmember mount Nm 24 - 25 BA62.30-P- 1005-02B Bolt for crossmember below instrument panel on A-pillar Nm - - 25 BA62.30-P- 1006-02B Bolt for vertical strut on crossmember below instrument panel Nm - - 9 BA62.30-P- 1007-02B Bolt for steering strut on crossmember below instrument panel Nm - 10 25 BA62.30-P- 1008-02B Bolt for steering strut on crossmember for windshield Nm - - 19 BA62.30-P- 1009-02B Bolt on CMS front Nm 25 25 25 BA62.30-P- 1010-02B Bolt for diagonal strut on crossmember Nm - 10 - TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: FRONT END AND FIRE WALL - BE62.00-Z-9999CZ > MODEL all

Body shell - Front end MODEL 452 BE62.10-P-1000-01A

Crossmember MODEL 451.3 /4 BE62.30-P-1000-01A

connector on footwell

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3112 · Applies to: 450, 451, 452, 454 · AR: AR68.00-Z-9451CA, AR68.10-P-1501MCU, AR68.10-P-1502MCU, AR68.10-P-1501MCC, AR68.10-P-1502MCC

illumination code (876) Interior light package 7 Remove vertical strut paneling (1)

8 Unclip footwell illumination and remove When replacing vertical strut paneling (1) on vehicles as of 31.8.10 with code (876) Interior light package

9 Unscrew bolts (3) and remove data link connector (X11/4) When replacing vertical strut paneling (1).

10 Unclip interior socket (X58/1) from rear of vertical strut paneling (1) and remove toward front When replacing vertical strut paneling (1). Installation: Pull metal insert out of interior socket (X58/1) before installation using pliers (2).

Pliers *169589003700 11 Install in the reverse order

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: INTERIOR EQUIPMENT - AR68.00-Z-9451CA > MODEL 451 Remove/install bottom paneling for dashboard on driver side MODEL 451.3/4 AR68.10-P-1501MCU Remove/install bottom paneling for dashboard on passenger side MODEL 451.3/4 AR68.10-P-1502MCU Remove/install bottom paneling for instrument panel on driver side MODEL 451.3/4 AR68.10-P-1501MCC Remove/install bottom paneling for MODEL 451.3/4 AR68.10-P-1502MCC Fig 2: Identifying Pliers (169 589 00 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

instrument panel on passenger

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3113 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1150MCC, AR68.10-P-1150MCF, AR68.10-P-1150MCU, AR68.20-P-2000MCC, AR68.20-P-2000MCU (+5 more)

side Remove/install center air nozzle MODEL 451.3/4 up to 30.8.10 AR68.10-P-1150MCC Remove/install center air nozzle MODEL 451.3/4 as of 31.8.10 AR68.10-P-1150MCF Remove/install center air nozzle MODEL 451.3/4 up to 30.8.10 AR68.10-P-1150MCU Remove/install center console MODEL 451.3/4 AR68.20-P-2000MCC Remove/install center console MODEL 451.3/4 AR68.20-P-2000MCU Remove/install center console reinforcement MODEL 451.3/4 AR68.20-P-2340MCC Remove/install center console reinforcement MODEL 451.3/4 AR68.20-P-2340MCU Remove/install center stowage compartment MODEL 451... AR68.10-P-1620MCC Remove/install cover at selector lever MODEL 451.3/4 AR68.20-P-2309MCC Remove/install cover at selector lever MODEL 451.3/4 AR68.20-P-2309MCU Remove/install cover on center console MODEL 451.3/4 up to 30.8.10 AR68.20-P-2350MCC Remove/install cover on center console MODEL 451.3/4 as of 31.8.10 AR68.20-P-2350MCF Remove/install dashboard top section MODEL 451.3/4 AR68.10-P-1020MCC Remove/install dashboard top section MODEL 451.3/4 AR68.10-P-1020MCU Remove/install floor covering MODEL 451.3/4 AR68.20-P-2040MCC Remove/install floor covering MODEL 451.3/4 AR68.20-P-2040MCU Remove/install footrest on passenger side MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle AR68.30-P-1340MCC Remove/install front roof frame paneling MODEL 451.3 AR68.30-P-4450MCC Remove/install front roof frame paneling MODEL 451.4 AR68.30-P-4450MCO Remove/install front roof frame paneling MODEL 451.3 AR68.30-P-4450MCU Remove/install front roof frame paneling MODEL 451.4 AR68.30-P-4450MCV Remove/install glove box MODEL 451.3/4 AR68.10-P-1400MCU Remove/install glove compartment MODEL 451.3/4 with CODE (I63) AR68.10-P-1400MCC

Glove compartment

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3114 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1200MCC, AR68.40-P-0001MCC, AR68.40-P-0001MCU, AR68.30-P-1380MCC, AR68.30-P-1380MCU (+5 more)

Remove/install glove compartment lid MODEL 451.3/4 with CODE (I63) Glove compartment AR68.10-P-1200MCC Remove/install inside rearview mirror MODEL 451.3/4 AR68.40-P-0001MCC Remove/install inside rearview mirror MODEL 451.3/4 AR68.40-P-0001MCU Remove/install interior paneling on roll bar MODEL 451.4 AR68.30-P-1380MCC Remove/install interior paneling on roll bar MODEL 451.4 AR68.30-P-1380MCU Remove/install lower section of dashboard MODEL 451.3/4 AR68.10-P-1040MCU Remove/install lower section of instrument panel MODEL 451.3/4 AR68.10-P-1040MCC Remove/install luggage compartment floor covering MODEL 451.3/4 AR68.20-P-4810MCC Remove/install luggage compartment floor covering MODEL 451.3/4 AR68.20-P-4810MCU Remove/install paneling on A-pillar MODEL 451.3/4 AR68.30-P-4050MCC Remove/install paneling on A-pillar MODEL 451.3/4 AR68.30-P-4050MCU Remove/install paneling on B-pillar MODEL 451.3 AR68.30-P-4700MCU Remove/install paneling on B-pillar MODEL 451.4 AR68.30-P-4700MCV Remove/install paneling on rear pillar MODEL 451.4 AR68.30-P-4505MCO Remove/install passenger side footrest MODEL 451.3## /4## 2# with CODE (RHD) Right-hand drive vehicle AR68.30-P-1340MCE Remove/install rear roof frame paneling MODEL 451.3 AR68.30-P-4470MCC Remove/install side air outlet MODEL 451.3/4 AR68.10-P-1100MCC Remove/install side paneling in trunk MODEL 451.3/4 AR68.30-P-4800MCC Remove/install side paneling in trunk MODEL 451.3/4 AR68.30-P-4800MCU Remove/install side paneling in trunk MODEL 451.391/491 with ENGINE 780.009 AR68.30-P-4800MEV Remove/install side paneling on instrument panel MODEL 451.3/4 AR68.10-P-1503MCC Remove/install side paneling on instrument panel MODEL 451.3/4 AR68.10-P-1503MCU

Remove/install side roof frame

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3115 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4480MCC, AR68.30-P-4480MCO, AR68.30-P-4480MCU, AR68.30-P-2000MCC, AR68.60-P-5480MCC (+2 more)

paneling MODEL 451.3 AR68.30-P-4480MCC Remove/install side roof frame paneling MODEL 451.4 AR68.30-P-4480MCO Remove/install side roof frame paneling MODEL 451.3 AR68.30-P-4480MCU Remove/install steering column trim MODEL 451.3/4 AR68.30-P-2000MCC Remove/install sun visor MODEL 451.3/4 AR68.60-P-5480MCC Remove/install sun visor MODEL 451.3/4 AR68.60-P-5480MCU Remove/install vertical strut paneling MODEL 451.3/4 AR68.00-P-1500MCC TESTING & REPAIR > REMOVE/INSTALL PANELING ON INSTRUMENT PANEL - AR68.10- P-1000-06MCC > 1. Unscrew bolt (2). 2. Pull paneling (1) toward outside in marked area (arrow A) and unclip. 3. Carefully pull paneling (1) toward rear in lower area (arrows B) and then pivot upward so that paneling (1) can be loosened in upper area (arrows C). 4. Loosen paneling (1) in upper area (arrow D) and remove toward rear. 5. Install in the reverse order.

Route wiring harness (3)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3125 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1150MCF

12 Route wiring harness (3) through opening in instrument panel lower section (1)

13 Remove instrument panel lower section (1) upward (arrows B) out of driver side paneling (6) and passenger side paneling (7) Installation: Ensure that instrument panel lower section (1) is seated correctly in guide rails (arrows C).

14 Disconnect kneebag separating point (X99/17) With code (294) Kneebag

15 Remove instrument panel lower section (1) from vehicle and lay down on suitable base

16 Remove retaining clamps on dashboard lower section (1) When replacing instrument panel lower section (1) Four retaining clamps are fastened to the dashboard lower section (1).

18 Remove electric cable harness (14) With code (294) Kneebag, when replacing instrument panel lower section (1).

19 Remove left and right kneebag (13) With code (294) Kneebag, when replacing instrument panel lower section (1). AR91.60- P- 0050MCU 20 Install in the reverse order

AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1012- 01C Screw/bolt, kneebag bracket to crossmember Nm 4 4 TESTING & REPAIR > REMOVE/INSTALL CENTER AIR NOZZLE - AR68.10-P-1150MCF > MODEL 451.3/4 as of 31.8.10 Vehicles without code (I01) Air conditioning Plus

Use a suitable screwdriver to release bracket (arrow C) of

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3127 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1150MCU

4 Use a suitable screwdriver to release bracket (arrow C) of flexible shaft (3) and detach flexible shaft (3) from guide wheel (4)

5 Press back catch hook (arrow E) and remove eyelet (9) from relay lever (10) Vehicles without code (I01) Air conditioning Plus

6 Press catch hook (arrows D) together using suitable pliers and push wire out of bracket on heater housing in direction of arrow Vehicles without code (I01) Air conditioning Plus

7 Unscrew bolts (2) from center air vent (1)

8 Unclip center air vent (1) in front area (arrow B) from bracket (5)

9 Fold center air vent (1) out of instrument panel upper section, unhook from guides (arrows A) and remove until electrical connectors (6) are accessible

10 Release electrical connectors (6) and disconnect from heater/AC operating unit (N23)

11 Remove center air vent (1) with heater/air conditioning (N23) Observe installation position of flexible shaft (3)

12 Remove heater/AC operating unit (N23) When replacing center air vent (1).

Vehicles without code (I01) Air conditioning Plus AR83.20- P- 1850MCF Vehicles with code (I01) Air conditioning Plus AR83.25- P- 1124MCF 13 Install in the reverse order

14 Perform function test on heater/air conditioning operating unit (N23)

TESTING & REPAIR > REMOVE/INSTALL CENTER AIR NOZZLE - AR68.10-P-1150MCU > MODEL 451.3/4 up to 30.8.10 Shown on vehicle with Code (I01) AC

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3129 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1400MCU

1 Open glove compartment.

2 Loosen pins (2) with suitable screwdriver and pull out of glove compartment lid (1) using pliers.

3 Remove glove compartment lid (1) Installation: When replacing glove compartment lid (1) insert new lock cylinder (3) into glove compartment lid (1) according to key code. 4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL GLOVE BOX - AR68.10-P-1400MCU > MODEL 451.3/4 Fig 1: Identifying Glove Compartment Lid Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3130 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1501MCU

1 Remove passenger side paneling (1)

AR68.10- P- 1502MCU 2 Unscrew bolts (2) and remove glove box (3) from passenger side paneling (1)

3 Remove glove compartment cover (4) When replacing glove box (3) with code (I63) Glove compartment. AR68.10- P- 1200MCC 4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL BOTTOM PANELING FOR DASHBOARD ON DRIVER SIDE - AR68.10-P-1501MCU > MODEL 451.3/4 Shown on vehicle without code (294) Kneebag Fig 1: Identifying Glove Box Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

harness (3) on driver-side

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3132 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1502MCU

paneling (1) (arrow C). 8 Unscrew bolts (4) on driver-side paneling (1).

9 Remove driver-side paneling (1). Installation: Observe installation position of electrical lines as well as fanfare horns and airbag clock spring contact wiring harness (3).

10 Remove sheet metal nut (5) from driver-side paneling (1). When replacing driver-side paneling (1).

11 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL BOTTOM PANELING FOR DASHBOARD ON PASSENGER SIDE - AR68.10-P-1502MCU > MODEL 451.3/4 Shown on vehicle up to 30.8.10 Fig 1: Identifying Passenger Side Dashboard Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL SIDE PANELING ON INSTRUMENT PANEL -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3135 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1503MCU

AR68.10-P-1503MCU > MODEL 451.3/4

Remove/install

1 Remove left or right paneling from instrument panel AR68.10-P-1000- 06MCC 2 Remove bolt (4) on bottom section of instrument panel (3)

3 Release bottom section of instrument panel (3) in area of bracket (arrows)

4 Unscrew bolts (2) from side paneling (1).

5 Remove side paneling (1)

6 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL CENTER STOWAGE COMPARTMENT - AR68.10- P-1620MCC > MODEL 451.3/4 up to 30.8.10 except CODE (C50) smart radio 10 except CODE (C57) smart radio 9 MODEL 451.3/4 as of 31.8.10 except CODE (516) RADIO WITH USB INTERFACE Vehicles up to 30.8.10 Fig 1: Identifying Side Paneling Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Vehicles as of 31.8.10

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3136 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2000MCU

Remove/install

1 Remove cover (1) on center console Vehicles up to 30.8.10 AR68.20-P- 2350MCC Vehicles as of 31.8.10 AR68.20-P- 2350MCF 2 Unscrew bolts (3) from center stowage compartment (2)

3 Remove center stowage compartment (2)

4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL CENTER CONSOLE - AR68.20-P-2000MCU > Fig 1: Identifying Center Stowage Compartment Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Center Stowage Compartment And Screws Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

In tall in the rever e order

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3138 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2040MCC

10 In tall in the rever e order

TESTING & REPAIR > REMOVE/INSTALL FLOOR COVERING - AR68.20-P-2040MCC > MODEL 451.3/4 Remove/install

1 Remove left and right front seat

AR91.10- P- 1000MCC 2 Remove bass module speaker On vehicles with code (C54) Sound system 2 or On vehicles as of 31.8.10 with code (C17) smart surround sound system AR82.62- P- 7839MCC 3 Remove electronic accelerator pedal On vehicles with code (LHD) Left-hand drive vehicle AR30.20- P- 2000MCC 4 Remove pedal assembly seal On vehicles with code (LHD) Left-hand drive vehicle AR29.10- P- 0341MCC On vehicles with code (RHD) right-hand drive vehicle AR29.10- P- 0341MCE 5

AR68.00- P- Fig 1: Identifying Floor Covering Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove vertical strut paneling

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3139 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2040MCU

1500MCC 6 Remove center console

AR68.20- P- 2000MCC 7 Remove bracket (2)

8 Loosen retaining clip (3) on floor covering (1) on heater/AC housing

9 Slightly lift floor covering (1) and guide connector (4) through openings in floor covering (1) The number of connectors (4) can vary depending on vehicle model and equipment.

10 Remove floor covering (1) from vehicle

11 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL FLOOR COVERING - AR68.20-P-2040MCU > MODEL 451.3/4 Remove/install

1 Remove driver seat

AR91.10- P- Fig 1: Identifying Floor Covering Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3141 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2340MCU

1 Remove shift lever knob (1)

AR26.60- P- 6601MCU 2 Remove power top switch (S84) On model 451.4 AR77.39- P- 1000MCU 3 Unclip catch hook (6) from selector lever position display (7), remove selector lever position display (7) upward and lay down to side with electrical line connected The catch hooks (6) are shown with the center console (4) removed, for better illustration.

4 Loosen catch hook (5) on selector lever cover (3) The catch hooks (5) are shown with the center console (4) removed, for better illustration.

5 Lift selector lever cover (3), guide selector lever position display (7) through opening in selector lever cover (3) and remove selector lever cover (3)

6 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL CENTER CONSOLE REINFORCEMENT - AR68.20-P-2340MCU > MODEL 451.3/4 Fig 1: Identifying Cover Components At Selector Lever Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove cockpit switch group

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3145 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-4810MCU

1 Remove cockpit switch group

AR54.25- P- 1000MCC 2 Unscrew bolts (3) from dashboard lower section (5)

3 Unscrew bolt (4) from center console cover (1)

4 Open glove compartment cover (2) On vehicles with code (I63) Glove box

5 Unclip center console cover (1) in the upper area

6 Carefully pull instrument panel lower section (5) downward and pivot center console cover (1) out toward out and remove

7 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL LUGGAGE COMPARTMENT FLOOR COVERING - AR68.20-P-4810MCU > MODEL 451.3/4 Remove/install

1 Remove driver seat

AR91.10- P- 1010MCU 2 Remove passenger seat

AR91.10- P- 1020MCU Remove Fig 1: Identifying Load Compartment Floor Covering And Retaining Clips Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3149 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4050MCU

1 Unclip catch hook (7) on lower steering column trim (2) from brackets (5) on upper steering column trim (1) and remove lower steering column trim (2) Installation: First position guides (8) in area of instrument panel. 2 Unscrew bolts (3) from upper steering column trim (1)

3 Unclip bracket (6) from jacket tube in marked area (arrow) with suitable screwdriver and carefully remove upper steering column trim (1) upward A cutout is located in the bearing shell of the jacket tube in the marked area (arrow), through which the bracket (6) is accessible. Installation: First position guides (4) in area of instrument panel. 4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL PANELING ON A-PILLAR - AR68.30-P-4050MCU

MODEL 451.3/4 Shown on model 451.3 Fig 1: Identifying Steering Column Trim Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3155 · Applies to: 450, 451, 452, 454 · AR: AR68.60-P-5480MCU

1 Carefully slide inside rearview mirror (1) upward in direction of arrow and remove Ensure that the front headliner (2) is not scratched when folding inside rearview mirror (1) in/out; otherwise, it must be replaced. 2 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL SUN VISOR - AR68.60-P-5480MCU > MODEL 451.3/4

Remove/install

Fig 1: Identifying Inside Rearview Mirror & Front Headliner Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Sun Visor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

with assembly wedge (8)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3158 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2309MCC, AR68.20-P-2309MCU, AZ68.50-P-0002MCC

assembly wedge (8) as shown. *110589035900 2 Push left front door panel cover (1) and right front door panel cover (2) toward front and guide out of door paneling (7) in rear area (arrow A).

3 Remove selector lever cover (3) * not for USA AR68.20-P-2309MCC * for USA only AR68.20-P-2309MCU 4 Loosen combination switch caps (4) from combination switch (S4) with suitable knife and remove Ensure that combination switch (S4) is not damaged.

5 Unclip combination switch cover (5) from instrument cluster with assembly wedge (8) and remove. *110589035900 6 Unclip additional instrument covers (6) from cockpit clock and tachometer with assembly wedge (8) and remove With code (V31) Cockpit clock and tachometer package

*110589035900 7 Install in the reverse order Replace corresponding trim parts with new trim parts

8 Clean installed trim parts with cleaning agent approved by Daimler AG

RETROFITTING & CONVERSION > RETROFITTING LUGGAGE NET ON TRUNK FLOOR - AZ68.50-P-0002MCC > Fig 3: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

illumination

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3168 · Applies to: 450, 451, 452, 454 · AR: AR68.00-Z-9451CA, AR68.10-P-1501MCU, AR68.10-P-1502MCU, AR68.10-P-1501MCC, AR68.10-P-1502MCC

7 Remove vertical strut paneling (1)

8 Unclip footwell illumination and remove When replacing vertical strut paneling (1) on vehicles as of 31.8.10 with code (876) Interior light package

9 Unscrew bolts (3) and remove data link connector (X11/4) When replacing vertical strut paneling (1).

10 Unclip interior socket (X58/1) from rear of vertical strut paneling (1) and remove toward front When replacing vertical strut paneling (1). Installation: Pull metal insert out of interior socket (X58/1) before installation using pliers (2).

Pliers Fig 2 11 Install in the reverse order

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: INTERIOR EQUIPMENT - AR68.00-Z-9451CA > MODEL 451 Remove/install bottom paneling for dashboard on driver side MODEL 451.3 /4 AR68.10-P-1501MCU Remove/install bottom paneling for dashboard on passenger side MODEL 451.3 /4 AR68.10-P-1502MCU Remove/install bottom paneling for instrument panel on driver side MODEL 451.3 /4 AR68.10-P-1501MCC Remove/install bottom paneling for instrument panel on passenger side MODEL 451.3 /4 AR68.10-P-1502MCC Fig 2: Identifying Pliers (169 589 00 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install center air nozzle

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3169 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1150MCC, AR68.10-P-1150MCF, AR68.10-P-1150MCU, AR68.20-P-2000MCC, AR68.20-P-2000MCU (+5 more)

MODEL 451.3 /4 up to 30.8.10 AR68.10-P-1150MCC Remove/install center air nozzle MODEL 451.3 /4 as of 31.8.10 AR68.10-P-1150MCF Remove/install center air nozzle MODEL 451.3 /4 up to 30.8.10 AR68.10-P-1150MCU Remove/install center console MODEL 451.3 /4 AR68.20-P-2000MCC Remove/install center console MODEL 451.3 /4 AR68.20-P-2000MCU Remove/install center console reinforcement MODEL 451.3 /4 AR68.20-P-2340MCC Remove/install center console reinforcement MODEL 451.3 /4 AR68.20-P-2340MCU Remove/install center stowage compartment MODEL 451... AR68.10-P-1620MCC Remove/install cover at selector lever MODEL 451.3/ 4 AR68.20-P-2309MCC Remove/install cover at selector lever MODEL 451.3 /4 AR68.20-P-2309MCU Remove/install cover on center console MODEL 451.3 /4 up to 30.8.10 AR68.20-P-2350MCC Remove/install cover on center console MODEL 451.3 /4 as of 31.8.10 AR68.20-P-2350MCF Remove/install dashboard top section MODEL 451.3 /4 AR68.10-P-1020MCC Remove/install dashboard top section MODEL 451.3 /4 AR68.10-P-1020MCU Remove/install floor covering MODEL 451.3 /4 AR68.20-P-2040MCC Remove/install floor covering MODEL 451.3 /4 AR68.20-P-2040MCU Remove/install footrest on passenger side MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle AR68.30-P-1340MCC Remove/install front roof frame paneling MODEL 451.3 AR68.30-P-4450MCC Remove/install front roof frame paneling MODEL 451.4 AR68.30-P-4450MCO Remove/install front roof frame paneling MODEL 451.3 AR68.30-P-4450MCU Remove/install front roof frame paneling MODEL 451.4 AR68.30-P-4450MCV Remove/install glove box MODEL 451.3 /4 AR68.10-P-1400MCU Remove/install glove compartment MODEL 451.3 /4 with CODE (I63) Glove compartment AR68.10-P-1400MCC

Remove/install glove

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3170 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1200MCC, AR68.40-P-0001MCC, AR68.40-P-0001MCU, AR68.30-P-1380MCC, AR68.30-P-1380MCU (+5 more)

compartment lid MODEL 451.3 /4 with CODE (I63) Glove compartment AR68.10-P-1200MCC Remove/install inside rearview mirror MODEL 451.3/ 4 AR68.40-P-0001MCC Remove/install inside rearview mirror MODEL 451.3 /4 AR68.40-P-0001MCU Remove/install interior paneling on roll bar MODEL 451.4 AR68.30-P-1380MCC Remove/install interior paneling on roll bar MODEL 451.4 AR68.30-P-1380MCU Remove/install lower section of dashboard MODEL 451.3 /4 AR68.10-P-1040MCU Remove/install lower section of instrument panel MODEL 451.3 /4 AR68.10-P-1040MCC Remove/install luggage compartment floor covering MODEL 451.3 /4 AR68.20-P-4810MCC Remove/install luggage compartment floor covering MODEL 451.3 /4 AR68.20-P-4810MCU Remove/install paneling on A- pillar MODEL 451.3 /4 AR68.30-P-4050MCC Remove/install paneling on A- pillar MODEL 451.3 /4 AR68.30-P-4050MCU Remove/install paneling on B- pillar MODEL 451.3 AR68.30-P-4700MCU Remove/install paneling on B- pillar MODEL 451.4 AR68.30-P-4700MCV Remove/install paneling on rear pillar MODEL 451.4 AR68.30-P-4505MCO Remove/install passenger side footrest MODEL 451.3## /4## 2# with CODE (RHD) Right-hand drive vehicle AR68.30-P-1340MCE Remove/install rear roof frame paneling MODEL 451.3 AR68.30-P-4470MCC Remove/install side air outlet MODEL 451.3/ 4 AR68.10-P-1100MCC Remove/install side paneling in trunk MODEL 451.3 /4 AR68.30-P-4800MCC Remove/install side paneling in trunk MODEL 451.3 /4 AR68.30-P-4800MCU Remove/install side paneling in trunk MODEL 451.391 /491 with ENGINE 780.009 AR68.30-P-4800MEV Remove/install side paneling MODEL 451.3 /4 AR68.10-P-1503MCC

on instrument panel

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3171 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1503MCU, AR68.30-P-4480MCC, AR68.30-P-4480MCO, AR68.30-P-4480MCU, AR68.30-P-2000MCC (+3 more)

Remove/install side paneling on instrument panel MODEL 451.3 /4 AR68.10-P-1503MCU Remove/install side roof frame paneling MODEL 451.3 AR68.30-P-4480MCC Remove/install side roof frame paneling MODEL 451.4 AR68.30-P-4480MCO Remove/install side roof frame paneling MODEL 451.3 AR68.30-P-4480MCU Remove/install steering column trim MODEL 451.3/ 4 AR68.30-P-2000MCC Remove/install sun visor MODEL 451.3 /4 AR68.60-P-5480MCC Remove/install sun visor MODEL 451.3 /4 AR68.60-P-5480MCU Remove/install vertical strut paneling MODEL 451.3 /4 AR68.00-P-1500MCC TESTING & REPAIR > REMOVE/INSTALL PANELING ON INSTRUMENT PANEL - AR68.10- P-1000-06MCC > 1. Unscrew bolt (2). 2. Pull paneling (1) toward outside in marked area (arrow A) and unclip. 3. Carefully pull paneling (1) toward rear in lower area (arrows B) and then pivot upward so that paneling (1) can be loosened in upper area (arrows C). 4. Loosen paneling (1) in upper area (arrow D) and remove toward rear. 5. Install in the reverse order.

Route wiring harness (3)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3181 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1502MCU

12 Route wiring harness (3) through opening in instrument panel lower section (1)

13 Remove instrument panel lower section (1) upward (arrows B) out of driver side paneling (6) and passenger side paneling (7) Installation: Ensure that instrument panel lower section (1) is seated correctly in guide rails (arrows C).

14 Disconnect kneebag separating point (X99/17) With code (294) Kneebag

15 Remove instrument panel lower section (1) from vehicle and lay down on suitable base

16 Remove retaining clamps on dashboard lower section (1) When replacing instrument panel lower section (1) Four retaining clamps are fastened to the dashboard lower section (1).

18 Remove electric cable harness (14) With code (294) Kneebag, when replacing instrument panel lower section (1).

19 Remove left and right kneebag (13) With code (294) Kneebag, when replacing instrument panel lower section (1). AR91.60- P- 0050MCU 20 Install in the reverse order

AIRBAG Number Designation Model 451.3 Model 451.4 BA91.60-P-1012- 01C Screw/bolt, kneebag bracket to crossmember Nm 4 4 TESTING & REPAIR > REMOVE/INSTALL BOTTOM PANELING FOR DASHBOARD ON PASSENGER SIDE - AR68.10-P-1502MCU > MODEL 451.3 /4 Shown on vehicle up to 30.8.10

Unscrew bolts (6) on passenger-side

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3184 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1150MCF

9 Unscrew bolts (6) on passenger-side paneling (1) Rechargeable drill / screwdriver

10 Remove passenger-side paneling (1) On vehicles with code (41Z) AUX jack, observe installation position of wiring harness on external audio source separation point (X39/45)

11 Remove glove box

AR68.10- P- 1400MCU 12 Unclip expander (9) of external audio source separation point (X39/45) from clamping ring (8) with a suitable screwdriver When replacing passenger-side paneling (1) on vehicles with code (41Z) AUX jack.

13 Press clamping ring (8) together and push out external audio source separation point (X39/45) toward the rear and out of passenger-side paneling (1) When replacing passenger-side paneling (1) on vehicles with code (41Z) AUX jack.

14 Remove sheet metal nut (arrow D) and sheet metal nut (10) from passenger-side paneling (1) When replacing passenger-side paneling (1).

15 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL CENTER AIR NOZZLE - AR68.10-P-1150MCF > MODEL 451.3 /4 as of 31.8.10 Vehicles without code (I01) Air conditioning Plus

Use a suitable screwdriver to release bracket (arrow C) of

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3186 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1150MCU

4 Use a suitable screwdriver to release bracket (arrow C) of flexible shaft (3) and detach flexible shaft (3) from guide wheel (4)

5 Press back catch hook (arrow E) and remove eyelet (9) from relay lever (10) Vehicles without code (I01) Air conditioning Plus

6 Press catch hook (arrows D) together using suitable pliers and push wire out of bracket on heater housing in direction of arrow Vehicles without code (I01) Air conditioning Plus

7 Unscrew bolts (2) from center air vent (1)

8 Unclip center air vent (1) in front area (arrow B) from bracket (5)

9 Fold center air vent (1) out of instrument panel upper section, unhook from guides (arrows A) and remove until electrical connectors (6) are accessible

10 Release electrical connectors (6) and disconnect from heater/AC operating unit (N23)

11 Remove center air vent (1) with heater/air conditioning (N23) Observe installation position of flexible shaft (3)

12 Remove heater/AC operating unit (N23) When replacing center air vent (1).

Vehicles without code (I01) Air conditioning Plus AR83.20- P- 1850MCF Vehicles with code (I01) Air conditioning Plus AR83.25- P- 1124MCF 13 Install in the reverse order

14 Perform function test on heater/air conditioning operating unit (N23)

TESTING & REPAIR > REMOVE/INSTALL CENTER AIR NOZZLE - AR68.10-P-1150MCU > MODEL 451.3 /4 up to 30.8.10 Shown on vehicle with Code (I01) AC

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3188 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1400MCU

1 Open glove compartment.

2 Loosen pins (2) with suitable screwdriver and pull out of glove compartment lid (1) using pliers.

3 Remove glove compartment lid (1) Installation: When replacing glove compartment lid (1) insert new lock cylinder (3) into glove compartment lid (1) according to key code. 4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL GLOVE BOX - AR68.10-P-1400MCU > MODEL 451.3 /4 Fig 1: Identifying Glove Compartment Lid Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3189 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1501MCU

1 Remove passenger side paneling (1)

AR68.10- P- 1502MCU 2 Unscrew bolts (2) and remove glove box (3) from passenger side paneling (1)

3 Remove glove compartment cover (4) When replacing glove box (3) with code (I63) Glove compartment. AR68.10- P- 1200MCC 4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL BOTTOM PANELING FOR DASHBOARD ON DRIVER SIDE - AR68.10-P-1501MCU > MODEL 451.3 /4 Shown on vehicle without code (294) Kneebag Fig 1: Identifying Glove Box Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

harness (3) on driver-side

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3191 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1502MCU

paneling (1) (arrow C). 8 Unscrew bolts (4) on driver-side paneling (1).

9 Remove driver-side paneling (1). Installation: Observe installation position of electrical lines as well as fanfare horns and airbag clock spring contact wiring harness (3).

10 Remove sheet metal nut (5) from driver-side paneling (1). When replacing driver-side paneling (1).

11 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL BOTTOM PANELING FOR DASHBOARD ON PASSENGER SIDE - AR68.10-P-1502MCU > MODEL 451.3 /4 Shown on vehicle up to 30.8.10 Fig 1: Identifying Passenger Side Dashboard Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL SIDE PANELING ON INSTRUMENT PANEL -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3194 · Applies to: 450, 451, 452, 454 · AR: AR68.10-P-1503MCU

AR68.10-P-1503MCU > MODEL 451.3 /4 Remove/install

1 Remove left or right paneling from instrument panel

AR68.10-P-1000- 06MCC 2 Remove bolt (4) on bottom section of instrument panel (3)

3 Release bottom section of instrument panel (3) in area of bracket (arrows)

4 Unscrew bolts (2) from side paneling (1).

5 Remove side paneling (1)

6 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL CENTER STOWAGE COMPARTMENT - AR68.10- P-1620MCC > MODEL 451.3 /4 up to 30.8.10 except CODE (C50) smart radio 10 except CODE (C57) smart radio 9 MODEL 451.3 /4 as of 31.8.10 except CODE (516) RADIO WITH USB INTERFACE Vehicles up to 30.8.10 Fig 1: Identifying Intsrument Panel Side Paneling Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

MODEL 451.3 /4

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3196 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2000MCU, AR68.20-P-2040MCC

Remove/install

1 Remove center console

AR68.20-P-2000MCU 2 Disconnect electrical connector (1) from transponder coil (L11)

3 Unclip transponder coil (L11) and remove upward

4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL FLOOR COVERING - AR68.20-P-2040MCC > MODEL 451.3 /4 Fig 1: Identifying Electrical Connector And Transponder Coil Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Floor Covering Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3197 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2040MCU

1 Remove left and right front seat

AR91.10- P- 1000MCC 2 Remove bass module speaker On vehicles with code (C54) Sound system 2 or On vehicles as of 31.8.10 with code (C17) smart surround sound system AR82.62- P- 7839MCC 3 Remove electronic accelerator pedal On vehicles with code (LHD) Left-hand drive vehicle AR30.20- P- 2000MCC 4 Remove pedal assembly seal On vehicles with code (LHD) Left-hand drive vehicle AR29.10- P- 0341MCC On vehicles with code (RHD) right-hand drive vehicle AR29.10- P- 0341MCE 5 Remove vertical strut paneling

AR68.00- P- 1500MCC 6 Remove center console

AR68.20- P- 2000MCC 7 Remove bracket (2)

8 Loosen retaining clip (3) on floor covering (1) on heater/AC housing

9 Slightly lift floor covering (1) and guide connector (4) through openings in floor covering (1) The number of connectors (4) can vary depending on vehicle model and equipment.

10 Remove floor covering (1) from vehicle

11 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL FLOOR COVERING - AR68.20-P-2040MCU > MODEL 451.3 /4

Disconnecto electrical

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3201 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2309MCU, AR68.20-P-2340MCU

8 Disconnecto electrical connector (6)

9 Remove selector lever cover When replacing center console (3) AR68.20-P-2309MCU 10 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL CENTER CONSOLE REINFORCEMENT - AR68.20-P-2340MCU > MODEL 451.3 /4 Vehicles as of 31.8.10 Fig 1: Identifying Center Console Reinforcement Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Unclip center console cover (1) in the upper area

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3205 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-4810MCU

box 5 Unclip center console cover (1) in the upper area

6 Carefully pull instrument panel lower section (5) downward and pivot center console cover (1) out toward out and remove

7 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL LUGGAGE COMPARTMENT FLOOR COVERING - AR68.20-P-4810MCU > MODEL 451.3 /4 Remove/install

1 Remove driver seat

AR91.10- P- 1010MCU 2 Remove passenger seat

AR91.10- P- 1020MCU 3.1 Remove retaining clips (2) from load compartment floor covering (1). On vehicles without code (I05) Separation protection between luggage compartment and passenger compartment (DFO) or without code (S02) Top Tether (child seat equipment)

On vehicles with code (I05) Separation protection between luggage compartment and passenger compartment (DFO) or with code (S02) Top Tether (child seat equipment) Fig 1: Identifying Load Compartment Floor Covering And Retaining Clip Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3208 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4050MCU

1 Unclip catch hook (7) on lower steering column trim (2) from brackets (5) on upper steering column trim (1) and remove lower steering column trim (2) Installation: First position guides (8) in area of instrument panel. 2 Unscrew bolts (3) from upper steering column trim (1)

3 Unclip bracket (6) from jacket tube in marked area (arrow) with suitable screwdriver and carefully remove upper steering column trim (1) upward A cutout is located in the bearing shell of the jacket tube in the marked area (arrow), through which the bracket (6) is accessible. Installation: First position guides (4) in area of instrument panel. 4 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL PANELING ON A-PILLAR - AR68.30-P-4050MCU

MODEL 451.3 /4 Shown on model 451.3 Fig 1: Identifying Steering Column Trim Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

airbag, only one bolt (5) is installed.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3214 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4700MCU

3 Loosen edge guard (6) in rear area of side roof frame paneling (1)

4 Unhook bracket (9) from recesses (arrows B) Installation: Position edge guard (6) on side roof frame paneling (1).

5 Remove front roof frame paneling

AR68.30- P- 4450MCU 6 Unscrew bolt (2) from side roof frame paneling (1)

7 Loosen edge guard (7) in area of side roof frame paneling (1)

8 Unclip side roof paneling (1) On vehicles without code (I52) Head airbag

9 Unclip AIRBAG cover (3) On vehicles with code (I52) Head airbag

10 Unscrew bolt (4) On vehicles with code (I52) Head airbag

11 Pivot out side roof frame paneling (1) until clips (8) can be detached On vehicles with code (I52) Head airbag

12 Detach clips (8) with clip remover On vehicles with code (I52) Head airbag

Clip remover Fig 3 13 Unhook brackets (10) for cutout (arrows A)

14 Remove side roof frame paneling (1)

15 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL PANELING ON B-PILLAR - AR68.30-P-4700MCU

MODEL 451.3 Fig 3: Identifying Snap-Release Tool (452 589 01 63 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install in the reverse order

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3220 · Applies to: 450, 451, 452, 454 · AR: AR68.60-P-5480MCU, AR68.10-P-1100MCC

2 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL SUN VISOR - AR68.60-P-5480MCU > MODEL 451.3 /4

Remove/install

1 Fold left and right sun visor (1) downward and unclip from bracket (3)

2 Unscrew bolts (4) from sun visor (1) Installation: Install sun visor (1) with vanity mirror on passenger side. 3 Install in the reverse order

4 Attach safety sticker (2) to sun visor (1) When replacing sun visor (1). TESTING & REPAIR > REMOVE/INSTALL SIDE AIR OUTLET - AR68.10-P-1100MCC > MODEL 451.3 /4 Fig 1: Identifying Sun Visor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: REAR WALL AND REAR

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3348 · Applies to: 450, 451, 452, 454 · AR: AR64.00-Z-9451CA, AR64.20-P-1300MCC, AR64.20-P-1062MCC, AR64.20-P-5731MCC, AR64.20-P-1140MCC (+5 more)

END - AR64.00-Z-9451CA > MODEL 451 Completely replace rear floor MODEL 451.3/4 AR64.20-P-1300MCC Partially replace rear lamp insert MODEL 451.3 AR64.20-P-1062MCC Remove/install end plate MODEL 451.3/4 AR64.20-P-5731MCC Replace crossmember on rear floor assembly, front bottom MODEL 451.3/4 AR64.20-P-1140MCC Replace end crossmember internal part MODEL 451.3/4 AR64.20-P-1120MCC Replace rear floor assembly section MODEL 451.3/4 AR64.20-P-1310MCC Replace rear lamp insert MODEL 451.3 AR64.20-P-1061MCC Replace rear lamp insert MODEL 451.4 AR64.20-P-1061MCO Replace rear-end floor reinforcement MODEL 451.3/4 AR64.20-P-1141MCC TESTING & REPAIR > SEPARATE REAR LAMP INSERT - AR64.20-P-1061-01MCO > 1. Expose spot welds on rear lamp insert (1) and cut out (areas A, B, C, D, E and F). 2. Heat rear lamp insert (1) with hot air gun (areas E and F). Areas (E and F) are bonded. 3. Remove damaged rear lamp insert (1).

2. Fit rear lamp insert (1) and fasten with vise grip pliers.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3352 · Applies to: 450, 451, 452, 454 · AR: AR64.20-P-1061MCO

1. Rear lamp insert (1) (areas J, K, L, M, N and O).
2. Rear lamp insert (1) (area H).
3. Grind all spot welds down flat if required.
4. Clean all other welds with wire brush. TESTING & REPAIR > REPLACE REAR LAMP INSERT - AR64.20-P-1061MCO > MODEL 451.4 Fig 1: Fitting Rear Lamp Insert Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BR00 45 Z 1003

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3362 · Applies to: 450, 451, 452, 454 · AR: AR64.20-P-1140MCC

01A Sealant, white, 310 ml, DB upply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunchenGermanyTel. +49- 899268-0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR > REPLACE CROSSMEMBER ON REAR FLOOR ASSEMBLY, FRONT BOTTOM - AR64.20-P-1140MCC > MODEL 451.3/4 Shown on model 451.3 Removing

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the AS00.00-Z-0007- 01A Fig 1: Replacing Crossmember On Rear Floor Assembly Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

vehicle with airbag and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3374 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR63.20-P-0862MCC, AR63.20-P-1351MCC, AR63.20-P-1351MCO (+4 more)

ETR units General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027-01FF General information on repairs to body

AH60.00-P-0001-01FF Generally conventional tools are required for body work, additional tools required are listed above. Pneumatic/hydraulic blind rivet tool gotis://K_68- 80_06.

The repair method using riveting described here can be replaced by plug welding if required. Adapt preparatory work accordingly.

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 4 Partially remove side wall reinforcement

AR63.20-P-0862MCC 5 Remove B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 6 Remove rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 7 Remove rear wheel well

AR63.10-P-0661MCC 8 Remove B-pillar inner section

AR63.20-P-1355MCC 9 Remove rear-end floor reinforcement (1)

AR64.20-P-1141- 01MCC 10 Prepare connecting points for rear-end floor reinforcement (1) on body

AR64.20-P-1141- 04MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 11 Prepare rear-end floor

AR64.20-P-1141-

reinforcement (1) for

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3375 · Applies to: 450, 451, 452, 454 · AR: AR63.20-P-1355MCC, AR63.10-P-0661MCC, AR64.20-P-1061MCC, AR64.20-P-1061MCO, AR63.20-P-1351MCC (+5 more)

installation 02MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

12 Install rear-end floor reinforcement (1) and weld in

AR64.20-P-1141- 03MCC

Rivet *BR00.45-Z-1001-13A 13 Install B-pillar inner section

AR63.20-P-1355MCC 14 Install rear wheel well

AR63.10-P-0661MCC 15 Install rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 16 Install B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 17 Partially install side wall reinforcement

AR63.20-P-0862MCC 18 Partially install side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 19 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

20 Prime area to be repaired using primer filler

21 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003-01A 22 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A 23 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 24 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 25 Reinstall all detachable parts removed

1. Grind mating surfaces down to bare metal in the cross-hatched areas.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3383 · Applies to: 450, 451, 452, 454 · AR: AR64.20-P-1300MCC

Thoroughly clean all bonding surfaces and do not coat with zinc dust paint. Observe pretreatment of bonding surfaces. Otherwise the adhesive force of the 2-component adhesive starts to decrease. Grind spot weld flanges down to bare metal on both sides. Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR > COMPLETELY REPLACE REAR FLOOR - AR64.20-P-1300MCC > MODEL 451.3/4 Illustrated on model 451.3 MODIFICATION NOTES 30.1.09 Information on alternative repair methods are worked in (riveting or plug welding as alternative and structural bonding) Removing

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. AS00.00-Z-0007-01A Fig 1: Identifying Rear Floor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

welding fumes.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3384 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR63.20-P-0862MCC, AR63.20-P-1351MCC, AR63.20-P-1351MCO (+1 more)

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non- deburred vehicle parts. Deburr repair panels. AS00.00-Z-0017-01A Measures for preventing damage to vehicles or components when performing electric welding work

AH00.00-P-0005-01FF Notes on performing repair, body work and welding on vehicles with airbags and ETR units

AH91.00-P-0002-01SM Pretreatment of bonding surfaces

AH60.00-P-0008- 01MCC General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027-01FF General information on repairs to body

AH60.00-P-0001-01FF Generally conventional tools are required for body work, additional tools required are listed above. Pneumatic/hydraulic blind rivet tool gotis://K_68-80_06.0

The repair method using riveting described here can be replaced by plug welding if required. Adapt preparatory work accordingly.

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 4 Partially remove side wall reinforcement

AR63.20-P-0862MCC 5 Remove B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 6 Remove rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3385 · Applies to: 450, 451, 452, 454 · AR: AR64.20-P-1061MCO, AR63.10-P-0661MCC, AR63.20-P-1355MCC, AR64.20-P-1141MCC, AR63.40-P-1191MCC (+4 more)

AR64.20-P-1061MCO 7 Remove rear wheel well

AR63.10-P-0661MCC 8 Remove B-pillar inner section

AR63.20-P-1355MCC 9 Remove rear floor assembly reinforcement

AR64.20-P-1141MCC 10 Remove crossmember below front seat

AR63.40-P-1191MCC 11 Remove rear floor assembly (1)

AR64.20-P-1300- 01MCC 12 Prepare connecting points for rear floor assembly (1) on body

AR64.20-P-1300- 10MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 13 Prepare rear floor assembly (1) for installation

AR64.20-P-1300- 02MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

14 Install rear floor assembly (1) and weld in The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR64.20-P-1300- 04MCC

Adhesive *BR00.45-Z-1092-02A

Rivet *BR00.45-Z-1001-13A 15 Install crossmember below front seat

AR63.40-P-1191MCC 16 Install rear floor assembly reinforcement

AR64.20-P-1141MCC 17 Install B-pillar inner section

AR63.20-P-1355MCC 18 Install rear wheel well

AR63.10-P-0661MCC 19 Install rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 20 Install B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 21 Partially install side wall

AR63.20-P-0862MCC

reinforcement

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3386 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR97.10-P-4000MCC, AR97.20-P-1500FF

22 Partially install side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 23 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

24 Prime area to be repaired using primer filler

25 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003-01A 26 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A 27 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 28 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 29 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1092- 02A Adhesive kit, body, 2-component adhesive A 009 989 36 71 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunichGermanyTel. +49-899268- 0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 BR00.45-Z-1001- 13A Blind rivet 6.4x14 A 003 990 35 97

TESTING & REPAIR > REMOVE/INSTALL END PLATE - AR64.20-P-5731MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3398 · Applies to: 450, 451, 452, 454 · AR: AR64.20-P-5731MCC

MODEL 451.3/4 Shown on model 451.3 Fig 1: Fitting End Plate Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Number

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3402 · Applies to: 450, 451, 452, 454 · AR: BE64.00-Z-9999CZ

Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA64.20-P-1001- 01B Bolt, CMS rear end to drive module Nm 27 22 27 TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: REAR WALL AND REAR END - BE64.00-Z-9999CZ > MODEL all Body shell - Rear MODEL 452 BE64.20-P-1000-02A SPECIAL TOOLS > 450 589 00 62 00 RECORD RELEASE BOLT - WS64.00-P-0050B > GROUP 64/Set B MODEL 450, 451, 452 Use: Set of record release bolts for lowering rear module for repair purposes. NOTE: Set of record release bolts for rear module Smart no. 0005137. SPECIAL TOOLS > SPECIAL TOOLS: SMART: REAR WALL AND REAR END - WS64.00-Z- 9999CZ > MODEL all 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P-0027K Fig 1: Identifying Record Release Bolt (450 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > TESTING AND REPAIR WORK: SMART: REAR WALL AND

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3404 · Applies to: 450, 451, 452, 454 · AR: AR64.00-Z-9451CA, AR64.20-P-1300MCC, AR64.20-P-1062MCC, AR64.20-P-5731MCC, AR64.20-P-1140MCC (+5 more)

REAR END - AR64.00-Z-9451CA > MODEL 451 Completely replace rear floor MODEL 451.3 /4 AR64.20-P-1300MCC Partially replace rear lamp insert MODEL 451.3 AR64.20-P-1062MCC Remove/install end plate MODEL 451.3/ 4 AR64.20-P-5731MCC Replace crossmember on rear floor assembly, front bottom MODEL 451.3 /4 AR64.20-P-1140MCC Replace end crossmember internal part MODEL 451.3/ 4 AR64.20-P-1120MCC Replace rear floor assembly section MODEL 451.3/ 4 AR64.20-P-1310MCC Replace rear lamp insert MODEL 451.3 AR64.20-P-1061MCC Replace rear lamp insert MODEL 451.4 AR64.20-P-1061MCO Replace rear-end floor reinforcement MODEL 451.3 /4 AR64.20-P-1141MCC TESTING & REPAIR INDEX > SEPARATE REAR LAMP INSERT - AR64.20-P-1061-01MCC > 1. Expose spot welds on rear lamp insert (1) and cut out (areas A, B, C, D, E, F and G). 2. Heat rear lamp insert (1) with hot air gun (areas D and E). Areas D and E are bonded. 3. Remove damaged rear lamp insert (1).

1. Apply adhesive to mating surfaces in cross-hatched areas.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3408 · Applies to: 450, 451, 452, 454 · AR: AR64.20-P-1061MCC

Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise the adhesion of the glue is decreased. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications for drying and processing time of adhesive. 2. Fit rear lamp insert (1) and fasten with vise grip pliers. 3. Rear lamp insert (1) (areas L, M, P and R). 4. Rear lamp insert (1) (area N). Area O is together with the side wall paneling. 5. Grind all spot welds down flat if required 6. Clean all other weld joints with wire brush TESTING & REPAIR INDEX > REPLACE REAR LAMP INSERT - AR64.20-P-1061MCC > MODEL 451.3 Fig 1: Identifying Rear Lamp Insert And Weld In Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

3. Grind all spot welds down flat if required.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3421 · Applies to: 450, 451, 452, 454 · AR: AR64.20-P-1120MCC

1. Clean all other weld joints with wire brush. TESTING & REPAIR INDEX > PREPARE CONNECTING POINTS FOR END CROSSMEMBER INNER SECTION ON BODY. - AR64.20-P-1120-04MCC > Shown on model 451.3
2. Grind mating surfaces down to bare metal in the crosshatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR INDEX > REPLACE END CROSSMEMBER INTERNAL PART - AR64.20-P-1120MCC > MODEL 451.3/ 4 Shown on model 451.3 Fig 1: Identifying Connecting Points For End Crossmember Inner Section On Body Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BR00 45

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3425 · Applies to: 450, 451, 452, 454 · AR: AR64.20-P-1140MCC

Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45- Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunchenGermanyTel. +49-899268-0Fax +49- 899101978www.Loctite.de BR00.45- Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR INDEX > REPLACE CROSSMEMBER ON REAR FLOOR ASSEMBLY, FRONT BOTTOM - AR64.20-P-1140MCC > MODEL 451.3 /4 Shown on model 451.3 Removing

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. AS00.00- Z-0007- 01A Fig 1: Identifying Crossmember On Rear Floor Assembly, Front Bottom Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > REMOVE/INSTALL END PLATE - AR64.20-P-5731MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3463 · Applies to: 450, 451, 452, 454 · AR: AR64.20-P-5731MCC

MODEL 451.3/ 4 Shown on model 451.3 Fig 1: Identifying Grind Spot Weld Area On End Plate Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Number

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3467 · Applies to: 450, 451, 452, 454 · AR: BE64.00-Z-9999CZ

Designation 450.3/4 451.3/4 452.3/4 BA64.20-P-1001- 01B Bolt, CMS rear end to drive module Nm 27 22 27 TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: REAR WALL AND REAR END - BE64.00-Z-9999CZ > MODEL all Body shell - Rear MODEL 452 BE64.20-P-1000-02A SPECIAL TOOLS > 450 589 00 62 00 RECORD RELEASE BOLT - WS64.00-P-0050B > GROUP 64/Set B MODEL 450, 451, 452 Use: Set of record release bolts for lowering rear module for repair purposes. NOTE: Set of record release bolts for rear module Smart no. 0005137. SPECIAL TOOLS > SPECIAL TOOLS: SMART: REAR WALL AND REAR END - WS64.00-Z- 9999CZ > MODEL all 129 589 03 21 00 Feeler gauge FG 60/62/63/64/65/ 67/72/77/82/88/ Set K WS60.00-P-0027K Fig 1: Identifying Record Release Bolts (450 589 00 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: SIDE WALL - AR63.00-Z-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3789 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1189MCC, AR63.30-P-1143MCC, AR63.40-P-1180MCC, AR63.40-P-1180MCD, AR63.10-P-0115MCC (+5 more)

9451CA > MODEL 451 Partially replace crossmember below front seat MODEL 451.3/4 AR63.40-P-1189MCC Partially replace longitudinal member inner shell on entrance MODEL 451.3/4 AR63.30-P-1143MCC Partially replace main floor MODEL 451.3/4 Front main floor AR63.40-P-1180MCC Partially replace main floor panel MODEL 451.3/4 Rear main floor panel AR63.40-P-1180MCD Partially replace side wall paneling MODEL 451.3 AR63.10-P-0115MCC Partially replace side wall paneling MODEL 451.4 AR63.10-P- 0115MCO Partially replace side wall reinforcement MODEL 451.3/4 AR63.20-P-0862MCC Partially replace upper A-pillar reinforcement MODEL 451.4 AR63.20-P-1116MCO Prepare side longitudinal member reinforcement section MODEL 451.3/4 AR63.30-P-0818MCC Remove/install A-pillar outer section MODEL 451.4 AR63.20-P- 1102MCO Remove/install B-pillar inner section MODEL 451.3/4 AR63.20-P-1355MCC Remove/install side wall paneling MODEL 451.3 AR63.10-P-0110MCC Remove/install side wall paneling MODEL 451.4 AR63.10-P-0110MCO Replace A-pillar inner section MODEL 451.3/4 AR63.20-P-1104MCC Replace battery box MODEL 451.3/4 AR63.40-P-1196MCC Replace B-pillar reinforcement MODEL 451.3 AR63.20-P-1351MCC Replace B-pillar reinforcement MODEL 451.4 AR63.20-P- 1351MCO Replace center main floor panel reinforcement MODEL 451.3/4 AR63.40-P-1110MCC Replace complete wheel well liner assembly at rear MODEL 451.3/4 AR63.10-P-0661MCC Replace console below front seat MODEL 451.3/4 Center console AR63.40-P-1192MCC

below front seat

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3790 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1192MCD, AR63.40-P-1300MCC, AR63.40-P-1191MCC, AR63.40-P-1191MCD, AR63.40-P-1193MCC (+5 more)

Replace console below front seat MODEL 451.3/4 Outer console below front seat AR63.40-P-1192MCD Replace console for accelerator pedal MODEL 451.3/4 AR63.40-P-1300MCC Replace crossmember below front seat MODEL 451.3/4 Crossmember below front seat top section AR63.40-P-1191MCC Replace crossmember below front seat MODEL 451.3/4 Crossmember below front seat, front bottom section AR63.40-P-1191MCD Replace crossmember mounting console on bottom front rear floor assembly MODEL 451.3/4 AR63.40-P-1193MCC Replace longitudinal member inner shell on entry MODEL 451.3/4 AR63.30-P-1164MCC Replace lower A-pillar reinforcement MODEL 451.3 AR63.20-P-1114MCC Replace lower A-pillar reinforcement MODEL 451.4 AR63.20-P- 1114MCO Replace side longitudinal member reinforcement MODEL 451.3/4 AR63.30-P-0816MCC Replace side wall reinforcement MODEL 451.3/4 AR63.20-P-0860MCC Replace upper A-pillar outer paneling MODEL 451.4 AR63.20-P- 1105MCO Replace upper A-pillar reinforcement MODEL 451.3 AR63.20-P-1113MCC Replace upper A-pillar reinforcement MODEL 451.4 AR63.20-P- 1113MCO Replace wheel well locking lug MODEL 451.3/4 Front wheel well locking lug AR63.20-P-0013MCC TESTING & REPAIR > PARTIALLY SEPARATE SIDE WALL PANELING - AR63.10-P-0115- 01MCO > All operations steps are shown on the front bottom front bottom side wall paneling (1.1) as an example. Adapt repair sections according to damage profile. 1. Scribe cut on side wall paneling (1) and separate (area A).

urface

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3801 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0661MCC

Ob erve manufacturer' pecification for drying and proce ing time of adhe ive Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR > REPLACE COMPLETE WHEEL WELL LINER ASSEMBLY AT REAR - AR63.10-P-0661MCC > MODEL 451.3/4 Illustrated on model 451.3 Fig 1: Identifying Rear Wheelhouse Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

work and welding on vehicle

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3803 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR63.20-P-0862MCC, AR63.20-P-1351MCC, AR63.20-P-1351MCO (+2 more)

with airbags and ETR units Pretreatment of bonding surfaces

AH60.00-P-0008- 01MCC General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027-01FF General information on repairs to body

AH60.00-P-0001-01FF The generally required conventional tools are required for body work.

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 4 Partially remove side wall reinforcement

AR63.20-P-0862MCC 5 Remove B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 6 Remove rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 7 Install rear wheel well (1)

AR63.10-P-0661- 01MCC 8 Prepare connecting points on rear wheel well (1) on body

AR63.10-P-0661- 04MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 9 Prepare rear wheel well (1) for installation

AR63.10-P-0661- 02MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

10 Install rear wheel well (1) and weld in The repair method using bonding described here is

AR63.10-P-0661- 03MCC

not required for rea on of

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3804 · Applies to: 450, 451, 452, 454 · AR: AR64.20-P-1061MCC, AR64.20-P-1061MCO, AR63.20-P-1351MCC, AR63.20-P-1351MCO, AR63.20-P-0862MCC (+4 more)

strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant.

Adhesive *BR00.45-Z-1092-02A 11 Install rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 12 Install B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 13 Install side wall reinforcement

AR63.20-P-0862MCC 14 Install side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 15 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

16 Prime area to be repaired using primer filler

17 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003-01A 18 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A 19 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 20 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 21 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1092- Adhesive kit, body, 2-component A 009 989 36 71

TESTING & REPAIR > REPLACE WHEEL WELL LOCKING LUG - AR63.20-P-0013MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3809 · Applies to: 450, 451, 452, 454 · AR: AR63.20-P-0013MCC

MODEL 451.3/4 Front wheel well locking lug Shown on model 451.3 Fig 1: Identifying Wheel Well Locking Lug And Side Wall Paneling Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 451.3

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3816 · Applies to: 450, 451, 452, 454 · AR: AR63.20-P-0860MCC

1. Fit side wall reinforcement (1) and fasten with vise grip pliers
2. Tack weld side wall reinforcement (1) to body.
3. Side wall reinforcement (1) (areas C, D and E). Other spot welds required can be completed together with the side wall paneling.
4. Grind all spot welds down flat, if required
5. Clean all other spot welds with wire brush. TESTING & REPAIR > REPLACE SIDE WALL REINFORCEMENT - AR63.20-P-0860MCC > MODEL 451.3/4 Shown on model 451.3 Fig 1: Identifying Side Wall Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REPLACE B-PILLAR REINFORCEMENT - AR63.20-P-1351MCO >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3858 · Applies to: 450, 451, 452, 454 · AR: AR63.20-P-1351MCO

MODEL 451.4 Fig 2: Identifying B-Pillar Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

work and welding on vehicles

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3860 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCO, AR63.20-P-0862MCC

with airbags and ETR units Pretreatment of bonding surfaces

AH60.00-P-0008- 01MCC General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027-01FF General information on repairs to body

AH60.00-P-0001-01FF The generally required conventional tools are required for body work.

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Partially remove side wall paneling

AR63.10-P-0115MCO 4 Partially remove side wall reinforcement

AR63.20-P-0862MCC 5 Separate B-pillar reinforcement (1)

AR63.20-P-1351- 01MCO 6 Prepare connecting points on B- pillar reinforcement (1) on body

AR63.20-P-1351- 02MCO

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 7 Prepare B-pillar reinforcement (1) for installation

AR63.20-P-1351- 03MCO

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

8 Install B-pillar reinforcement (1) The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR63.10-P-0696- 05MCO

Adhesive

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3861 · Applies to: 450, 451, 452, 454 · AR: AR63.20-P-0862MCC, AR63.10-P-0115MCO, AR97.10-P-4000MCC, AR97.20-P-1500FF

*BR00.45-Z-1092-02A 9 Partially install side wall reinforcement

AR63.20-P-0862MCC 10 Partially install side wall paneling

AR63.10-P-0115MCO 11 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

12 Prime area to be repaired using primer filler

13 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003-01A 14 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A 15 Paint area repaired and adjacent surfaces Notes on paintwork repairs

AH98.00-P-9408- 02MCC 16 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 17 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1092- 02A Adhesive kit, body, 2-component adhesive A 009 989 36 71 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunichGermanyTel. +49-899268- 0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR > REMOVE B-PILLAR INTERNAL COMPONENT - AR63.20-P-1355- 01MCC >

work and welding on vehicles

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3871 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR63.20-P-0862MCC, AR63.20-P-1351MCC, AR63.20-P-1351MCO (+3 more)

with airbags and ETR units Pretreatment of bonding surfaces

AH60.00-P-0008- 01MCC General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027-01FF General information on repairs to body

AH60.00-P-0001-01FF The generally required conventional tools are required for body work.

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 4 Partially remove side wall reinforcement

AR63.20-P-0862MCC 5 Remove B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 6 Remove rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 7 Remove rear wheel well

AR63.10-P-0661MCC 8 Remove B-pillar inner section (1)

AR63.20-P-1355- 01MCC 9 Prepare connecting points on B- pillar inner section (1) on body

AR63.20-P-1355- 02MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 10 Prepare B-pillar inner section (1) for installation

AR63.20-P-1355- 03MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A Install

11 Install B-pillar inner section (1) and weld in The repair method using bonding described here is not AR63.20-P-1355- 04MCC

required for reasons of

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3872 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0661MCC, AR64.20-P-1061MCC, AR64.20-P-1061MCO, AR63.20-P-1351MCC, AR63.20-P-1351MCO (+5 more)

strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant.

Adhesive *BR00.45-Z-1092-02A 12 Install rear wheel well

AR63.10-P-0661MCC 13 Install rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 14 Install B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 15 Install side wall reinforcement

AR63.20-P-0862MCC 16 Install side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 17 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

18 Prime area to be repaired using primer filler

19 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003-01A 20 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A 21 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 22 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 23 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20

TESTING & REPAIR > REPLACE SIDE LONGITUDINAL MEMBER REINFORCEMENT -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3876 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-0816MCC

AR63.30-P-0816MCC > MODEL 451.3/4 Shown on model 451.3 Fig 1: Identifying Longitudinal Member Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Side Longitudinal Member Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

adjacent surfaces

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3880 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-0818MCC

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 24 Apply additional cavity preservation

AR97.20-P- 1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 25 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunchenGermanyTel. +49 899268-0Fax +49 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42 TESTING & REPAIR > PREPARE SIDE LONGITUDINAL MEMBER REINFORCEMENT SECTION - AR63.30-P-0818MCC > MODEL 451.3/4

Shown on model 451.3

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3888 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-1143MCC

The step is shown as an example on the rear area of the connecting points on the longitudinal member inner shell on the entry. 1. Sand mating surfaces down to bare metal in the cross-hatched areas. Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2-component adhesive may be adversely affected. Observe pretreatment of bonding surfaces. Grind spot weld flanges down to bare metal on both sides. Coat inside of spot weld flanges, not bonded, with zinc dust paint. TESTING & REPAIR > PARTIALLY REPLACE LONGITUDINAL MEMBER INNER SHELL ON ENTRANCE - AR63.30-P-1143MCC > MODEL 451.3/4 Illustrated on model 451.4 Fig 1: Identifying Longitudinal Member Inner Shell Mating Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Notes on performing repair, body

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3890 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR63.20-P-0862MCC, AR64.20-P-1061MCC, AR64.20-P-1061MCO (+4 more)

work and welding on vehicles with airbags and ETR units

AH91.00-P-0002-01SM General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027-01FF General information on repairs to body

AH60.00-P-0001-01FF The generally required conventional tools are required for body work

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 4 Partially remove side wall reinforcement

AR63.20-P-0862MCC 5 Remove rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 6 Remove B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 7 Remove rear wheel well

AR63.10-P-0661MCC 8 Remove B-pillar inner section According to damage profile AR63.20-P-1355MCC 9 Partially remove longitudinal member inner shell on entry (1)

AR63.30-P-1143- 01MCC 10 Partially prepare connecting points for longitudinal member inner shell on entry (1) on body

AR63.30-P-1143- 04MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 11 Prepare section of longitudinal member inner shell on entry (1) for installation

AR63.30-P-1143- 02MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A

Install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3891 · Applies to: 450, 451, 452, 454 · AR: AR63.20-P-1355MCC, AR63.10-P-0661MCC, AR63.20-P-1351MCC, AR63.20-P-1351MCO, AR64.20-P-1061MCC (+5 more)

12 Install section on longitudinal member inner shell on entry (1) The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR63.30-P-1143- 03MCC

Adhesive *BR00.45-Z-1092-02A 13 Install B-pillar inner section According to damage profile AR63.20-P-1355MCC 14 Install rear wheel well

AR63.10-P-0661MCC 15 Install B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 16 Install rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 17 Install side wall reinforcement

AR63.20-P-0862MCC 18 Install side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 19 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

20 Prime area to be repaired using primer filler

21 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003-01A 22 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A 23 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 24 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 25 Reinstall all detachable parts

Shown on model 451.3

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3896 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-1164MCC

1. Grind mating surfaces down to bare metal in the cross-hatched areas. Thoroughly clean all bonding surfaces and do not coat with zinc dust paint. Observe pretreatment of bonding surfaces, otherwise the adhesive force of the 2-component adhesive starts to decrease. Grind spot weld flanges down to bare metal on both sides. Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR > REPLACE LONGITUDINAL MEMBER INNER SHELL ON ENTRY - AR63.30-P-1164MCC > MODEL 451.3/4 Illustrated on model 451.4 Fig 1: Identifying Longitudinal Member Inner Shell Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

work and welding on vehicles

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3898 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR63.20-P-0862MCC, AR64.20-P-1061MCC, AR64.20-P-1061MCO (+4 more)

with airbags and ETR units Pretreatment of bonding surfaces

AH60.00-P-0008- 01MCC General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027-01FF General information on repairs to body

AH60.00-P-0001-01FF The generally required conventional tools are required for body work

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 4 Partially remove side wall reinforcement

AR63.20-P-0862MCC 5 Remove rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 6 Remove B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 7 Remove rear wheel well

AR63.10-P-0661MCC 8 Remove B-pillar inner section

AR63.20-P-1355MCC 9 Remove longitudinal member inner shell on entry (1)

AR63.30-P-1164- 01MCC 10 Prepare connecting points for longitudinal member inner shell on entry (1) on body

AR63.30-P-1164- 04MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A 11 Prepare longitudinal member inner shell on entry (1) for installation

AR63.30-P-1164- 02MCC

Zinc dust paint suitable for spot welding *BR00.45-Z-1001-07A

Install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3899 · Applies to: 450, 451, 452, 454 · AR: AR63.20-P-1355MCC, AR63.10-P-0661MCC, AR63.20-P-1351MCC, AR63.20-P-1351MCO, AR64.20-P-1061MCC (+5 more)

12 Install longitudinal member inner shell on entry (1) The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR63.30-P-1164- 03MCC

Adhesive *BR00.45-Z-1092-02A 13 Install B-pillar inner section

AR63.20-P-1355MCC 14 Install rear wheel well

AR63.10-P-0661MCC 15 Install B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 16 Install rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 17 Install side wall reinforcement

AR63.20-P-0862MCC 18 Install side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 19 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

20 Prime area to be repaired using primer filler

21 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003-01A 22 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A 23 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 24 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 25 Reinstall all detachable parts removed

5. Fit center main floor panel reinforcement (1) and fasten with manual temporary fasteners.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3904 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1110MCC

1. Center main floor panel reinforcement (1) (areas H and J).
2. Rivet center main floor panel reinforcement (1) with 6.4 x 14 Polygrip flat/round head rivet (areas A, B, C, D, E, F, G and K). TESTING & REPAIR > REPLACE CENTER MAIN FLOOR PANEL REINFORCEMENT - AR63.40-P-1110MCC > MODEL 451.3/4 Illustrated on model 451.3 MODIFICATION NOTES 30.1.09 Information on alternative repair methods added (riveting or plug welding as alternative) Removing

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. AS00.00-Z-0007-01A Fig 1: Identifying Center Main Floor Panel Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 451.3

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3914 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1180MCC

1. Fit rear main floor panel (1), front main floor panel, front longitudinal member, longitudinal member console and inner shell longitudinal member with straightening tool and fix in place using vise grip pliers and C-clamps. Observe set-up plans.
2. Tack weld rear main floor panel (1) (areas A, B, C and D).
3. Rear main floor panel (1) (areas C and D).
4. Rear main floor panel (1) (area B).
5. Rear main floor panel (1) (area A). Weld in intervals; minimizes heat distortion.
6. Grind all weld joints down flat if required.
7. Clean all other weld joints with wire brush.
8. Remove front main floor panel, front longitudinal member, longitudinal member console and longitudinal member inner shell, if required. TESTING & REPAIR > PARTIALLY REPLACE MAIN FLOOR - AR63.40-P-1180MCC > MODEL 451.3/4 Front main floor Illustrated on model 451.3 Fig 1: Identifying Rear Main Floor Panel Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

electric welding work

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3916 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR63.20-P-1102MCO, AR63.20-P-1114MCC, AR63.20-P-1114MCO (+5 more)

Notes on performing repair, body work and welding on vehicles with airbags and ETR units

AH91.00-P-0002-01SM Notes on replacing body parts

AH60.00-P-0027-01FF General information on repairs to body

AH60.00-P-0001-01FF The generally required conventional tools are required for body work

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fire-resistant weld protection blanket to prevent damage from flying sparks.

3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 4 Remove lower A-pillar outer section On model 451.4 AR63.20-P-1102MCO 5 Remove lower A-pillar reinforcement On model 451.3 AR63.20-P-1114MCC

On model 451.4 AR63.20-P-1114MCO 6 Partially remove side wall reinforcement

AR63.20-P-0862MCC 7 Partially remove longitudinal member reinforcement

AR63.30-P-0818MCC 8 Remove longitudinal member locking lug

AR62.20-P-1267MCC 9 Remove mounting console on bottom front longitudinal member

AR62.20-P-1265MCC 10 Partially remove outer longitudinal member inner shell on entrance

AR63.30-P-1143MCC 11 Remove front longitudinal member

AR62.20-P-1242MCC 12 Remove front floor section (1)

AR63.40-P-1180- 24MCC 13 Prepare connecting points for front main floor section (1) on body

AR63.40-P-1180- 25MCC

Prepare front main floor section

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3917 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1300MCC, AR63.30-P-1143MCC, AR62.20-P-1265MCC, AR62.20-P-1267MCC, AR63.30-P-0818MCC (+5 more)

14 Prepare front main floor section (1) for installation

AR63.40-P-1180- 26MCC Install

15 Install section of front main floor (1) The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR63.40-P-1180- 27MCC

Adhesive *BR00.45-Z-1092-02A 16 Install accelerator pedal mounting console

AR63.40-P-1300MCC 17 Partially install longitudinal member inner shell on entrance

AR63.30-P-1143MCC 18 Install mounting console on bottom front longitudinal member

AR62.20-P-1265MCC 19 Install longitudinal member locking lug

AR62.20-P-1267MCC 20 Partially install longitudinal member reinforcement

AR63.30-P-0818MCC 21 Partially install side wall reinforcement

AR63.20-P-0862MCC 22 Install lower A-pillar reinforcement On model 451.3 AR63.20-P-1114MCC

On model 451.4 AR63.20-P-1114MCO 23 Install lower outer A-pillar On model 451.4 AR63.20-P-1102MCO 24 Partially install side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 25 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

26 Prime area to be repaired using primer filler

27 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003-01A 28 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A

TESTING & REPAIR > PARTIALLY REPLACE CROSSMEMBER BELOW FRONT SEAT -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3929 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1189MCC

AR63.40-P-1189MCC > MODEL 451.3/4 Illustrated on model 451.4 Fig 1: Identifying Grinding Surface Of Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

vehicles with airbags and ETR

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3931 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR63.20-P-0862MCC, AR64.20-P-1061MCC, AR64.20-P-1061MCO (+5 more)

units Pretreatment of bonding surfaces

AH60.00-P-0008- 01MCC General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027-01FF General information on repairs to body

AH60.00-P-0001-01FF Generally conventional tools are required for body work, additional tools required are listed above. Pneumatic/hydraulic blind rivet tool gotis://K_68-80_06.0

The repair method using riveting described here can be replaced by plug welding if required. Adapt preparatory work accordingly.

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 4 Partially remove side wall reinforcement

AR63.20-P-0862MCC 5 Remove rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 6 Remove B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 7 Remove rear wheel well

AR63.10-P-0661MCC 8 Remove B-pillar inner section

AR63.20-P-1355MCC 9 Partially remove outer longitudinal member inner shell on entrance According to damage profile AR63.30-P-1143MCC 10 Partially remove crossmember below front seat (1)

AR63.40-P-1189- 01MCC 11 Prepare connecting points for crossmember below front seat (1) on body

AR63.40-P-1189- 04MCC

Partially prepare crossmember

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3932 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-1143MCC, AR63.20-P-1355MCC, AR63.10-P-0661MCC, AR63.20-P-1351MCC, AR63.20-P-1351MCO (+5 more)

12 Partially prepare crossmember below front seat (1) for installation

AR63.40-P-1189- 02MCC Install

13 Install section of crossmember below front seat (1) The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR63.40-P-1189- 03MCC

Rivet *BR00.45-Z-1001-13A

Adhesive *BR00.45-Z-1092-02A 14 Partially install longitudinal member inner shell on entrance According to damage profile AR63.30-P-1143MCC 15 Install B-pillar inner section

AR63.20-P-1355MCC 16 Install rear wheel well

AR63.10-P-0661MCC 17 Install B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 18 Install rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 19 Install side wall reinforcement

AR63.20-P-0862MCC 20 Install side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 21 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

22 Prime area to be repaired using primer filler

23 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003-01A 24 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A 25 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC

be replaced

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3940 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR63.20-P-0862MCC, AR64.20-P-1061MCC, AR64.20-P-1061MCO (+5 more)

by plug welding if required. Adapt preparatory work accordingly. 1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fireproof tarp to avoid damage from flying sparks.

3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 4 Partially remove side wall reinforcement

AR63.20-P-0862MCC 5 Remove rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 6 Remove B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 7 Remove rear wheel well

AR63.10-P-0661MCC 8 Remove B-pillar inner section

AR63.20-P-1355MCC 9 Partially remove outer longitudinal member inner shell on entrance According to damage profile AR63.30-P-1143MCC 10 Remove crossmember below front seat (1)

AR63.40-P-1190- 01MCC 11 Prepare connecting points for crossmember below front seat (1) on body

AR63.40-P-1190- 04MCC 12 Prepare crossmember below front seat (1) for installation

AR63.40-P-1190- 02MCC Install

13 Install crossmember below front seat (1) The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a seam sealant. AR63.40-P-1190- 03MCC

Rivet *BR00.45-Z-1001-13A

Adhesive *BR00.45-Z-1092-02A

Partially install longitudinal

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3941 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-1143MCC, AR63.20-P-1355MCC, AR63.10-P-0661MCC, AR63.20-P-1351MCC, AR63.20-P-1351MCO (+5 more)

14 Partially install longitudinal member inner shell on entrance According to damage profile AR63.30-P-1143MCC 15 Install B-pillar inner section

AR63.20-P-1355MCC 16 Install rear wheel well

AR63.10-P-0661MCC 17 Install B-pillar reinforcement On model 451.3 AR63.20-P-1351MCC

On model 451.4 AR63.20-P-1351MCO 18 Install rear lamp insert On model 451.3 AR64.20-P-1061MCC

On model 451.4 AR64.20-P-1061MCO 19 Install side wall reinforcement

AR63.20-P-0862MCC 20 Install side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 21 Clean weld joints and sheet metal flange using a shank brush and clean repair areas.

22 Prime area to be repaired using primer filler

23 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003-01A 24 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001-05A 25 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 26 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008-05A 27 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1092- Adhesive kit, body, 2-component adhesive A 009 989 36 71

9. Clean all other weld joints with wire brush.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3952 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1192MCC

TESTING & REPAIR > REPLACE CONSOLE BELOW FRONT SEAT - AR63.40-P-1192MCC

MODEL 451.3/4 Center console below front seat Shown on model 451.3 Removing

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. AS00.00-Z-0007- 01A Risk of injury caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non- deburred vehicle parts. Deburr repair panels. AS00.00-Z-0017- 01A Fig 1: Identifying Console Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Install console below front

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3954 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1192MCD

6 Install console below front seat (1) and weld in

AR63.40-P-1192- 04MCC 7 Clean welds and sheet metal flange with wire brush and clean areas to be repaired

8 Prime area to be repaired using primer filler

9 Supply standard seam seals with body sealant

AR97.10-P- 4000MCC

Sealant BR00.45-Z-1003- 01A 10 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 11 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 12 Apply additional cavity preservation

AR97.20-P- 1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 13 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunchenGermanyTel. +49 899268-0Fax +49 899101978www.Loctite.de TESTING & REPAIR > REPLACE CONSOLE BELOW FRONT SEAT - AR63.40-P-1192MCD

MODEL 451.3/4 Outer console below front seat

scraping or cutting body parts on

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3958 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR63.20-P-1102MCO, AR63.20-P-1114MCC, AR63.20-P-1114MCO (+4 more)

sharp vehicle parts gloves when working on or near sharp and non- deburred vehicle parts. Deburr repair panels. Measures for preventing damage to vehicles or components when performing electric welding work

AH00.00-P-0005- 01FF Notes on performing repair, body work and welding on vehicles with airbags and ETR units

AH91.00-P-0002- 01SM General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027- 01FF General information on repairs to body

AH60.00-P-0001- 01FF The generally required conventional tools are required for body work

1 Remove detachable parts in the repair area

2 Cover all detachable parts remaining in vehicle (area to be repaired) Use fire-resistant weld protection blanket to prevent damage from flying sparks.

3 Partially remove side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 4 Remove lower A-pillar outer section On model 451.4 AR63.20-P-1102MCO 5 Remove lower A-pillar reinforcement On model 451.3 AR63.20-P-1114MCC

On model 451.4 AR63.20-P-1114MCO 6 Partially remove side wall reinforcement

AR63.20-P-0862MCC 7 Partially remove side longitudinal member reinforcement

AR63.30-P-0818MCC 8 Remove longitudinal member locking lug

AR62.20-P-1267MCC 9 Remove mounting console on bottom front longitudinal member

AR62.20-P-1265MCC

Partially remove outer

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3959 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-1143MCC, AR62.20-P-1242MCC, AR63.40-P-1110MCC, AR63.40-P-1189MCC, AR63.40-P-1192MCC (+2 more)

10 Partially remove outer longitudinal member inner shell on entrance

AR63.30-P-1143MCC 11 Remove front longitudinal member

AR62.20-P-1242MCC 12 Remove center main floor panel reinforcement

AR63.40-P-1110MCC 13 Partially remove crossmember below front seat

AR63.40-P-1189MCC 14 Remove center mounting console below front seat

AR63.40-P-1192MCC 15 Partially remove front main floor panel

AR63.40-P-1180MCC 16 Partially remove rear main floor panel (3).

AR63.40-P-1180MCD 17 Pry out remaining piece of rear main floor panel (3) and support with suitable wooden wedge (2)

18 Expose spot welds on crossmember mounting console on rear floor assembly (1) and cut out (areas A and B)

19 Heat connecting flange using hot air blower (area A). Area A is bonded.

20 Remove damaged crossmember mounting console on rear floor assembly (1).

21 Grind mating surfaces on body and new crossmember mounting console on rear floor assembly (1.1) down to bare metal in cross-hatched areas. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. Observe pretreatment of bonding surfaces.

Zinc dust paint suitable for spot welding *BR00.45-Z-1001- 07A Install

22 Apply adhesive to mating surfaces in cross-hatched areas. The repair method using bonding described here is not required for reasons of strength and can be eliminated. To ensure corrosion protection, it is necessary to apply a

seam sealant.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3960 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1180MCD, AR63.40-P-1180MCC, AR63.40-P-1300MCC, AR63.40-P-1192MCC, AR63.40-P-1189MCC (+5 more)

Adhesive *BR00.45-Z-1092- 02A 23 Fit new crossmember mounting console on rear floor assembly (1.1) to coincide.

24 New crossmember mounting console on rear floor assembly (1.1) (areas C, D and E)

25 Remove wooden wedge (2).

26 Position remaining piece on rear main floor panel (3).

27 Grind all weld joints down flat, if required.

28 Clean all other weld joints using a shank brush

29 Partially install rear main floor panel (3)

AR63.40-P-1180MCD 30 Partially install front main floor panel

AR63.40-P-1180MCC 31 Install accelerator pedal mounting console

AR63.40-P-1300MCC 32 Install center mounting console below front seat

AR63.40-P-1192MCC 33 Partially install crossmember below front seat

AR63.40-P-1189MCC 34 Install center main floor panel reinforcement

AR63.40-P-1110MCC 35 Install front longitudinal member

AR62.20-P-1242MCC 36 Partially install longitudinal member inner shell on entrance

AR63.30-P-1143MCC 37 Install mounting console on bottom front longitudinal member

AR62.20-P-1265MCC 38 Install longitudinal member locking lug

AR62.20-P-1267MCC 39 Partially install longitudinal member reinforcement

AR63.30-P-0818MCC 40 Partially install side wall reinforcement

AR63.20-P-0862MCC 41 Install lower A-pillar reinforcement On model 451.3 AR63.20-P-1114MCC

On model 451.4

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3961 · Applies to: 450, 451, 452, 454 · AR: AR63.20-P-1114MCO, AR63.20-P-1102MCO, AR63.10-P-0115MCC, AR63.10-P-0115MCO, AR97.10-P-4000MCC (+1 more)

AR63.20-P-1114MCO 42 Install lower outer A-pillar On model 451.4 AR63.20-P-1102MCO 43 Partially install side wall paneling On model 451.3 AR63.10-P-0115MCC

On model 451.4 AR63.10-P-0115MCO 44 Clean weld joints and sheet metal flange using a shank brush and clean repair areas.

45 Prime area to be repaired using primer filler

46 Supply standard seam seals with body sealant

AR97.10-P-4000MCC

Sealant BR00.45-Z-1003- 01A 47 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45-Z-1001- 05A 48 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00-P-9408- 02MCC 49 Apply additional cavity preservation

AR97.20-P-1500FF

Teroson protective wax *BR00.45-Z-1008- 05A 50 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45-Z-1092- 02A Adhesive kit, body, 2-component adhesive A 009 989 36 71 BR00.45-Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45-Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunichGermanyTel. +49-899268- 0Fax +49- 899101978www.Loctite.de BR00.45-Z-1001- 07A Zinc dust paint suitable for spot welding A 000 986 34 42

TESTING & REPAIR INDEX > TESTING AND REPAIR WORK: SMART: SIDE WALL -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3966 · Applies to: 450, 451, 452, 454 · AR: AR63.00-Z-9451CA, AR63.40-P-1189MCC, AR63.30-P-1143MCC, AR63.40-P-1180MCC, AR63.40-P-1180MCD (+5 more)

AR63.00-Z-9451CA > MODEL 451 Partially replace crossmember below front seat MODEL 451.3 /4 AR63.40-P-1189MCC Partially replace longitudinal member inner shell on entrance MODEL 451.3 /4 AR63.30-P-1143MCC Partially replace main floor MODEL 451.3 /4 Front main floor AR63.40-P-1180MCC Partially replace main floor panel MODEL 451.3 /4 Rear main floor panel AR63.40-P-1180MCD Partially replace side wall paneling MODEL 451.3 AR63.10-P-0115MCC Partially replace side wall paneling MODEL 451.4 AR63.10-P-0115MCO Partially replace side wall reinforcement MODEL 451.3/ 4 AR63.20-P-0862MCC Partially replace upper A-pillar reinforcement MODEL 451.4 AR63.20-P-1116MCO Prepare side longitudinal member reinforcement section MODEL 451.3/ 4 AR63.30-P-0818MCC Remove/install A-pillar outer section MODEL 451.4 AR63.20-P-1102MCO Remove/install B-pillar inner section MODEL 451.3 /4 AR63.20-P-1355MCC Remove/install side wall paneling MODEL 451.3 AR63.10-P-0110MCC Remove/install side wall paneling MODEL 451.4 AR63.10-P-0110MCO Replace A-pillar inner section MODEL 451.3 /4 AR63.20-P-1104MCC Replace battery box MODEL 451.3 /4 AR63.40-P-1196MCC Replace B-pillar reinforcement MODEL 451.3 AR63.20-P-1351MCC Replace B-pillar reinforcement MODEL 451.4 AR63.20-P-1351MCO Replace center main floor panel reinforcement MODEL 451.3 /4 AR63.40-P-1110MCC

Replace complete wheel well

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3967 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0661MCC, AR63.40-P-1192MCC, AR63.40-P-1192MCD, AR63.40-P-1300MCC, AR63.40-P-1191MCC (+5 more)

liner assembly at rear MODEL 451.3 /4 AR63.10-P-0661MCC Replace console below front seat MODEL 451.3 /4 Center console below front seat AR63.40-P-1192MCC Replace console below front seat MODEL 451.3 /4 Outer console below front seat AR63.40-P-1192MCD Replace console for accelerator pedal MODEL 451.3/ 4 AR63.40-P-1300MCC Replace crossmember below front seat MODEL 451.3 /4 Crossmember below front seat top section AR63.40-P-1191MCC Replace crossmember below front seat MODEL 451.3 /4 Crossmember below front seat, front bottom section AR63.40-P-1191MCD Replace crossmember mounting console on bottom front rear floor assembly MODEL 451.3 /4 AR63.40-P-1193MCC Replace longitudinal member inner shell on entry MODEL 451.3 /4 AR63.30-P-1164MCC Replace lower A-pillar reinforcement MODEL 451.3 AR63.20-P-1114MCC Replace lower A-pillar reinforcement MODEL 451.4 AR63.20-P-1114MCO Replace side longitudinal member reinforcement MODEL 451.3/ 4 AR63.30-P-0816MCC Replace side wall reinforcement MODEL 451.3/ 4 AR63.20-P-0860MCC Replace upper A-pillar outer paneling MODEL 451.4 AR63.20-P-1105MCO Replace upper A-pillar reinforcement MODEL 451.3 AR63.20-P-1113MCC Replace upper A-pillar reinforcement MODEL 451.4 AR63.20-P-1113MCO Replace wheel well locking lug MODEL 451.3 /4 Front wheel well locking lug AR63.20-P-0013MCC TESTING & REPAIR INDEX > PREPARE SIDE WALL PANELING FOR INSTALLATION - AR63.10-P-0110-01MCC >

urface

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 3993 · Applies to: 450, 451, 452, 454 · AR: AR63.10-P-0661MCC

Ob erve manufacturer' pecification for drying and proce ing time of adhe ive Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR INDEX > REPLACE COMPLETE WHEEL WELL LINER ASSEMBLY AT REAR - AR63.10-P-0661MCC > MODEL 451.3 /4 Illustrated on model 451.3 Fig 1: Identifying Rear Wheelhouse Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > PARTIALLY INSTALL SIDE WALL REINFORCEMENT -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4013 · Applies to: 450, 451, 452, 454 · AR: AR63.20-P-0862MCC

AR63.20-P-0861-04MCC > Shown on model 451.3 1. Fit side wall reinforcement section (1.1 to 1.3) and fasten with vise grip pliers. 2. Tack weld side wall reinforcement section (1.1 to 1.3) to body according to damage profile with (arrows). 3. Side wall reinforcement section (1.1 to 1.3) according to damage profile (areas A and B). 4. Side wall reinforcement section (1) according to damage profile (areas C, D and E). Other spot welds required can be completed together with the side wall paneling. 5. Grind all spot welds down flat, if required 6. Clean all other spot welds with wire brush. TESTING & REPAIR INDEX > PARTIALLY REPLACE SIDE WALL REINFORCEMENT - AR63.20-P-0862MCC > MODEL 451.3/ 4 Fig 1: Identifying Side Wall Reinforcement Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 451.3

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4019 · Applies to: 450, 451, 452, 454 · AR: AR63.20-P-1104MCC

1. Fit A-pillar inner section (1), lower A-pillar reinforcement, inner shell longitudinal member, wheel well locking lug and section of side wall paneling with straightening tools and fix in place using vise grip pliers.
2. Tack weld A-pillar inner section (1) (areas A, B, C and D).
3. A-pillar inner section (1) (areas A, B, C and D).
4. A-pillar inner section (1) (areas E and F).
5. Grind all weld joints down flat if required.
6. Clean all other weld joints with wire brush.
7. Remove lower A-pillar reinforcement, inner shell longitudinal member, wheel well locking lug and section of side wall paneling, if required. TESTING & REPAIR INDEX > REPLACE A-PILLAR INNER SECTION - AR63.20-P-1104MCC

   MODEL 451.3 /4 Shown on model 451.3 Fig 1: Identifying A-Pillar Inner Section Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > REPLACE SIDE LONGITUDINAL MEMBER

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4059 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-0816MCC

REINFORCEMENT - AR63.30-P-0816MCC > MODEL 451.3/ 4 Shown on model 451.3 Fig 1: Identifying Longitudinal Member Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Side Longitudinal Member Reinforcement - Shown On Model 451.3 Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

LONGITUDINAL MEMBER REINFORCEMENT SECTION ON BODY - AR63.30-P-0818-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4067 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-0818MCC

04MCC > 1. Grind mating surfaces in cross-hatched areas according to damage profile down to bare metal. Grind spot weld flanges down to bare metal on both sides. Coat insides of spot weld flanges with zinc dust paint. TESTING & REPAIR INDEX > PREPARE SIDE LONGITUDINAL MEMBER REINFORCEMENT SECTION - AR63.30-P-0818MCC > MODEL 451.3/ 4 Fig 1: Identifying Side Longitudinal Member Reinforcement Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

5. Longitudinal member inner shell (1) on rear entry

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4075 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-1143MCC

(area B). 6. Longitudinal member inner shell (1) on rear entry (1) (area A). 7. Grind weld joints down flat if required. 8. Clean all other weld joints with wire brush. TESTING & REPAIR INDEX > PARTIALLY PREPARE CONNECTING POINTS FOR LONGITUDINAL MEMBER INNER SHELL ON ENTRY ON BODY - AR63.30-P-1143-04MCC > Shown on model 451.3 The step is shown as an example on the rear area of the connecting points on the longitudinal member inner shell on the entry. 1. Sand mating surfaces down to bare metal in the cross-hatched areas. Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2-component adhesive may be adversely affected. Observe pretreatment of bonding surfaces. Grind spot weld flanges down to bare metal on both sides. Coat inside of spot weld flanges, not bonded, with zinc dust paint. TESTING & REPAIR INDEX > PARTIALLY REPLACE LONGITUDINAL MEMBER INNER SHELL ON ENTRANCE - AR63.30-P-1143MCC > MODEL 451.3 /4 Illustrated on model 451.4 Fig 1: Identifying Longitudinal Member Inner Shell Mating Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 451.3

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4084 · Applies to: 450, 451, 452, 454 · AR: AR63.30-P-1164MCC

1. Grind mating surfaces down to bare metal in the cross-hatched areas. Thoroughly clean all bonding surfaces and do not coat with zinc dust paint. Observe pretreatment of bonding surfaces, otherwise the adhesive force of the 2-component adhesive starts to decrease. Grind spot weld flanges down to bare metal on both sides. Coat inside of spot weld flanges not bonded with zinc dust paint. TESTING & REPAIR INDEX > REPLACE LONGITUDINAL MEMBER INNER SHELL ON ENTRY - AR63.30-P-1164MCC > MODEL 451.3 /4 Illustrated on model 451.4 Fig 1: Identifying Longitudinal Member Inner Shell Grinding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

5. Fit center main floor panel reinforcement (1) and fasten with manual temporary fasteners.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4093 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1110MCC

1. Center main floor panel reinforcement (1) (areas H and J).
2. Rivet center main floor panel reinforcement (1) with 6.4 x 14 Polygrip flat/round head rivet (areas A, B, C, D, E, F, G and K). TESTING & REPAIR INDEX > REPLACE CENTER MAIN FLOOR PANEL REINFORCEMENT - AR63.40-P-1110MCC > MODEL 451.3 /4 Illustrated on model 451.3 MODIFICATION NOTES 30.1.09 Information on alternative repair methods added (riveting or plug welding as alternative) Removing

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. AS00.00- Z-0007- 01A Risk of injury caused by scraping or cutting Always wear protective gloves when working on or AS00.00- Fig 1: Identifying Center Main Floor Panel Reinforcement Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on model 451.3

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4103 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1180MCC

1. Fit rear main floor panel (1), front main floor panel, front longitudinal member, longitudinal member console and inner shell longitudinal member with straightening tool and fix in place using vise grip pliers and C-clamps. Observe set-up plans.
2. Tack weld rear main floor panel (1) (areas A, B, C and D).
3. Rear main floor panel (1) (areas C and D).
4. Rear main floor panel (1) (area B).
5. Rear main floor panel (1) (area A). Weld in intervals; minimizes heat distortion.
6. Grind all weld joints down flat if required.
7. Clean all other weld joints with wire brush.
8. Remove front main floor panel, front longitudinal member, longitudinal member console and longitudinal member inner shell, if required. TESTING & REPAIR INDEX > PARTIALLY REPLACE MAIN FLOOR - AR63.40-P-1180MCC > MODEL 451.3 /4 Front main floor Illustrated on model 451.3 Fig 1: Identifying Rear Main Floor Panel Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > PARTIALLY REPLACE CROSSMEMBER BELOW FRONT

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4119 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1189MCC

SEAT - AR63.40-P-1189MCC > MODEL 451.3 /4 Illustrated on model 451.4 Fig 1: Identifying Grinding Surface Of Crossmember Below Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > REPLACE CROSSMEMBER BELOW FRONT SEAT -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4129 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1191MCC

AR63.40-P-1191MCC > MODEL 451.3 /4 Crossmember below front seat top section Illustrated on model 451.4 Fig 1: Locating Grinding Areas Of Crossmember Below Left Front Seat Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Z-1001-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4134 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1191MCD

13A Blind rivet 6.4 x 14 A 003 990 35 97 TESTING & REPAIR INDEX > REPLACE CROSSMEMBER BELOW FRONT SEAT - AR63.40-P-1191MCD > MODEL 451.3 /4 Crossmember below front seat, front bottom section Shown on model 451.3 Removing

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. AS00.00- Z-0007- 01A Risk of injury caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. AS00.00- Z-0017- 01A Fig 1: Identifying Crossmember Below Front Seat With Support Stand, Wooden Wedge And Fixing Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Sealant

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4150 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1193MCC

BR00.45- Z-1003- 01A 10 Supplement standard underbody protection with permanent underbody sealant Underfloor protection BR00.45- Z-1001- 05A 11 Paint area repaired and adjacent surfaces

Notes on paintwork repairs

AH98.00- P-9408- 02MCC 12 Apply additional cavity preservation

AR97.20- P-1500FF

Teroson protective wax *BR00.45- Z-1008- 05A 13 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45- Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45- Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45- Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbHArabellastrasse 1781925 MunchenGermanyTel. +49 899268-0Fax +49 899101978www.Loctite.de TESTING & REPAIR INDEX > REPLACE CROSSMEMBER MOUNTING CONSOLE ON BOTTOM FRONT REAR FLOOR ASSEMBLY - AR63.40-P-1193MCC > MODEL 451.3 /4

1. Grind mating surfaces down to bare metal in the crosshatched areas.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4161 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1196MCC

Thoroughly clean all bonding surfaces and do not coat with zinc dust paint, otherwise adhesion of the 2-component adhesive may be adversely affected. Observe pretreatment of bonding surfaces. Observe manufacturer's specifications of 2- component adhesive for drying and processing time. TESTING & REPAIR INDEX > REPLACE BATTERY BOX - AR63.40-P-1196MCC > MODEL 451.3 /4 Illustrated on model 451.3 MODIFICATION NOTES 30.1.09 Information on alternative repair methods are worked in (riveting or plug welding as alternative and structural bonding) Removing

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non- deburred vehicle parts. Deburr repair panels. AS00.00- Z-0017- 01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units

AH91.00- P-0002- 01SM Fig 1: Identifying Battery Recess Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > REPLACE CONSOLE FOR ACCELERATOR PEDAL -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4164 · Applies to: 450, 451, 452, 454 · AR: AR63.40-P-1300MCC

13A TESTING & REPAIR INDEX > REPLACE CONSOLE FOR ACCELERATOR PEDAL - AR63.40-P-1300MCC > MODEL 451.3/ 4 Removing

Risk of death caused by high voltage used for electric welding. Risk of explosion caused by welding in the area of highly inflammable materials. Risk of injury caused by welding spatter and UV light while welding. Risk of poisoning caused by inhaling welding fumes. Use insulating mats. Wear protective clothing, safety glasses and protective mask. Remove highly inflammable materials from the hazard area. Use air extractor system. AS00.00- Z-0007- 01A Risk of injury caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non-deburred vehicle parts. Deburr repair panels. AS00.00- Z-0017- 01A Measures for preventing damage to vehicles or components when performing electric welding work

AH00.00- P-0005- 01FF Notes on performing repair, body work and welding on vehicles with airbags and ETR units

AH91.00- P-0002- 01SM Fig 1: Identifying Accelerator Pedal Console With Spot Welding Areas Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

GENERAL INFORMATION > NOTES ON SOFT TOPS - AH77.30-P-0001-01MCO >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4168 · Applies to: 450, 451, 452, 454 · AR: AR77.00-Z-9451CA, AR77.33-P-1010MCO, AR77.39-P-1010MCO

Model 451.4 The use of Daimler AG approved materials and tools is absolutely necessary for proper repair because the material characteristics of the recommended products influence the work results and working time. Repair work at soft top should only be carried out by trained skilled personnel. The drive cable, the soft top sliding blocks and the side strut bearings on the A-pillar must only be changed in pairs. To prevent torsion, i.e. twisting of body, which leads to adjustment faults during repair work on soft top and its detachable body components, the vehicle must be positioned horizontally on the ground. Grease side strut: During maintenance work on vehicle the side struts must be cleaned and greased. Use only cleaning felts and greases approved by Daimler AG. On vehicles which are exposed to high dust influence, it can be necessary to clean and grease the side struts in between the maintenance operations. Roof cassette locks: The roof cassette locks can also be cleaned and greased during maintenance work. Grease roof cassette locks only at specified points using types of grease approved by Daimler AG only. Ensure that the springs on the microswitch are not damaged or bent. Drive cable for soft top: Do not grease or oil drive cable on soft top. The drive cables are moistened with a special oil at the factory. Soft top: After replacing the soft top or rear soft top, increased closing forces can occur on the soft top and retaining clip. The vehicle must stand with closed soft top for at least 12 h at room temperature. TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: SLIDING ROOF, SOFT TOP, TOP ATTACHMENTS - AR77.00-Z-9451CA > MODEL 451 Remove, install side support seal MODEL 451.4 AR77.33-P-1010MCO Remove, install rear soft top drive wiring harness MODEL 451.4 Left wiring harness AR77.39-P-1010MCO

Remove, install rear soft top drive wiring

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4169 · Applies to: 450, 451, 452, 454 · AR: AR77.39-P-1010MCU, AR77.39-P-1010MCV, AR77.35-P-1000MCO, AR77.35-P-1001MCO, AR77.30-P-1152MCO (+5 more)

harness MODEL 451.4 Left wiring harness AR77.39-P-1010MCU Remove, install rear soft top drive wiring harness MODEL 451.4 Right wiring harness AR77.39-P-1010MCV Remove, install rear soft top window MODEL 451.4 AR77.35-P-1000MCO Remove, install rear soft top window seal MODEL 451.4 AR77.35-P-1001MCO Remove/install arresting bolt on rear soft top retaining clip MODEL 451.4 AR77.30-P-1152MCO Remove/install B-pillar catch MODEL 451.4 AR77.33-P-2100MCO Remove/install B-pillar catch MODEL 451.4 AR77.33-P-2100MCU Remove/install centering aid MODEL 451.4 AR77.33-P-2020MCO Remove/install folding top MODEL 451.4 AR77.30-P-1100MCO Remove/install folding top MODEL 451.4 AR77.30-P-1100MCU Remove/install folding top motor MODEL 451.4 AR77.39-P-4000MCO Remove/install folding top motor MODEL 451.4 AR77.39-P-4000MCU Remove/install guide tube for drive cable MODEL 451.4 AR77.30-P-1112MCO Remove/install guide tube for drive cable MODEL 451.4 AR77.30-P-1112MCU Remove/install headliner MODEL 451.4 AR77.31-P-1005MCO Remove/install power soft top switch MODEL 451.4 AR77.39-P-1000MCC Remove/install power soft top switch MODEL 451.4 AR77.39-P-1000MCU Remove/install rear soft top MODEL 451.4 AR77.30-P-1150MCO Remove/install rear soft top MODEL 451.4 AR77.30-P-1150MCU Remove/install rear soft top drive wiring harness MODEL 451.4 Right wiring harness AR77.39-P-1010MCP Remove/install rear soft top motor MODEL 451.4 AR77.39-P-4010MCO Remove/install rear soft top motor MODEL 451.4 AR77.39-P-4010MCU Remove/install rear soft top retaining clip MODEL 451.4 AR77.30-P-1151MCO Remove/install roller sun blind on panoramic sunroof MODEL 451.3 with CODE (E22) Glass roof (FFO) AR77.21-P-0205MCC Remove/install roller sun blind on panoramic sunroof MODEL 451.3 with CODE (E22) Glass roof (FFO) AR77.21-P-0205MCU Remove/install roof cassette spoiler MODEL 451.4 AR77.33-P-2030MCO Remove/install roof cassette spoiler MODEL 451.4 AR77.33-P-2030MCU Remove/install roof peak seal MODEL 451.4 AR77.30-P-3352MCC

Remove/install roof peak seal

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4170 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-3352MCU, AR77.33-P-2010MCO, AR77.33-P-2010MCU, AR77.33-P-1008MCO, AR77.30-P-3350MCC (+5 more)

MODEL 451.4 AR77.30-P-3352MCU Remove/install roof peak sliding plate MODEL 451.4 AR77.33-P-2010MCO Remove/install roof peak sliding plate MODEL 451.4 AR77.33-P-2010MCU Remove/install side support bearing MODEL 451.4 AR77.33-P-1008MCO Remove/install side wall seal MODEL 451.4 AR77.30-P-3350MCC Remove/install soft top bow on soft top MODEL 451.4 AR77.30-P-1200MCO Remove/install soft top bow on soft top MODEL 451.4 AR77.30-P-1200MCU Remove/install soft top bow slider MODEL 451.4 AR77.33-P-2000MCO Remove/install soft top bow slider MODEL 451.4 AR77.33-P-2000MCU Remove/install soft top drive cable MODEL 451.4 AR77.30-P-1104MCO Remove/install soft top drive cable MODEL 451.4 AR77.30-P-1104MCU Remove/install soft top main bearing MODEL 451.4 Left main bearing AR77.30-P-1108MCO Remove/install soft top main bearing MODEL 451.4 Right main bearing AR77.30-P-1108MCP Remove/install soft top main bearing MODEL 451.4 Left main bearing AR77.30-P-1108MCU Remove/install soft top main bearing MODEL 451.4 Right main bearing AR77.30-P-1108MCV Remove/install soft top roof cassette MODEL 451.4 AR77.30-P-1103MCO Remove/install soft top roof cassette MODEL 451.4 AR77.30-P-1103MCU Remove/install soft top roof cassette MODEL 451.4 AR77.30-P-1109MCO Remove/install soft top roof cassette MODEL 451.4 AR77.30-P-1109MCU Remove/install soft top roof cassette plug MODEL 451.4 AR77.30-P-1110MCO Remove/install soft top roof cassette plug MODEL 451.4 AR77.30-P-1110MCU Remove/install wind deflector MODEL 451.4 AR77.25-P-1000MCO Tension folding top MODEL 451.4 AR77.30-P-1102MCO Tension folding top MODEL 451.4 AR77.30-P-1102MCU TESTING & REPAIR > REMOVE/INSTALL WIND DEFLECTOR - AR77.25-P-1000MCO > MODEL 451.4 Dimensions:

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4171 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-1100MCU

1 Mark position of wind deflector (1) with suitable adhesive tape.

2 Heat wind deflector (1) with hot air gun and remove. Hot air blower http://gotis.aftersales.mercedes- benz.com 3 Remove glue residues with suitable cleaning agent.

Install

4 Measure position of wind deflector (1) and mark according to dimensions (A and B) with suitable adhesive tape.

5 Clean gluing surfaces on roof paneling using suitable cleaning agent. The bonding surface must be dry, free of dust and grease; otherwise adhesive force of glue starts to decrease. 6 Remove protective foil from wind deflector (1), position wind deflector (1) and glue on. Do not touch bonding surface or remove and reglue wind deflector (1) after gluing on; otherwise adhesive force of glue starts to decrease. 7 Remove tape

TESTING & REPAIR > REMOVE/INSTALL FOLDING TOP - AR77.30-P-1100MCU > MODEL 451.4 Fig 1: Identifying Wind Deflector Dimensions Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Shown on right side of vehicle

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4173 · Applies to: 450, 451, 452, 454 · AR: AR77.33-P-2030MCU

Removing

Notes on soft tops

AH77.30-P-0001- 01MCO 1 Remove spoiler on roof cassette

AR77.33-P-2030MCU Fig 3: Identifying Folding Top Components (3 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Folding Top Components (4 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove inside roof lining

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4174 · Applies to: 450, 451, 452, 454 · AR: AR77.31-P-1005MCO, AR77.30-P-1104MCU

2 Remove inside roof lining

AR77.31-P-1005MCO 3 Remove seal (2) from rear soft top (4) and fold toward front.

4 Unscrew bolts (6) and fold soft top (1) toward front.

5 Mark length of tensioning straps (10) on roof cassette.

6 Unscrew bolts (9), remove clamping plates (8) and pull tensioning straps (10) out of clamping plates (8) and roof cassette.

7 Remove side supports (7).

8 Actuate both side support recognition sensors (arrow), simultaneously actuate power soft top switch in closing direction and extend soft top (1) until sliding rails (11) are exposed. Aid of 2 helpers required.

9 Unhook drive cable (12) from sliding rails (11).

10 Pull soft top (1) with sliding rails (14 and 15) out of guides (13) on roof cassette. Aid of helper required.

11 Remove soft top (1) and put down. Aid of helper required.

Install

12 Connect STAR DIAGNOSIS, select soft top control, select power soft top switch and erase coding.

Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000- 04MCC 13 Measure distance (A) between drive cable (12) and guides (13). The distance (A) should be equal on the left and right; if the difference is > 1 mm, adjust drive cables (12) so that they run synchronous to one another: ↓

Remove/install soft top drive cable AR77.30-P-1104MCU

Attach double-sided adhesive

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4176 · Applies to: 450, 451, 452, 454 · AR: AR77.31-P-1005MCO, AR77.33-P-2030MCU, AR77.30-P-1102MCU

25 Attach double-sided adhesive tape in crosshatched areas of seal (2), remove protective foil and glue seal (2) to soft top (4) without creases. Remove loose pieces of old adhesive tape; it is not necessary to remove areas with good adhesion. *BR00.45-Z-1022-02B

Use double-sided adhesive tape with a width of 19 or 25 cm.

26 Install headliner

AR77.31-P-1005MCO 27 Install roof cassette spoiler Replace sealing strip (3) before installing roof cassette spoiler. AR77.33-P-2030MCU 28 Restore coding of power soft top switch, read out fault memory and connect STAR DIAGNOSIS

Connect STAR DIAGNOSIS and read out fault memory

AD00.00-P-2000- 04MCC 29 Perform function test and check soft top (1) for creases.

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1022- 02B Teroson double sided adhesive tapeFor bonding trim strips and emblem (UV and weather-resistant, black) www.henkel.com TESTING & REPAIR > TENSION FOLDING TOP - AR77.30-P-1102MCU > MODEL 451.4 Fig 1: Identifying Folding Top Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4177 · Applies to: 450, 451, 452, 454 · AR: AR77.33-P-2030MCU

Notes on soft tops

AH77.30-P-0001- 01MCO 1 Remove spoiler on roof cassette

AR77.33-P-2030MCU 2 Remove seal (2) from rear soft top (4) and fold toward front.

3 Unscrew bolts (6) and fold soft top (1) toward front.

4 Loosen bolts (9)

Install

5 Tension tensioning strap (10) on left and right, align clamping plate (8) and tighten bolt (9). The side edges of the soft top (1) should be flush with the contour of the side supports (7).

6 Open soft top (1) and close again.

7 Fold back soft top (1) and check tension of tensioning straps (10). The side edges of the soft top (1) should be flush with the contour of the side supports (7).

8 Open soft top (1) approx. 10

Fig 2: Identifying Folding Top Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Align tension cable retaining

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4178 · Applies to: 450, 451, 452, 454 · AR: AR77.33-P-2030MCU

cm 9 Align tension cable retaining plates (5) and tighten bolts (6). Ensure that creases are not present in the soft top covering (1).

10 Attach double-sided adhesive tape in crosshatched areas of seal (2), remove protective foil and glue seal (2) to soft top (4) without creases. Remove loose pieces of old adhesive tape; it is not necessary to remove areas with good adhesion. *BR00.45-Z-1022-02B

Use double-sided adhesive tape with a width of 19 or 25 cm.

11 Install roof cassette spoiler Replace sealing strip (3) before installing roof cassette spoiler. AR77.33-P-2030MCU 12 Perform a function test

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1022- 02B Teroson double sided adhesive tapeFor bonding trim strips and emblem (UV and weather-resistant, black) www.henkel.com TESTING & REPAIR > REMOVE/INSTALL SOFT TOP ROOF CASSETTE - AR77.30-P- 1103MCU > MODEL 451.4 Fig 1: Identifying Soft Top Roof Cassette Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

of roof cassette (1).

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4180 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-1104MCU

4 of roof cassette (1). wiring harness (4) is routed without chafing and tension.

5 Pull retaining tap on rear soft top (2) out of roof cassette (1).

6 Unscrew bolts (5) on left and right of roof cassette (1) and remove roof cassette (1)

7 Install in the reverse order

8 Perform a function test

TESTING & REPAIR > REMOVE/INSTALL SOFT TOP DRIVE CABLE - AR77.30-P-1104MCU

Fig 1: Identifying Soft Top Drive Cable Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Soft Top Drive Cable Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4181 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-1100MCU

Notes on soft tops

AH77.30-P-0001- 01MCO 1 Remove soft top (1).

AR77.30-P-1100MCU 2 Remove cover (2)

3 Unscrew nuts (3) and remove housing cover (4).

4 Lift guide tube (5) on drive cable (6).

5 Pull drive cable (6) out of guides (9).

Install

6 Insert drive cable (6) into guides (9) until the distance (A) between ends of drive cable (6) and guides (9) is same on left and right.

7 Insert guide tubes (5) and drive cable (6) into housing (8).

8 Position pinion (7) and install housing cover (4).

9 Check distance (A) between drive cable (6) and guides (9). The distance (A) between the ends of the drive cable (6) and the guides (9) should have the same on left and right, if applicable remove housing cover (4), lift guide tube (5) and reposition drive cable (6); perform operation steps 7 to 9 again.

10 Tighten nuts (3)

11 Install cover (2)

12 Install soft top (1).

AR77.30-P-1100MCU 13 Perform a function test

TESTING & REPAIR > REMOVE/INSTALL SOFT TOP MAIN BEARING - AR77.30-P- 1108MCU > MODEL 451.4 Left main bearing

Remove folding soft top

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4187 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-1100MCU

1 Remove folding soft top

AR77.30-P-1100MCU 2 Pull roof cassette seal (1) on left and right, from rear toward front, out of guide (3) Detach glued front area on roof cassette seal (1) if necessary with suitable tool.

3 Remove sealant and glue residues in front area of guide (3).

4 Remove old sealant from paneling (4).

Install

5 Insert roof cassette seal (1) from front toward rear into guide (3). Insert roof cassette seal (1) so that it is flush with the guide (3).The sealing lip on the roof cassette seal (1) should make contact with rear soft top covering (2) over the entire length.

6 Lift roof cassette seal (1) at front (arrow) and additionally glue to guide (3).

BR00.45-Z-1095-02A 7 Lift roof cassette seal (1) at rear and attach sealing strip (5) to paneling (4). Cut sealing strip (5) so that it is approx. 50 mm long. BR00.45-Z-1091-01A 8 Remove protective foil from sealing strip (5) and press on roof cassette seal (1). The sealing lip on the roof cassette seal (1) should make contact with the rear soft top covering (2) over the entire length.

9 Install folding soft top

AR77.30-P-1100MCU 10 Perform a function test

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1091- 01A Sealing strip 119.32 Terostat 20 x2 mm www.henkel.com BR00.45-Z-1095- 02A Ultra-fast super glue 20g. Sabesto Adolf Wurth GmbH&Co. KGReinhold-Wurth-Str. 12- 1774653 Kunzelsau- GaisbachGermanyTel. +49 7940 15-0Fax +49 7940 15- 1000www.wuerth.deArt. no.: 089309

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4193 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-1104MCU, AR77.30-P-1109MCU

Notes on soft tops

AH77.30-P-0001- 01MCO 1 Remove soft top drive cable

AR77.30-P-1104MCU 2 Remove roof cassette seals (4).

AR77.30-P-1109MCU 3 Remove bolts (5)

4 Unscrew bolts (3, 6)

5 Unhook rear soft top (2) from roof cassette (9) and fold toward rear.

6 Unscrew bolts (10, 11)

7 Remove cable ties (8)

8 Remove guide tube (1)

Install

9 Insert guide tube (1) and tighten bolts (10, 11) Observe assignment of guide tube (1).

10 Provide cable tie (8)

11 Hook rear soft top (2) into roof cassette (9) on left and right.

12 Tighten screws (3, 6).

Fig 2: Identifying Guide Tube For Drive Cable Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Tighten screws (5)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4194 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-1109MCU, AR77.30-P-1104MCU, AR77.30-P-1150MCU

13 Tighten screws (5)

14 Install roof cassette seals (4).

AR77.30-P-1109MCU 15 Install soft top drive cable

AR77.30-P-1104MCU 16 Perform a function test

TESTING & REPAIR > REMOVE/INSTALL REAR SOFT TOP - AR77.30-P-1150MCU > MODEL 451.4 Fig 1: Identifying Rear Soft Top Components (1 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Rear Soft Top Components (2 Of 4) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Notes for soft tops

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4201 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-1152MCO

AH77.30-P- 0001- 01MCO 1 Remove panelings from rear pillar.

AR68.30-P- 4505MCO 2 Fold up retaining clip (4), unscrew bolts (3) and pull seal (2) out of retaining clip (4).

3 Unhook rear soft top (1) from retaining clip (4), from outside toward inside.

4 Remove clips (9) remaining in retaining clip (4) using suitable tool. Installation: Insert clips (9) into hooking lug on rear soft top (1).

5 Unscrew bolts (5) and remove retaining clip (4).

6 Remove notch lever (8). When replacing retaining clip (4).

7 Remove arresting bolt (6). When replacing retaining clip (4). AR77.30-P- 1152MCO 8 Install in the reverse order

9 Adjust retaining clip (4) on rear soft top (1).

AR77.30-P- 1151- 01MCO 10 Perform a function test

TESTING & REPAIR > REMOVE/INSTALL ARRESTING BOLT ON REAR SOFT TOP RETAINING CLIP - AR77.30-P-1152MCO > MODEL 451.4

Fold retaining clip (2) upward, remove lock washer (5)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4203 · Applies to: 450, 451, 452, 454 · AR: AR77.33-P-2000MCU, AR77.30-P-3350MCC

3 Fold retaining clip (2) upward, remove lock washer (5) and pull out arresting bolt (6). Aid of helper required.

4 Install in the reverse order

5 Adjust retaining clip (2) on rear soft top (1).

AR77.30-P- 1151-01MCO 6 Perform a function test

TESTING & REPAIR > REMOVE/INSTALL SOFT TOP BOW ON SOFT TOP - AR77.30-P- 1200MCU > MODEL 451.4 Shown on left side of vehicle

Remove/install

Notes on soft tops

AH77.30-P-0001- 01MCO 1 Remove sliding rail (5, 6) and end pieces (4).

AR77.33-P-2000MCU 2 Slide soft top bow (1) out of retaining tabs (2) on soft top (3). The soft top bows (1) are equal.

3 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL SIDE WALL SEAL - AR77.30-P-3350MCC > MODEL 451.4 Fig 1: Identifying Soft Top Bow On Soft Top Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL ROOF PEAK SEAL - AR77.30-P-3352MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4205 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-3352MCU, AR68.30-P-4450MCV

MODEL 451.4 Removing

Notes on soft tops

AH77.30-P-0001- 01MCO 1 Open soft top

2 Remove side supports.

3 Remove front roof frame paneling

AR68.30-P-4450MCV 4 Remove roof peak seal (1) starting at marked area (arrow)

5 Remove sealing profile (2)

Install

6 Position sealing profile (2) on both sides on roof frame (3) and A-pillar (4)

*BR00.45-Z-1021-01A 7 Press roof peak seal (1) on A-pillar (4) onto body flange starting at top left and top right and drive down with plastic mallet, if necessary Mount roof peak seal (1) as close as possible in the radii as otherwise leaks may occur. The roof peak seal (1) and side wall seal at the left or right must make contact in the center of the door sill without gap (arrow).

8 Check seating of roof peak seal (1) The sealing lip of the roof peak seal (1) must

Fig 1: Identifying Roof Peak Seal Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

contact the body without

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4206 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4450MCV, AR77.31-P-1005MCO

any contortions. 9 Install side supports

10 Check installation position of roof peak seal (1) The A-pillar (4) must line up flush with the side support molded part.

11 Install front roof frame paneling

AR68.30-P-4450MCV 12 Close soft top

REPAIR MATERIALS Number Designation Order number BR00.45-Z-1021-01A Sealing profile Terostat 2710-6 A 001 987 73 46 TESTING & REPAIR > REMOVE/INSTALL HEADLINER - AR77.31-P-1005MCO > MODEL 451.4 Fig 1: Identifying Headliner Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

headliner (1) on soft top seal;

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4209 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4450MCO

center mounting strips (6), if necessary. TESTING & REPAIR > REMOVE/INSTALL SIDE SUPPORT BEARING - AR77.33-P- 1008MCO > MODEL 451.4 Removing

Notes for soft tops

AH77.30-P-0001- 01MCO 1 Completely open soft top

2 Remove left and right side support (3).

3 Mark position of side support bearing (1) with pen.

4 Remove front roof frame paneling

AR68.30-P-4450MCO Fig 1: Identifying Side Strut Bearing And Bolt Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Side Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Unscrew bolts (2) and

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4210 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4450MCO, AR77.33-P-1010MCO

5 Unscrew bolts (2) and remove side support bearing (1). Turn side support bearing (1) 90° to remove it from A-pillar.

Install

6 Insert side support bearing (1) into A-pillar according to marking and tighten bolts (2).

7 Install left and right side support (3) and check course of body contours. There should not be any offset in the course of the body contour.If an offset should be present, remove left or right side support (3), loosen bolts (2) and readjust position of side support bearing (1), tighten bolts (2). Check course of body contour again.

8 Remove left and right side support (3).

9 Remove markings.

10 Install front roof frame paneling

AR68.30-P-4450MCO 11 Install left and right side support (3).

12 Check soft top for proper function, close soft top.

TESTING & REPAIR > REMOVE, INSTAL SIDE SUPPORT SEAL - AR77.33-P-1010MCO > MODEL 451.4

01MCO

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4212 · Applies to: 450, 451, 452, 454 · AR: AR77.33-P-2000MCU

1 Completely open soft top

2 Remove side support (1)

3 Remove side support seal (2) from side support (1) Lay side support (1) down on suitable base to prevent damage when removing side support seal (2).

Before removal, observe route and position of side support seal (2).

Install

4 Moisten side support seal (2) at connection points with lubricant.

5 Insert guide (1.1) of side support (1) into shackle (2.1) on side support seal (2) Lay side support (1) down on suitable base to prevent damage when installing side support seal (2).

Ensure that guide pin (1.2) is seated correctly.

6 Insert shackle (2.3) into guide pin (1.3) Ensure that shackle (2.3) is seated correctly.

7 Position side support seal (2) over entire length (arrows) of side support (1) Ensure that recess (2.2) is seated correctly. Ensure that side support seal (2) is seated correctly in guide rail (1.4) and guide rail cutout (1.5).

8 Install side support (1)

9 Close soft top

TESTING & REPAIR > REMOVE/INSTALL SOFT TOP BOW SLIDER - AR77.33-P-2000MCU

MODEL 451.4 Shown on left side of vehicle

Shown on left side of vehicle

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4213 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-1100MCU

Removing

Notes on soft tops

AH77.30-P-0001- 01MCO 1 Remove soft top (1).

AR77.30-P-1100MCU 2 Pull tensioning straps (2) out of rear sliding rails (4), center sliding rails (5) and end pieces (3).

3 Pull rear sliding rails (4) with bow springs (6) out of soft top bow and

Fig 1: Identifying Soft Top Bow Slider Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Soft Top Bow Slider Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

remove pockets in soft top (1).

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4214 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-1100MCU

4 Pull center sliding rails (5) with bow springs (7) out of soft top bow and remove pockets in soft top (1).

5 Pull end pieces (3) out of soft top bows and remove from pockets in soft top (1).

6 Loosen bow springs (8) from roof peak (arrow) using suitable tool.

Install

7 Match new bow springs (6, 7) to center sliders (5) or rear sliders (4) The bow springs (6, 7, 8) are different.

8 Insert new bow springs (8) into roof peak.

9 Insert new bow springs (7) into new center sliding rails (5), hook into pockets in soft top (1) and insert into soft top bow.

10 Insert new bow springs (6) into new rear sliding rails (4), hook into pockets in soft top (1) and insert into soft top bow.

11 Install end pieces (3) on bow springs (6, 7, 8), hook into pockets in soft top (1) and insert into soft top bow.

12 Pull tensioning straps (2) into rear sliding rails (4), center sliding rails (5) and end pieces (3). Ensure that tensioning straps (2) are not twisted when pulled in.

13 Install soft top (1).

AR77.30-P-1100MCU TESTING & REPAIR > REMOVE/INSTALL ROOF PEAK SLIDING PLATE - AR77.33-P- 2010MCU > MODEL 451.4

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4215 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-1100MCU, AR77.33-P-2020MCO

Notes on soft tops

AH77.30-P-0001- 01MCO 1 Remove soft top (3).

AR77.30-P-1100MCU 2 Pull tensioning straps (2) out of sliding rails and end pieces Installation: Ensure that tensioning straps (2) are not twisted when pulled in.

3 Remove sliding plates (1) with push springs (4) from roof edge.

4 Remove sockets (5) from roof edge.

5 Install in the reverse order

TESTING & REPAIR > REMOVE/INSTALL CENTERING AID - AR77.33-P-2020MCO > MODEL 451.4 Fig 1: Identifying Roof Peak Sliding Plate Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Mark position of B-pillar catch

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4219 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4700MCV

3 Mark position of B-pillar catch (3) using suitable pen

4 Unscrew bolts (2) and remove B-pillar lock (3).

Install

5 Position B-pillar catch (3) on B-pillar according to markings and tighten bolts (2)

6 Install side support and check correct arresting of side support and contact pressure of seal, loosen bolts (2) if applicable and readjust position of B-pillar catch (3). Then tighten bolts (2) The side support should arrest securely in second latch.

7 Close soft top and check transition between guide (4) in side support and guide (5) in roof cassette lock The dimension (A) should be smaller than 1 mm, the guide (4) in the side support and the guide (5) in the roof cassette lock should be at the same height.If necessary, open soft top, loosen bolts (2) and readjust position of B- pillar catch (3). Then tighten bolts (2). Then recheck transition between guide (4) in side support and guide (5) in roof cassette lock.

8 Remove side support

9 Remove markings.

10 Install paneling (1) on B-pillar

AR68.30-P-4700MCV 11 Check soft top for proper function, close soft top.

TESTING & REPAIR > REMOVE, INSTALL REAR SOFT TOP WINDOW - AR77.35-P- 1000MCO > MODEL 451.4 Shown on left side of vehicle

Remove/install

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4226 · Applies to: 450, 451, 452, 454 · AR: AR77.39-P-1010MCU

1 Unclip selector lever position indicator (2) from selector lever cover 2 Lift selector lever position indicator (2) until electrical connector (1) is accessible 3 Disconnect electrical connector (1) 4 Unclip soft top actuation switch (S84) from selector lever position indicator (2) and remove 5 Install in the reverse order 6 Check power soft top switch (S84) for proper function TESTING & REPAIR > REMOVE, INSTALL REAR SOFT TOP DRIVE WIRING HARNESS - AR77.39-P-1010MCU > MODEL 451.4 Left wiring harness Fig 1: Identifying Left Rear Soft Top Drive Wiring Harness Components (1 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

01MCO

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4228 · Applies to: 450, 451, 452, 454 · AR: AR77.30-P-1110MCU, AR77.39-P-4000MCU, AR77.39-P-4010MCU

1 Remove roof cassette locks (1).

AR77.30-P-1110MCU 2 Remove electric soft top motor (M12/6)

AR77.39-P-4000MCU 3 Guide electric wiring harness (3) out of roof cassette (2).

4 Remove electric wiring harness (3) on roof cassette (2) and steering wheel (4)

5 Remove clamp (5) from main bearing (6).

6 Remove left soft top drive (M12/7)

AR77.39-P-4010MCU 7 Disconnect electrical connector (9) and remove electric wiring harness (3) from steering wheel (10).

8 Guide soft top connector (X23/7) out of B-pillar, disconnect and open cable tie (11).

9 Remove retainer (7) from retaining bolts on left rear soft top microswitch (S84/41) using suitable tool and remove left rear soft top microswitch (S84/41) Do not damage retaining bolts, otherwise it is necessary to replace the electric wiring harness (3).

10 Remove retaining clip (8) from main bearing (6) and remove electric wiring harness (3) Installation: Route electric wiring harness (3) to prevent it from being damaged by chafing and pinching, otherwise electric wiring harness (3) must be replaced.

11 Install in the reverse order

12 Perform a function test

TESTING & REPAIR > REMOVE, INSTALL REAR SOFT TOP DRIVE WIRING HARNESS -

AR77.39-P-1010MCV >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4229 · Applies to: 450, 451, 452, 454 · AR: AR77.39-P-1010MCV, AR77.39-P-4010MCU

MODEL 451.4 Right wiring harness

Remove/install

Notes on soft tops

AH77.30-P-0001- 01MCO 1 Remove right soft top drive (M12/8)

AR77.39-P-4010MCU 2 Guide soft top connector (X23/7) out of B-pillar, disconnect and open cable tie (5).

3 Disconnect electrical connector (1) and remove electric wiring harness (4) from steering wheel (2).

4 Remove retainer (6) from retaining bolts on right rear soft top microswitch (S84/39) using suitable Do not damage retaining bolts, otherwise it is necessary to replace

Fig 1: Identifying Rear Soft Top Drive Wiring Harness Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

tool and remove right

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4230 · Applies to: 450, 451, 452, 454 · AR: AR77.39-P-4000MCU, AR77.30-P-1112MCU

rear soft top microswitch (S84/39) the electric wiring harness (4). 5 Remove retaining clip (7) from main bearing (3) and remove electric wiring harness (4) Installation: Route electric wiring harness (4) to prevent it from being damaged by chafing and pinching, otherwise electric wiring harness (4) must be replaced.

6 Install in the reverse order

7 Perform a function test

TESTING & REPAIR > REMOVE/INSTALL FOLDING TOP MOTOR - AR77.39-P-4000MCU > MODEL 451.4

Remove/install

Notes on soft tops

AH77.30-P-0001- 01MCO 1 Remove guide tube (1) from drive cable.

AR77.30-P-1112MCU 2 Lift electric power soft Installation:

Fig 1: Identifying Folding Top Motor Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

top motor (M12/6) out of

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4231 · Applies to: 450, 451, 452, 454 · AR: AR77.39-P-4010MCU

roof cassette (2) Observe routing of electrical cables. 3 Disconnect electrical connector (3)

4 Install in the reverse order

5 Perform a function test

TESTING & REPAIR > REMOVE/INSTALL REAR SOFT TOP MOTOR - AR77.39-P-4010MCU

MODEL 451.4 Fig 1: Identifying Rear Soft Top Motor Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4232 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4700MCV, AR68.30-P-4800MCU

Notes on soft tops

AH77.30-P-0001- 01MCO 1 Unlock lock lever and fold rear soft top upward. Ensure that rear soft top is engaged correctly on both sides.

2 Remove retainer (1) from drive axle (4).

3 Remove left and right paneling (2) from B-pillar

AR68.30-P-4700MCV 4 Remove side paneling in trunk

AR68.30-P-4800MCU 5 Close rear soft top

6 Open soft top until lock on B- pillar is opened.

7 Relieve load from drive axle (4) by lifting roof cassette and remove drive axle (4). Aid of helper required.

8 Unscrew bolt (5) and remove left soft top drive (M12/7) or right soft top drive (M12/8) Counterhold nut of bolt (5).

9 Disconnect electrical connector (6) on left soft top drive (M12/7) or right soft top drive (M12/8) Carefully open arrest on connector (6), danger of breakage.

Install

Fig 2: Identifying Rear Soft Top Motor Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Connect electrical connector (6)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4233 · Applies to: 450, 451, 452, 454 · AR: AR68.30-P-4800MCU, AR68.30-P-4700MCV, AS77.00-Z-9999ZZ, BA77.00-Z-9999CZ

10 Connect electrical connector (6) to left soft top drive (M12/7) or right soft top drive (M12/8)

11 Insert left soft top drive (M12/7) or right soft top drive (M12/8) into main bearing, tighten bolt (5) and nut.

12 Lift roof cassette until left and right side of soft top are in the same position, then install drive axle (4). Aid of helper required.

13 Close soft top

14 Unlock lock lever and fold rear soft top upward. Ensure that rear soft top is engaged correctly on both sides.

15 Install retainer (1) on drive axle (4)

16 Install paneling on side in trunk

AR68.30-P-4800MCU 17 Install paneling (2) on B-pillar

AR68.30-P-4700MCV 18 Close rear soft top

19 Check soft top for proper function

SAFETY PRECAUTIONS > SAFETY INFORMATION: SLIDING ROOF, SOFT TOP, TOP ATTACHMENTS - AS77.00-Z-9999ZZ > MODEL all Risk of injury caused by body parts being trapped or crushed when working on partially open Vario roof (stop mode) or in its closing area as a result of the Vario roof suddenly collapsing MODEL 170, 171.4, 230 AS77.50-Z-0001- 01A TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: SLIDING ROOF, SOFT TOP, TOP ATTACHMENTS - BA77.00-Z-9999CZ > MODEL all Convertible top MODEL 452.3 /4 BA77.30-P-1000- 01C Convertible top MODEL 450.4 (except 450.418) BA77.30-P-1000- 01D Electric sliding roof MODEL 450.3 with CODE (V29) Electric glass sliding roof (FFO) BA77.20-P-1000-01I Electric sliding MODEL 454.0 with CODE (V29) Electric glass sliding BA77.20-P-1000-

roof

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4234 · Applies to: 450, 451, 452, 454 · AR: BE77.00-Z-9999CZ

roof (FFO) 01D Hardtop MODEL 452.3 /4 BA77.30-P-1000- 02A Panoramic roof MODEL 451.3 BA77.21-P-1000- 01D Soft top mechanics MODEL 450.4 BA77.33-P-1000- 01D TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: SLIDING ROOF, SOFT TOP, TOP ATTACHMENTS - BE77.00-Z-9999CZ > MODEL all Vario roof and soft top mechanism MODEL 451.4 BE77.33-P-1000-01B TEST & ADJUSTMENT VALUES > ELECTRIC WIRING DIAGRAM FOR ELECTRIC SOFT TOP - PE77.39-P-2200-97MCU > Code: Designation: Position: E21 Center high-mounted stop lamp 14L K66/1 Open soft top relay 6L K66/2 Close soft top relay 10L M12/6 Electric soft top motor 16L M12/7 Left soft top drive 18L M12/8 Right soft top drive 33L N10/10 SAM control unit 39A N10/10 SAM control unit 20A N10/10 SAM control unit 12A N10/10 SAM control unit 4A N10/10 SAM control unit 28A N10/10f15 Fuse 15 3A N10/10f20 Fuse 20 37A N10/10f28 Fuse 28 34A R1 Heated rear window 35L S84 Power soft top switch 38L S84/37 Soft top microswitch 24L S84/38 Left roof cassette microswitch 23L S84/39 Right rear soft top microswitch 31L S84/40 Right roof cassette microswitch 21L

TEST & ADJUSTMENT VALUES > VARIO ROOF AND SOFT TOP MECHANISM - BE77.33-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4238 · Applies to: 450, 451, 452, 454 · AR: GF77.30-P-0999MCU

P-1000-01B > Model 451.4 SOFT TOP, LOCATION OF COMPONENTS Number Designation Model 451.4 BE77.33-P-1001- 01B Soft top tension O 35 (+10) BASIC KNOWLEDGE > TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF SOFT TOP - GF77.30-P-0999MCU > MODEL 451.4 Fig 3: Electric Soft Top - Wiring Diagram (3 Of 3) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: SUBSTRUCTURE -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4243 · Applies to: 450, 451, 452, 454 · AR: AR61.00-Z-9451CA, AR61.25-P-6600MCC, AR61.25-P-6600MCU, AR61.25-P-6611MEV, AR61.25-P-6612MEV (+5 more)

AR61.00-Z-9451CA > MODEL 451 Remove/install bulkhead MODEL 451.4 AR61.25-P-6600MCC Remove/install bulkhead MODEL 451.4 AR61.25-P-6600MCU Remove/install console for batteries on floor MODEL 451.391/ 491 AR61.25-P-6611MEV Remove/install console for batteries on longitudinal member MODEL 451.391/ 491 AR61.25-P-6612MEV Remove/install console for front axle support MODEL 451.391/ 491 AR61.25-P-6613MEV Remove/install diagonal strut MODEL 451.4 AR61.10-P-5138MCC Remove/install diagonal strut MODEL 451.4 AR61.10-P-5138MCU Remove/install diagonal strut MODEL 451.491 AR61.10-P-5138MEV Remove/install diagonal strut console on longitudinal member MODEL 451.4 Diagonal strut console on front longitudinal member AR61.10-P- 5140MCO Remove/install diagonal strut console on longitudinal member MODEL 451.4 Diagonal strut console on rear longitudinal member AR61.10-P-5140MCP Remove/install mounting console for bulkhead on floor MODEL 451.4 (except 451.491) AR61.25-P- 6610MCO Replace tank support MODEL 451.3/4 (except 451.391 /491) Tankkonsole rechts AR61.10-P-5708MCC Replace tank support MODEL 451.3/4 (except 451.391 /491) Tankkonsole links AR61.10-P-5708MCD Replace thread for integral carrier mount MODEL 451.3/4 AR61.10-P-6200MCC Replace thread for integral carrier mount MODEL 451.3/4 AR61.10-P-6200MCU TESTING & REPAIR > REMOVE, INSTALL BRACKET FOR DIAGONAL STRUTS - AR61.10- P-5138-01MCC > UNDERBODY FRAME Number Designation Model 451.4 except 451.491

TESTING & REPAIR > REMOVE/INSTALL DIAGONAL STRUT - AR61.10-P-5138MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4245 · Applies to: 450, 451, 452, 454 · AR: AR61.10-P-5138MCU

MODEL 451.4

Remove/install

Risk of death caused by vehicle slipping or toppling off of the lifting Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00- Z-0010- 01A Fig 1: Removing/Installing Bolts On Diagonal Struts Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Diagonal Struts & Screws Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

platform.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4246 · Applies to: 450, 451, 452, 454 · AR: AR61.10-P-5140MCO

1 Raise vehicle using the vehicle lift and remove underfloor paneling Rechargeable drill/screwdriver http://gotis.aftersales.mercedes-benz.com

2 Unscrew bolts (2) and remove diagonal struts (1) *BA61.25- P-1002- 01B 3 Install in the reverse order

UNDERBODY FRAME Number Designation Model 451.4 except 451.491 BA61.25-P-1002- 01B Bolt, diagonal strut to underbody Nm 65 TESTING & REPAIR > REMOVE/INSTALL DIAGONAL STRUT CONSOLE ON LONGITUDINAL MEMBER - AR61.10-P-5140MCO > MODEL 451.4 Diagonal strut console on front longitudinal member MODIFICATION NOTES 30.1.09 Information on alternative repair methods added (riveting or plug welding as alternative) Fig 1: Removing/Installing Diagonal Strut Console On Front Longitudinal Member Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

LONGITUDINAL MEMBER - AR61.10-P-5140MCP >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4249 · Applies to: 450, 451, 452, 454 · AR: AR61.10-P-5140MCP

MODEL 451.4 Diagonal strut console on rear longitudinal member MODIFICATION NOTES 30.1.09 Information on alternative repair methods added (riveting or plug welding as alternative) Removing

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non- deburred vehicle parts. Deburr repair panels. AS00.00-Z-0017-01A General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027- 01FF General information on repairs to body

AH60.00-P-0001- 01FF Generally conventional tools are required for body work, additional tools required are listed above. Pneumatic/hydraulic blind rivet toolgotis://K_68- 80_06.0

Fig 1: Removing/Installing Diagonal Strut Console On Rear Longitudinal Member Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REPLACE TANK SUPPORT - AR61.10-P-5708MCC >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4257 · Applies to: 450, 451, 452, 454 · AR: AR61.10-P-5708MCC

MODEL 451.3/4 (except 451.391 /491) Tankkonsole rechts Illustrated on model 451.3 MODIFICATION NOTES 30.1.09 Information on alternative repair methods are worked in (riveting or plug welding as alternative and structural gluing eliminated) Removing

Risk of injury caused by scraping or cutting body parts on sharp vehicle parts Always wear protective gloves when working on or near sharp and non- deburred vehicle parts. Deburr repair panels. AS00.00-Z-0017-01A Notes on performing repair, body work and welding on vehicles with airbags and ETR units

AH91.00-P-0002- 01SM Pretreatment of bonding surfaces

AH60.00-P-0008- 01MCC General information on riveting

AH60.00-P-0003- 01MCC Notes on replacing body parts

AH60.00-P-0027- 01FF General information on repairs to

AH60.00-P-0001- Fig 1: Locating Right Tank Console Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR > REMOVE/INSTALL BULKHEAD - AR61.25-P-6600MCU >

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4264 · Applies to: 450, 451, 452, 454 · AR: AR61.25-P-6600MCU

MODEL 451.4

Remove/install

Risk of death caused by vehicle slipping or toppling off of the lifting platform. Align vehicle between columns of vehicle lift and position four support plates at vehicle lift support points specified by vehicle manufacturer. AS00.00- Z-0010- 01A 1 Lift vehicle with vehicle lift and remove rear underfloor paneling Rechargeable drill/screwdriverhttp://gotis.aftersales.mercedes- benz.com

Fig 3: Identifying Thread Insert Repair Kit (450 589 01 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Bulkhead Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Remove bolts (2) from

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4265 · Applies to: 450, 451, 452, 454 · AR: AR61.25-P-6610MCO

2 Remove bolts (2) from diagonal struts (3). BA61.25- P-1002- 01B 3 Remove bolts (4) from bulkhead (1) BA61.25- P-1001- 01A 4 Pull right diagonal strut (3) downward and unhook bulk head (1) from right mount on underbody

5 Unhook bulk head (1) from left mount on underbody and remove

6 Install in the reverse order

BULKHEAD TO UNDERBODY Number Designation Model 451.4 BA61.25-P-1001- 01A Bolt, bulkhead to underbody Nm 26 UNDERBODY FRAME Number Designation Model 451.4 except 451.491 BA61.25-P-1002- 01B Bolt, diagonal strut to underbody Nm 65 TESTING & REPAIR > REMOVE/INSTALL MOUNTING CONSOLE FOR BULKHEAD ON FLOOR - AR61.25-P-6610MCO > MODEL 451.4 (except 451.491)

TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: SUBSTRUCTURE INDEX -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4270 · Applies to: 450, 451, 452, 454 · AR: AR61.00-Z-9451CA, AR61.25-P-6600MCC, AR61.25-P-6600MCU, AR61.25-P-6611MEV, AR61.25-P-6612MEV (+5 more)

AR61.00-Z-9451CA > MODEL 451 Remove/install bulkhead MODEL 451.4 AR61.25-P-6600MCC Remove/install bulkhead MODEL 451.4 AR61.25-P-6600MCU Remove/install console for batteries on floor MODEL 451.391/ 491 AR61.25-P-6611MEV Remove/install console for batteries on longitudinal member MODEL 451.391/ 491 AR61.25-P-6612MEV Remove/install console for front axle support MODEL 451.391/ 491 AR61.25-P-6613MEV Remove/install diagonal strut MODEL 451.4 AR61.10-P-5138MCC Remove/install diagonal strut MODEL 451.4 AR61.10-P-5138MCU Remove/install diagonal strut MODEL 451.491 AR61.10-P-5138MEV Remove/install diagonal strut console on longitudinal member MODEL 451.4 Diagonal strut console on front longitudinal member AR61.10-P-5140MCO Remove/install diagonal strut console on longitudinal member MODEL 451.4 Diagonal strut console on rear longitudinal member AR61.10-P-5140MCP Remove/install mounting console for bulkhead on floor MODEL 451.4 (except 451.491) AR61.25-P-6610MCO Replace tank support MODEL 451.3 /4 (except 451.391 /491) Tankkonsole rechts AR61.10-P-5708MCC Replace tank support MODEL 451.3 /4 (except 451.391 /491) Tankkonsole links AR61.10-P-5708MCD Replace thread for integral carrier mount MODEL 451.3 /4 AR61.10-P-6200MCC Replace thread for integral carrier mount MODEL 451.3 /4 AR61.10-P-6200MCU GENERAL INFORMATION > NOTES ON REPLACING BODY PARTS - AH60.00-P-0027-01FF

Model 451.3/4, 454.0

4. Deburr rivet holes on left tank support (1) and body on both sides.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4275 · Applies to: 450, 451, 452, 454 · AR: AR61.10-P-5708MCC

Shown on model 451.3 5. Fit left tank support (1) and fasten with manual temporary fasteners. 6. Rivet left tank support (1) from top with 6.4 x 14 Polygrip flat/round head rivet (areas A and B). TESTING & REPAIR > REPLACE TANK SUPPORT - AR61.10-P-5708MCC > MODEL 451.3 /4 (except 451.391 /491) Tankkonsole rechts Illustrated on model 451.3 Fig 2: Identifying Rivet Area And Bolts On Left Tank Support Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Supplement standard

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4278 · Applies to: 450, 451, 452, 454 · AR: AR61.10-P-5708MCD

01A 10 Supplement standard underbody protection with permanent underbody sealant Underfloor protection *BR00.45- Z-1001- 05A 11 Paint area repaired and adjacent surfaces

Notes on paintwork repairs AH98.00- P-9408- 02MCC 12 Apply additional cavity preservation

AR97.20- P-1500FF Teroson protective wax *BR00.45- Z-1008- 05A 13 Reinstall all detachable parts removed

REPAIR MATERIALS Number Designation Order number BR00.45- Z-1003- 01A Sealant, white, 310 ml, DB supply specification 6069.20 A 001 989 63 20 BR00.45- Z-1092- 02A Adhesive kit, body, 2- component adhesive A 009 989 36 71 BR00.45- Z-1001- 05A Underfloor protection 800 ml A 001 986 46 10 BR00.45- Z-1008- 05A Teroson protective waxArt. no.: 122.73Q Henkel Loctite Deutschland GmbH Arabellastrasse 1781925 MunichGermanyTel. +49-899268-0Fax +49- 899101978www.Loctite.de BR00.45- Z-1001- 13A Blind rivet 6.4x14 A 003 990 35 97 TESTING & REPAIR > REPLACE TANK SUPPORT - AR61.10-P-5708MCD > MODEL 451.3 /4 (except 451.391 /491) Tankkonsole links Illustrated on model 451.3

Ensure that moisture has not penetrated into the damaged point (seal damage point

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4287 · Applies to: 450, 451, 452, 454 · AR: AR67.10-P-1000MCC, AR67.10-P-1600MCC

immediately after damage with adhesive tape and repair it as soon as possible). The crater at the impact point should not exceed a diameter of 5 mm. Cracks extending radially from the impact point should not be longer than 50 mm. They should not end at the rubber window seal and never reach to the outer edge of the window. Repairing windshield is allowed under the following conditions: The repair point must be outside the long-range field of vision. The long-range field of vision is 29 cm wide and is centered around the center point of the steering wheel The area to be repaired must be clean, free of grease and dry. Replace windows If the paint is damaged when replacing the windows, clean damaged points and treat with anticorrosion agents. Then coat repair point with paint (see paint repair guidelines). When cleaned and primed never touch bonding surfaces. Before applying adhesive to painted sheet metal, it is necessary to clean the gluing point and treat it with a primer (bonding agent). Do not remove remaining adhesive residues; cut back to a height of approx. 2 mm. Cut back adhesive residues max. 15 minutes before applying new adhesive bead, because the adhesive material on the cutting surface reacts to the ambient air which can lead to adhesion problems. Always observe curing time of adhesive material to ensure that adhesive bead achieves full strength. For this purpose, open driver and passenger side window for the duration of the curing time to prevent the windshield from being pressed outwards by the air pressure when the doors are closed. Replace spacers damaged during removal. Observe correct distance of spacers to prevent tension in the component. After replacing windshield, rear window or roof, durability is reached after approx. 2 h measured from the time the component is installed. The rated accident strength is achieved only after approx. 8 h. TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: WINDOWS - AR67.00-Z- 9451CA > MODEL 451 Remove/install windshield MODEL 451.3/4 AR67.10-P-1000MCC Repair of windshield MODEL 451.3/4, 454.0 AR67.10-P-1600MCC

16. Install windlass (16) on inner side of window.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4298 · Applies to: 450, 451, 452, 454 · AR: AR67.10-P-1000MCC

1. Install second end of cutting wire (17) in coil of windlass (16).
2. Install reversible ratchet on windlass (16) and tension cutting wire (17). The windlass coil (16) can only be turned in one direction. Ensure that the cutting wire (17) is located in the guide groove of the windlass (16).
3. Insert suitable interior protection between cutting wire (17) and inner paneling. Use parabolic chisel at awkward locations.
4. Slowly wrap cutting wire (17) onto coil of windlass (15) and cut out window up to marking (C).
5. Slowly wrap cutting wire (17) onto coil of windlass (16) and cut out window up to marking (D).
6. Move windlass (16) to next position.
7. Slowly wrap cutting wire (17) onto coil of windlass (16) and cut out window up to marking (E).
8. Move windlass (15) to next position.
9. Slowly wrap cutting wire (17) onto coil of windlass (15) and cut out window up to marking (E). Secure window against falling down to prevent damage.
10. Remove windlasses (15, 16) from window.
11. Fasten cup suction tool at outside of window and remove window from body flange. Cup suction tool gotis://K_67.0_03.0 Aid of helper required. TESTING & REPAIR > REMOVE/INSTALL WINDSHIELD - AR67.10-P-1000MCC > MODEL 451.3/4 Shown on model 451.3 Fig 9: Identifying Windlass Positions Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

3. Apply a drop of finish resin (14) to scraped finish resin surface and polish to transparent finish

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4311 · Applies to: 450, 451, 452, 454 · AR: AR67.10-P-1600MCC

using polishing cloth from repair kit. To achieve good repair results, a small quantity of dry finish polish (14) should already be present on the polishing cloth. The final result is a shining transparent point, similar to a dried rain drop. 4. Clean repair surfaces using cleaning agent (12). TESTING & REPAIR > REPAIR OF WINDSHIELD - AR67.10-P-1600MCC > MODEL 451.3/4, 454.0 Notes on stone impact repair on laminated glass windows

AH67.10-P-0002- 01MCC The following tools are required for stone impact repair for windshield PS laminated glass window repair system http://gotis.aftersales.mercedes- benz.com

1 Prepare repair of windshield

AR67.10-P-1600- 01MCC 2 Repair windshield

AR67.10-P-1600- 02MCC 3 Finish windshield repair

AR67.10-P-1600- 03MCC SAFETY PRECAUTIONS > RISK OF INJURY CAUSED BY SLIPPING WHEN INSERTING BLADE IN THE MULTICUTTER AND BY GLASS SPLINTERS WHEN CUTTING OUT BONDED WINDOWS - AS67.00-Z-0001-01A > Always interrupt air supply or power supply before inserting or removing blade. Wear protective gloves and safety glasses. Risk of injury Fig 1: Identifying Windshield Wiper Field And Long-Range Field Of Vision Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TORQUE SPECIFICATIONS > TIGHTENING TORQUES: SMART: WINDOWS - BA67.00-Z-

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4313 · Applies to: 450, 451, 452, 454 · AR: GF67.29-P-0003MCC

9999CZ > MODEL all Side windows MODEL 452.3 BA67.30-P-1000-01C BASIC KNOWLEDGE > HEATED REAR WINDOW, FUNCTION - GF67.29-P-0003MCC > MODEL 451.3/4 Function requirements: Circuit 15 On Function Actuation of the rear window heater switch is directly read in by the SAM control unit. The SAM control module then supplies power to the heated rear window, for 10 min. The integrated LED provides a status feedback message via the rear window heater switch. Actuating the rear window heater switch again before expiration of the heating period deactivates the rear window heater.

Heated rear window (HRW), location of components

GF67.29-P-0003- 01MCC Electric wiring diagram for * not for USA PE67.29-P- Fig 1: Heated Rear Window Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

heated rear window

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4314 · Applies to: 450, 451, 452, 454 · AR: GF67.29-P-0998MCC, PE67.29-P-2000MCC, PE67.29-P-2000MCU, GF67.29-P-9997MCC, GF54.21-P-4157MCC (+3 more)

2000MCC

• for USA only PE67.29-P- 2000MCU

SAM control unit, component description N10/10* not for USA GF54.21-P- 4157MCC

• for USA only GF54.21-P- 4157MCU

Component description for the heater/air conditioning operating unit N23Vehicles without code (I01) Air conditioning Plus GF83.40-P- 3001MCC

Vehicles with code (I01) Air conditioning Plus* not for USA GF83.40-P- 3001MCD

Vehicles with code (I01) Air conditioning Plus* for USA only GF83.40-P- 3001MCU BASIC KNOWLEDGE > CONTENTS, FUNCTION DESCRIPTION OF HEATED REAR WINDOW - GF67.29-P-0998MCC > MODEL 451.3/4

Heated rear window, function

GF67.29-P- 0003MCC

Heated rear window (HRW), location of components

GF67.29-P-0003- 01MCC Electric wiring diagram for heated rear window * not for USA PE67.29-P-2000MCC

• for USA only PE67.29-P-2000MCU

Overview of system components for heated rear window (HRW)

GF67.29-P- 9997MCC BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS FOR HEATED REAR WINDOW (HRW) - GF67.29-P-9997MCC > MODEL 451.3/4 SAM control unit, component description N10/10* not for USA GF54.21-P-4157MCC

• for USA only GF54.21-P-4157MCU Component description for the heater/air conditioning operating unit N23Vehicles without code (I01) Air conditioning Plus GF83.40-P-3001MCC

Vehicles with code (I01) Air conditioning Plus* not for USA GF83.40-P-3001MCD

N23s1

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4316 · Applies to: 450, 451, 452, 454 · AR: PE67.29-P-2000MCU

Rear window defroster switch 14 L R1 Heated rear window 3 L R1 Heated rear window 8 L U23 Valid for cabriolet 6 A U606 Valid for all except convertibles 1 A W6 Ground (left wheelhousing in trunk) 5 H W6 Ground (left wheelhousing in trunk) 9 H X18/19 Trunk lid connector 2 E X23/7 Soft top connector 6 E X23/7 Soft top connector 8 E Z6/16 Soft top ground connector sleeve 8 H Z6/20 Trunk lid ground connector sleeve 3 H WIRING DIAGRAMS > ELECTRIC WIRING DIAGRAM FOR HEATED REAR WINDOW - PE67.29-P-2000MCU > Fig 1: Heated Rear Window - Wiring Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

TESTING & REPAIR INDEX > TESTING AND REPAIR WORK: SMART: WINDOWS -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4326 · Applies to: 450, 451, 452, 454 · AR: AR67.00-Z-9451CA, AR67.10-P-1000MCC, AR67.10-P-1600MCC

AR67.00-Z-9451CA > MODEL 451 Remove/install windshield MODEL 451.3 /4 AR67.10-P-1000MCC Repair of windshield MODEL 451.3 /4, 454.0 AR67.10-P-1600MCC TESTING & REPAIR INDEX > PREPARE WINDOW FOR INSTALLATION - AR67.10-P-1000- 03MCC > REPAIR MATERIALS Number Designation Order number BR00.45-Z-1041-02B TS adhesive (with isopropanol cleaner) A 451 989 00 71 Adhesive kit for isopropanol cleaner The gluing area on the window must be absolutely free of dust and grease, flaws can lead to adhesion problems of the adhesive when glazing. 1. Check surface of window for scratches and damage; replace if necessary. 2. Cut off residual adhesive material of window with scraper down to a height of approx. 2 mm. Remove adhesive material residues. Cut back adhesive residues on window max. 15 minutes before applying new adhesive bead, because the adhesive material on the cutting surface reacts to the ambient air which can lead to Fig 1: Identifying Adhesive Kit For Isopropanol Cleaner Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

16. Install windlass (16) on inner side of window.

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4335 · Applies to: 450, 451, 452, 454 · AR: AR67.10-P-1000MCC

1. Install second end of cutting wire (17) in coil of windlass (16).
2. Install reversible ratchet on windlass (16) and tension cutting wire (17). The windlass coil (16) can only be turned in one direction. Ensure that the cutting wire (17) is located in the guide groove of the windlass (16).
3. Insert suitable interior protection between cutting wire (17) and inner paneling. Use parabolic chisel at awkward locations.
4. Slowly wrap cutting wire (17) onto coil of windlass (15) and cut out window up to marking (C).
5. Slowly wrap cutting wire (17) onto coil of windlass (16) and cut out window up to marking (D).
6. Move windlass (16) to next position.
7. Slowly wrap cutting wire (17) onto coil of windlass (16) and cut out window up to marking (E).
8. Move windlass (15) to next position.
9. Slowly wrap cutting wire (17) onto coil of windlass (15) and cut out window up to marking (E). Secure window against falling down to prevent damage.
10. Remove windlasses (15, 16) from window.
11. Fasten cup suction tool at outside of window and remove window from body flange. Cup suction tool Aid of helper required. TESTING & REPAIR INDEX > REMOVE/INSTALL WINDSHIELD - AR67.10-P-1000MCC > MODEL 451.3 /4 Shown on model 451.3 Fig 9: Identifying Windlass Coil, Cutting Wire And Groove Of Windlass Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

3. Apply a drop of finish resin (14) to scraped finish resin surface and polish to transparent finish

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4347 · Applies to: 450, 451, 452, 454 · AR: AR67.10-P-1600MCC

using polishing cloth from repair kit. To achieve good repair results, a small quantity of dry finish polish (14) should already be present on the polishing cloth. The final result is a shining transparent point, similar to a dried rain drop. 4. Clean repair surfaces using cleaning agent (12). TESTING & REPAIR INDEX > REPAIR OF WINDSHIELD - AR67.10-P-1600MCC > MODEL 451.3 /4, 454.0 Notes on stone impact repair on laminated glass windows

AH67.10-P- 0002-01MCC The following tools are required for stone impact repair for windshield PS laminated glass window repair system

1 Prepare repair of windshield

AR67.10-P- 1600-01MCC 2 Repair windshield

AR67.10-P- 1600-02MCC 3 Finish windshield repair

AR67.10-P- 1600-03MCC SAFETY PRECAUTIONS > RISK OF INJURY CAUSED BY SLIPPING WHEN INSERTING BLADE IN THE MULTICUTTER AND BY GLASS SPLINTERS WHEN CUTTING OUT BONDED WINDOWS - AS67.00-Z-0001-01A > Always interrupt air supply or power supply before inserting or removing blade. Wear protective gloves and safety glasses. Risk of injury When inserting or removing the blade for the multicutter, body parts may be cut if the tightening wrench slips or if the multicutter switches on unintentionally. Fig 1: Identifying Windshield Wiper Field And Long-Range Field Of Vision Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

BASIC KNOWLEDGE > HEATED REAR WINDOW (HRW), LOCATION OF COMPONENTS -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4349 · Applies to: 450, 451, 452, 454 · AR: GF67.29-P-0003MCC

GF67.29-P-0003-01MCC > BASIC KNOWLEDGE > HEATED REAR WINDOW, FUNCTION - GF67.29-P-0003MCC > MODEL 451.3 /4 Fig 1: Identifying Sam Control Unit, Heated Rear Window Switch And Heated Rear Window Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Heated Rear Window Function Diagram Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Function requirements:

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4350 · Applies to: 450, 451, 452, 454 · AR: GF67.29-P-0998MCC

Circuit 15 On Function Actuation of the rear window heater switch is directly read in by the SAM control unit. The SAM control module then supplies power to the heated rear window, for 10 min. The integrated LED provides a status feedback message via the rear window heater switch. Actuating the rear window heater switch again before expiration of the heating period deactivates the rear window heater.

Heated rear window (HRW), location of components

GF67.29-P- 0003- 01MCC Electric wiring diagram for heated rear window * not for USA PE67.29-P- 2000MCC

• for USA only PE67.29-P- 2000MCU

SAM control unit, component description N10/10* not for USA GF54.21-P- 4157MCC

• for USA only GF54.21-P- 4157MCU

Component description for the heater/air conditioning operating unit N23Vehicles without code (I01) Air conditioning Plus GF83.40-P- 3001MCC

Vehicles with code (I01) Air conditioning Plus* not for USA GF83.40-P- 3001MCD

Vehicles with code (I01) Air conditioning Plus* for USA only GF83.40-P- 3001MCU BASIC KNOWLEDGE > CONTENTS, FUNCTION DESCRIPTION OF HEATED REAR WINDOW - GF67.29-P-0998MCC > MODEL 451.3 /4

Heated rear window, function

GF67.29-P- 0003MCC

Heated rear window (HRW), location of components

GF67.29-P-0003- 01MCC Electric wiring diagram for heated rear window * not for USA PE67.29-P- 2000MCC

• for USA only PE67.29-P- 2000MCU

Overview of system components for heated rear window (HRW)

GF67.29-P- 9997MCC

BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS FOR HEATED REAR

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4351 · Applies to: 450, 451, 452, 454 · AR: GF67.29-P-9997MCC, GF54.21-P-4157MCC, GF54.21-P-4157MCU, GF83.40-P-3001MCC, GF83.40-P-3001MCD (+2 more)

WINDOW (HRW) - GF67.29-P-9997MCC > MODEL 451.3 /4 SAM control unit, component description N10/10* not for USA GF54.21-P-4157MCC

• for USA only GF54.21-P-4157MCU Component description for the heater/air conditioning operating unit N23Vehicles without code (I01) Air conditioning Plus GF83.40-P-3001MCC

Vehicles with code (I01) Air conditioning Plus* not for USA GF83.40-P-3001MCD

Vehicles with code (I01) Air conditioning Plus* for USA only GF83.40-P-3001MCU Contents, function description of heated rear window

GF67.29-P-0998MCC WIRING DIAGRAMS > LEGEND OF WIRING DIAGRAM FOR HEATED REAR WINDOW - PE67.29-P-2000-60MCU > Model 451 Code Designation Coordinates N10/10 SAM control unit 4A N10/10 SAM control unit 11A N10/10f28 Fuse 28 3A N10/10f28 Fuse 28 7A N23 Heater/AC operating unit 13L N23s1 Heated rear window switch 15L R1 Rear window defroster 3L R1 Rear window defroster 8L U23 Valid for convertibles 6A U606 Valid for all except convertibles 1A W6 Ground (left wheel well in luggage compartment) 5H W6 Ground (left wheel well in luggage compartment) 10H X18/19 Trunk lid connector 2E X23/7 Soft top connector 6E X23/7 Soft top connector 8E Z6/16 Soft top ground connector sleeve 8H

Z6/20

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4352 · Applies to: 450, 451, 452, 454 · AR: PE67.29-P-2000MCU, OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU (+2 more)

Trunk lid ground connector sleeve 3H WIRING DIAGRAMS > ELECTRIC WIRING DIAGRAM FOR HEATED REAR WINDOW - PE67.29-P-2000MCU > MODEL 451 PE67.29-P-2000- 99MCU Electric wiring diagram for heated rear window

PE67.29-P-2000- 99MCU PE67.29-P-2000- 60MCU Legend of wiring diagram for heated rear window

PE67.29-P-2000- 60MCU OV00.01-P-1901- 03MCC Use of wiring diagrams

OV00.01-P-1901- 03MCC OV00.01-P-1901MCU Search aid for all wiring diagram groups

OV00.01-P-1901MCU OV00.01-P-1001- 27MC Abbreviations for wiring diagrams

OV00.01-P-1001- 27MC OV00.01-P-1001- 28MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P-1001- 28MC GF00.19-P-1000MCU Location and assignment of line and connectors

GF00.19-P-1000MCU GF00.19-P-2000MCU Location and assignment of ground points

GF00.19-P-2000MCU GF00.19-P-3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)

GF00.19-P-3000MCU PE54.00-P-1100MCU

Further wiring diagrams PE54.00-P-1100MCU PE83.00-P-1100MCU

Further wiring diagrams PE83.00-P-1100MCU WIRING DIAGRAMS > ELECTRIC WIRING DIAGRAM FOR HEATED REAR WINDOW - PE67.29-P-2000-99MCU > Code: Designation: Position: N10/10 SAM control unit 4 A N10/10 SAM control unit 11 A N10/10f28 Fuse 28 2 A

WIRING DIAGRAMS > ELECTRIC WIRING DIAGRAM FOR HEATED REAR WINDOW -

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4354 · Applies to: 450, 451, 452, 454 · AR: PE67.29-P-2000MCU, OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU, GF00.19-P-3000MCU (+2 more)

PE67.29-P-2000MCU > MODEL 451 PE67.29-P-2000- 99MCU Electric wiring diagram for heated rear window

PE67.29-P-2000- 99MCU PE67.29-P-2000- 60MCU Legend of wiring diagram for heated rear window

PE67.29-P-2000- 60MCU OV00.01-P-1901- 03MCC Use of wiring diagrams

OV00.01-P-1901- 03MCC OV00.01-P-1901MCU Search aid for all wiring diagram groups

OV00.01-P-1901MCU OV00.01-P-1001- 27MC Abbreviations for wiring diagrams

OV00.01-P-1001- 27MC OV00.01-P-1001- 28MC Abbreviations of signal and circuit designations for wiring diagrams

OV00.01-P-1001- 28MC GF00.19-P-1000MCU Location and assignment of line and connectors

GF00.19-P-1000MCU GF00.19-P-2000MCU Location and assignment of ground points

GF00.19-P-2000MCU GF00.19-P-3000MCU Location and assignment of Z connector sleeves (line connectors in wiring harness)

GF00.19-P-3000MCU PE54.00-P-1100MCU

Further wiring diagrams PE54.00-P-1100MCU PE83.00-P-1100MCU

Further wiring diagrams PE83.00-P-1100MCU SPECIAL TOOLS > 450 589 08 63 00 CUTTING WIRE - WS67.00-P-0020B > FG 65/67/Set B MODEL 450, 451, 452, 454 Use: Cutting wire for cutting out glued windows and glass roof NOTE: Cutting wiresmart no.: 000 5177 V001 0000 00

Removing

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4405 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2040MCC, AR68.20-P-2040MCU

1 Remove floor covering * not for USA AR68.20-P-2040MCC

• for USA only AR68.20-P-2040MCU Fig 1: Identifying Shift Module Components (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Identifying Shift Module Components (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.

Raise electronic selector lever

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4408 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2040MCC, AR68.20-P-2040MCU

18 Raise electronic selector lever module control unit (N15/5) and contact electrical connector (6)

19 Contact the electrical connector of transponder coil (1) and electrical connectors (3)

20 Tighten bolts (2) on the left and right of the control unit for the electronic selector lever module (N15/5) Transmission 717.4 *BA26.60-P-1001-01C

Model 451.391/491 *BA26.60-P-1001-01I

*450589030900 21 Pull transport security device (9) out of the electronic selector lever module control unit (N15/5) (arrow E) and clip into the park position (arrow A) on the electronic selector lever module control unit (N15/5) After repairs to the electronic selector lever module control unit (N15/5) the transport security device (9) must again be clipped into the park position (arrow A) on the electronic selector lever module control unit (N15/5).

22 Install floor covering * not for USA AR68.20-P-2040MCC

• for USA only AR68.20-P-2040MCU SHIFT MECHANISM Number Designation Transmission 717.4 in model 451 BA26.60-P-1001- 01C Bolt, shift module to body Nm 12 SHIFT MECHANISM Number Designation Model 451.391/491 BA26.60-P-1001- 01I Bolt, shift module to body Nm 12

Remove cable ties on cable (1)

2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 4489 · Applies to: 450, 451, 452, 454 · AR: AR68.20-P-2000MCU

4 Remove cable ties on cable (1) ties in the marked areas (arrows).

5 Pry off ball joint (5) with an open end wrench size 12 on relay lever (4) of the park pawl and remove cable (1) from bracket (3)

6 Press grommet (2) out of the body towards the engine compartment and remove cable (1) to the rear

7 Install in the reverse order

TESTING & REPAIR INDEX > REMOVE/INSTALL TRANSPONDER COIL - AR80.35-P- 4515MCU > MODEL 451.3 /4

Remove/install

1 Remove center console AR68.20-P-2000MCU 2 Disconnect electrical connector (1) from transponder coil (L11)

3 Unclip transponder coil (L11) and remove upward

4 Install in the reverse order

TORQUE SPECIFICATIONS > MANUAL TRANSMISSION, GENERAL - BA26.00-P-1000-01D

Transmission 717 COMPLETE MANUAL TRANSMISSION Number Designation Transmission 717 except 717.478 Transmission 717.478 Transmission 717.48 BA26.00- P-1001- Bolt, transmission bearing to longitudinal member Nm 35 35 - Fig 1: Identifying Transponder Coil And Electrical Connector Courtesy of MERCEDES-BENZ OF NORTH AMERICA.