454 — forfour (2004-2006) — Brakes¶
Workshop and reference excerpts for 454 — forfour (2004-2006) in the Brakes system.
69 excerpts from 1 sources.
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf¶
Slide on BRABUS hand brake¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 12 · Applies to: 450, 451, 452, 454 · AR: AP42.00-P-4280MCC
7 Slide on BRABUS hand brake handle (8) up to the end stop on the hand brake lever (5)
8 Tighten self-locking Inbus screws (7) on the BRABUS hand brake handle (8) evenly
9 Slide boot (6) rearwards and using an assembly wedge position under the floor covering (arrow) Fig 4 MAINTENANCE > REPLACE BRAKE FLUID - AP42.00-P-4280MCC > MODEL 451.3 /4 Fig 4: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Brake Fluid Reservoir, Brake Caliper And Wheel Brake Cylinder Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Carry out the bleeding¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 14 · Applies to: 450, 451, 452, 454 · AR: AP42.00-P-4298MCC
7 Carry out the bleeding process on the left wheel brake cylinder (3), right brake caliper (2) and left brake caliper (2) in the same manner BA42.10- P-1001- 08C BA42.10- P-1002- 10A 8 Check brake pedal travel The brake system must be bled manually in the event of a soft pedal feel or long pedal travel. Refer to: ↓
Bleed brake system manually AR42.10- P-0010- 04SM 9 Press dust cap onto brake bleeder valve
10 Lower vehicle with vehicle lift
11 Disconnect brake fluid changer
12 Check brake fluid level and correct if necessary
AP42.10- P- 4210MCC 13 Screw on cap of brake fluid reservoir (1)
14 Install maintenance flap
15 Check leaktightness of brake system
Check brake system for leaks
AR42.10- P-0100- 01MCC BRAKE CYLINDER Number Designation Model 451.3/4 BA42.10-P-1001-08C Brake bleed valve to rear axle wheel brake cylinder Nm 7 FRONT AXLE FLOATING CALIPER Number Designation Model 451.3/4 BA42.10-P-1002-10A Brake bleeder valve to brake caliper Nm 7 MAINTENANCE > CHECK WET BOILING POINT OF BRAKE FLUID - AP42.00-P-4298MCC > MODEL 451.3 /4
Dispose of pipette (2)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 16 · Applies to: 450, 451, 452, 454 · AR: AP42.10-P-4210MCC
6 Dispose of pipette (2)
7 Seal brake fluid reservoir
MAINTENANCE > BRAKE SYSTEM - INSPECT FLUID LEVEL - AP42.10-P-4210MCC > MODEL 451.3 /4 Risk of poisoning caused by Only pour brake fluid into suitable and AS42.50- Fig 2: Identifying Pipette (452 589 00 21 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 3: Identifying Brake Fluid Meter (452 589 00 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Brake Fluid Reservoir Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
swallowing brake fluid. Risk of¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 17 · Applies to: 450, 451, 452, 454 · AR: AP42.10-P-4251MCU
injury caused by brake fluid coming into contact with skin and eyes. appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. Z-0001- 01A Risk of injury caused by moving parts that can pinch, crush or, in extreme cases even sever extremities. Always remove ignition key when working on windshield wiper mechanism. AS82.30- Z-0001- 01A Brake fluid notes
AH42.50- P-0001- 01A Notes on repairs to brake system
AH42.00- P-0003- 01A 1 Remove maintenance flap
2 Check fluid level The brake fluid level must be between the MAX and MIN marking embossed in the brake fluid reservoir (1).If the fluid level is too low, establish and eliminate the cause. As a separate repair order. If no cause can be found, correct brake fluid level.
General brake fluid Sheet 330.1 BB00.40- P-0330- 01A Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40- P-0331- 00A 3 Install maintenance flap
MAINTENANCE > CHECK LINING THICKNESS OF BRAKE PADS AND CONDITION OF BRAKE DISKS - AP42.10-P-4251MCU > MODEL 451.3/4
Checking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 18 · Applies to: 450, 451, 452, 454 · AR: AP42.10-P-4253MCU
1 Check lining thickness of brake pads (1) on front axle Check brake pads (1) in the installed condition. Observe recommended wear limit so that wear limit is not dropped below up to the next maintenance service.If necessary: ↓Replace brake pads (1) subject to separate repair order.
Remove/check/install front axle brake pads AR42.10- P- 1600MCU 2 Inspect brake disk (2) for scores and cracks If necessary: ↓Replace brake disk (2) subject to separate repair order.
Remove/install front axle brake disk AR42.10- P- 0230MCU MAINTENANCE > CHECK BRAKE LINING THICKNESS - AP42.10-P-4253MCU > MODEL 451.3/4 Shown on left side of vehicle Fig 1: Identifying Brake Pads And Brake Disk Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Checking¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 19 · Applies to: 450, 451, 452, 454 · AR: AP42.20-P-4240MCU
1 Remove stop plug (1) from brake anchor plate of left and right drum brake
2 Check lining thickness of brake shoes The wear limit of brake shoe is to be evaluated through the inspection hole. Observe the wear limit to ensure that the wear limit is not exceeded before the next maintenance service.If necessary: ↓Remove brake drum (2) for exact determination of the lining thickness of the brake shoes subject to separate repair order.
Remove/install brake drum AR42.10- P- 1010MCU
Remove/install brake shoes at rear axle AR42.10- P- 0165MCU 3 Seal inspection hole in brake anchor plate of left and right drum brake using stop plug (1)
MAINTENANCE > CHECK SETTING OF HANDBRAKE - AP42.20-P-4240MCU > Fig 1: Identifying Plug And Brake Drum Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 20 · Applies to: 450, 451, 452, 454 · AR: AP42.20-P-4241MCU
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 Raise vehicle with vehicle lift
Checking
2 With the handbrake released, both rear wheels must turn freely
3 Tighten the hand brake lever 4 to 5 notches and check whether the rear wheels can still be turned It must no longer be possible to turn the rear wheels, adjust the drum brake if necessary. If adjustment is no longer possible due to worn brake shoes, the brake shoes should be replaced.If necessary: ↓Adjust drum brake or replace brake shoes on rear axle subject to separate repair order.
Adjust drum brake AR42.10- P-1010- 11SM
Remove/install brake shoes at rear axle AR42.10- P- 0165MCU MAINTENANCE > CHECK AUTOMATIC HANDBRAKE ADJUSTER - AP42.20-P-4241MCU > MODEL 451.3 /4
Remove/install rear axle speed sensor¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 26 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0010MCU
MODEL 451.3 /4 P- 0714MCU
Remove/install right front brake line MODEL 451.3 /4 AR42.10- P- 0033MCC
Remove/install right front brake line MODEL 451.3 /4 AR42.10- P- 0033MCU
Remove/install right rear brake line MODEL 451.3 /4 AR42.10- P- 0037MCC
Remove/install right rear brake line MODEL 451.3 /4 AR42.10- P- 0037MCU
Remove/install splash shield on front brake MODEL 451.3/ 4 AR42.10- P- 0233MCC
Remove/install splash shield on front brake MODEL 451.3 /4 AR42.10- P- 0233MCU
Remove/install wheel brake cylinder MODEL 451.3 /4 AR42.10- P- 0167MCC
Remove/install wheel brake cylinder MODEL 451.3 /4 AR42.10- P- 0167MCU
Remove/install yaw rate and lateral acceleration sensor MODEL 451.3 /4 AR42.45- P- 0841MCC
Remove/install yaw rate and lateral acceleration sensor MODEL 451.3 /4 AR42.45- P- 0841MCU TESTING & REPAIR > BLEED BRAKE SYSTEM - AR42.10-P-0010MCU > MODEL 451.3/4
Brake system - inspect fluid¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 29 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0017MCU
level
AP42.10- P- 4210MCC Install
13 Screw on cap of brake fluid reservoir (1)
14 Install maintenance flap
15 Raise vehicle with vehicle lift
16 Press dust cap onto brake bleeder valve
17 Mount wheels
AR40.10- P- 1100MCU 18 Check brake system for leaks
AR42.10- P-0100- 01MCC BRAKE CYLINDER Number Designation Model 451.3/4 BA42.10-P-1001-08C Brake bleed valve to rear axle wheel brake cylinder Nm 7 FRONT AXLE FLOATING CALIPER Number Designation Model 451.3/4 BA42.10-P-1002-10A Brake bleeder valve to brake caliper Nm 7 TESTING & REPAIR > REMOVE/INSTALL BRAKE LINES - AR42.10-P-0017MCU > MODEL 451.3/4
ELECTRONIC STABILITY PROGRAM (ESP)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 43 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0034MCU
Number Designation Model 451.3/4 BA42.45-P-1008-01F Bolt, ESP hydraulic unit bracket to floor panel Nm 25 TESTING & REPAIR > REMOVE/INSTALL BRAKE LINE FROM THE MASTER BRAKE CYLINDER TO THE ESP HYDRAULIC UNIT - AR42.10-P-0034MCU > Fig 3: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Socket Wrench Set (451 589 00 03 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 46 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0035MCU
Designation Model 451.3/4 BA42.10-P-1005-04E Brake pipe to master brake cylinder Nm 16 BA42.10-P-1010-04E Brake line to ESP hydraulic unit Nm 16 ELECTRONIC STABILITY PROGRAM (ESP) Number Designation Model 451.3/4 BA42.45-P-1008-01F Bolt, ESP hydraulic unit bracket to floor panel Nm 25 TESTING & REPAIR > REMOVE/INSTALL BRAKE LINE FROM THE ESP HYDRAULIC UNIT TO THE REAR AXLE - AR42.10-P-0035MCU > MODEL 451.3 /4 Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Brake Fluid Expansion Reservoir Cap Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL LEFT REAR BRAKE LINE - AR42.10-P-0036MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 51 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0036MCU
MODEL 451.3 /4 Fig 5: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 7: Identifying Socket Wrench Set (451 589 00 03 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
0330MCC¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 58 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0041MCC
Adjust
9 Pull brake pedal (1) back firmly in direction of arrow (arrow A) Automatic adjustment of the brake light switch (S9/1) when pulling back the brake pedal (1) is clearly audible.
Checking
10 Connect STAR DIAGNOSIS and delete fault memory Type 450 AD00.00- P-2000- 04SM Model 451 AD00.00- P-2000- 04MCC 11 Check brake light switch signal using Star Diagnosis
12 Close Star Diagnosis Type 450 AD00.00- P-2000- 04SM Model 451 AD00.00- P-2000- 04MCC TESTING & REPAIR > ADJUST MECHANICAL STOP LAMP SWITCH - AR42.10-P-0041MCC
MODEL 451.3 /4 MODEL 450.3/ 4 Remove/install
1 Remove stop lamp switch The brake light switch must be removed for adjustment. AR42.10-P- 0040MCC 2 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL FRONT AXLE BRAKE CALIPER - AR42.10-P- 0070MCU > MODEL 451.3 /4
TESTING & REPAIR > CHECK BRAKE SYSTEM FOR LEAKS - AR42.10-P-0100-01MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 61 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0164MCU
- After bleeding the brake system, depress the brake pedal firmly several times so that the correct clearance is adjusted between the brake disk and brake lining. The vacuum in the brake booster is reduced by depressing the brake pedal several times. When the hand brake is applied a hard, permanent actuation point must adjust at the brake pedal when the foot brake is depressed. If the pedal travel reduces after the brake pedal is pumped several times, the complete brake system should be bled.
- Check all connections and screw joints for leaks.
- If necessary replenish brake fluid in the brake fluid reservoir or correct brake fluid by draining at any bleed valve.
- If the test drive is carried out after a repair to the hydraulic system of the brake system, then braking
with ESP regulation is to be carried out.
TESTING & REPAIR > REMOVE/INSTALL BRAKE CARRIER PLATE - AR42.10-P-0164MCU
MODEL 451.3 /4 Fig 2: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Compressing Locking Device On Hand Brake Cable Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Route brake lines (8) of brake fluid¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 74 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0500MCU
16 Route brake lines (8) of brake fluid reservoir (2) to master brake cylinder (5) starting at top and working down The aid of a second person on a ladder is necessary.
17 Clip brake lines (8) into brackets (9)
18 Connect brake lines (8) to master brake cylinder (5) Check the gaskets (7) for damage; replace if necessary.
Fig 3 19 Install retainer (6) on brake lines (8)
20 Install underfloor paneling
21 Lower vehicle with lifting platform
22 Clip brake lines (8) of brake fluid reservoir (2) into bracket (arrow B) on firewall
23 Clip brake fluid reservoir (2) onto fresh-air intake (1)
24 Connect electrical connector (4) to brake fluid reservoir (2)
25 Install right headlamp unit
AR82.10- P- 4730MCU 26 Bleed brake system
AR42.10- P- 0010MCU TESTING & REPAIR > REMOVE/INSTALL BRAKE CARRIER - AR42.10-P-0500MCU > MODEL 451.3/4 Fig 3: Identifying Pliers (450 589 15 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Differences in braking power above 20 % are not permissible.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 76 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-1010MCU
TESTING & REPAIR > REMOVE/INSTALL BRAKE DRUM - AR42.10-P-1010MCU > MODEL 451.3/4 Remove/install
1 Remove left or right rear wheel Installation: Adjust brake after assembling the rear wheel. AR40.10- P- 1100MCU Refer to: ↓Adjust drum brake AR42.10- P-1010- 11SM 2 Unscrew bolt (2)
3 Remove brake drum (1) from wheel hub (3) Check brake drum (1) for wear. BE42.10- P-1001- 12C Installation: Clean friction surface of brake shoes on the inside of the brake drum (1) and centering face (A) on the wheel hub (3) to a metallic bright finish.Grease centering face (A) on wheel hub (3) lightly with brake paste.Brake paste BR00.45- Z-1060- 06A 4 Install in the reverse order
TEST VALUES FOR DRUM BRAKE Number Designation Model 451.3/4 BE42.10-P-1001- 12C Brake drum diameter New mm 203,0 Wear limit for maintenance service mm 204,5 AUXILIARY REPAIR MATERIALS Fig 1: Identifying Brake Drum, Centering Surface, Screw And Wheel Hub Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Response of wear indicator (with pad backing¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 80 · Applies to: 450, 451, 452, 454 · AR: AR42.20-P-0500MCU
plate) mm ≈7,7 TEST VALUES FOR FRONT BRAKE DISKS Number Designation Model 451.3/4 BE42.10-P-1001-08E Brake disk thickness New mm 9,7 Wear limit mm 8 FRONT AXLE FLOATING CALIPER Number Designation Model 451.3/4 BA42.10-P-1001-10A Bolt, brake caliper to brake caliper support Nm 30 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1070-06A Molykote 111 grease Q0014759V000000000 TESTING & REPAIR > REMOVE/INSTALL HAND BRAKE LEVER - AR42.20-P-0500MCU > Fig 3: Identifying Vernier Caliper (450 589 01 19 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Brake Piston Resetting Device (450 589 02 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
brake lever (1)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 82 · Applies to: 450, 451, 452, 454 · AR: AR42.20-P-0501MCC
5 brake lever (1) corrugation of the pull rod (6) must face to the left (towards the clamping piece (2)). The function of the hand brake is not assured if the pull rod (6) is incorrectly positioned.Do not tilt the hand brake lever (1) so that the pull rod (6) or clamping housing is not bent.
6 Unclip the parking brake indicator switch (S12) on the hand brake lever (1) When replacing the hand brake lever (1).
7 Install in the reverse order
8 Carry out function test of hand brake
PARKING BRAKE Number Designation Model 451.3/4 BA42.20-P-1002-01D Bolt, hand brake lever to floor panel Nm 21 TESTING & REPAIR > REMOVE/INSTALL PARKING BRAKE INDICATOR SWITCH - AR42.20-P-0501MCC > MODEL 451.3/4
Remove/install
1 Adjust the seats forwards and fold down the seat backrests forwards
2 Apply parking brake
Fig 1: Identifying Parking Brake Indicator Switch, Electrical Connector, Hand Brake Lever And Catch Hook Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove the clips (arrows A) on the rear¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 83 · Applies to: 450, 451, 452, 454 · AR: AR42.20-P-0545MCU
3 Remove the clips (arrows A) on the rear floor covering (5) and fold down the rear floor covering (5) forward until the catch hook (3) is accessible When folding down the floor covering ensure that this is not damaged by breaking or cracking. 4 Unlock catch hook (3) of parking brake indicator switch (S12) and remove parking brake indicator switch (S12) from hand brake lever Installation: The parking brake indicator switch (S12) must be located in its guide (arrow B) in the rear area. 5 Disconnect electrical connector (1)
6 Install in the reverse order
TESTING & REPAIR > PARKING BRAKE CABLE REMOVAL AND INSTALLATION - AR42.20-P-0545MCU > MODEL 451.3/4 Remove/install
1 Remove left rear and right rear brake shoes
AR42.10- P- 0165MCU 2 Slide the leeve (2) over the hand brake cable (1), compre lock (arrow) on hand brake cable (1) by means of a sleeve (2) and guide hand brake cable (1) out of the brake anchor plate (3) Figure 3 Unhook hand brake cable (1) at the rocker of the pull rod (4), compress lock on hand brake cable (1) by means of sleeve (2) and guide hand brake Figure Fig 1: Removing/Installing Parking Brake Cable Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
cable (1) out of the support on the frame-type integral support (5)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 84 · Applies to: 450, 451, 452, 454 · AR: AR42.20-P-0570MCU
4 Unclip hand brake cable (1) from the brackets on the axle tube (6) and remove
5 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL PULL ROD - AR42.20-P-0570MCU > MODEL 451.3/4 Fig 2: Identifying Sleeve (451 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Removing/Installing Pull Rod (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
tool and press out guide¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 86 · Applies to: 450, 451, 452, 454 · AR: AR42.30-P-0712MCC
sleeve (5) downwards 8 Install in the reverse order
9 Carry out function test of hand brake
TESTING & REPAIR > REMOVE/INSTALL LEFT FRONT OR RIGHT RPM SENSOR - AR42.30-P-0712MCC > MODEL 451.3/4
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 lifting platform and remove underfloor paneling Rechargeable drill / screwdriver
2 Mark the position of brackets (5) on electrical line (1) and on brake line (4)
3 Unscrew bolt (3) on the left front RPM sensor (L6/1) or right front RPM sensor (L6/2) Replace self-locking bolt (3).
Separate RPM sensor connector Fig 1: Identifying Left And Right Front RPM Sensor, Connector, Electrical Line And Brackets Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Connect STAR DIAGNOSIS and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 90 · Applies to: 450, 451, 452, 454 · AR: AR42.45-P-0817MCU
read out fault memory
AD00.00- P-2000- 04MCC TESTING & REPAIR > REMOVE/INSTALL ELECTRONIC STABILITY PROGRAM (ESP) HYDRAULIC UNIT - AR42.45-P-0817MCU > MODEL 451.3/4
Remove/install
Risk of death when touching components on vehicles with high-voltage on-board electrical system Do not touch components and open lines of the high-voltage on-board electrical system. Persons with electronic implants (e.g. cardiac pacemakers) must never work on high- voltage on-board electrical systems. AS54.00- Z-0001- 02MEV Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes. Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. AS42.50- Z-0001- 01A Note on high-voltage battery Model 451.391/491 AH54.10- P-0006- 01MEV Fig 1: Identifying Electronic Stability Program (ESP) Hydraulic Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL ELECTRONIC STABILITY PROGRAM (ESP)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 94 · Applies to: 450, 451, 452, 454 · AR: AR42.45-P-0820MCU
CONTROL UNIT - AR42.45-P-0820MCU > MODEL 451.3 /4
Remove/install
Information on preventing damage to electronic components due to electrostatic discharge
AH54.00- P-0001- 01A 1 Disconnect battery
AR54.10- P- Fig 3: Identifying Socket Wrench Set (451 589 00 03 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Electronic Stability Program (ESP) Control Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install in the reverse¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 96 · Applies to: 450, 451, 452, 454 · AR: AR42.45-P-0841MCU
10 Install in the reverse order
11 Flash the ESP control unit (N47-5) When replacing the ESP control unit (N47-5). AR54.21- P- 0012MCU ELECTRONIC STABILITY PROGRAM (ESP) Number Designation Model 451.3/4 BA42.45-P-1003- 01F Bolt, ESP [Electronic Stability Program] control unit to ESP module Nm 3 BA42.45-P-1008- 01F Bolt, ESP hydraulic unit bracket to floor panel Nm 25 TESTING & REPAIR > REMOVE/INSTALL YAW RATE AND LATERAL ACCELERATION SENSOR - AR42.45-P-0841MCU > MODEL 451.3 /4 Fig 2: Identifying Set Of Torque Tools (452 589 03 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BA42.45-P-¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 104 · Applies to: 450, 451, 452, 454 · AR: BE42.00-Z-9999CZ
1005-01F Brake line to ESP hydraulic unit Nm 14 - 14 BA42.45-P- 1006-01F Nut, intermediate bracket to ESP hydraulic unit Nm 18 - 18 BA42.45-P- 1007-01F Nut, intermediate bracket to front axle carrier Nm - - 20 BA42.45-P- 1008-01F Bolt, ESP hydraulic unit bracket to floor panel Nm - 25 - TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: BRAKES - HYDRAULIC AND MECHANICAL SYSTEMS - BE42.00-Z-9999CZ > MODEL all
antilock brake system (ABS) MODEL 450.3 /4 BE42.30-P- 1000-01B
Check values for front brake pad MODEL 450.3 /4, 451.3 /4, 452.3 /4 BE42.10-P- 1000-05E
Check values for front brake pad MODEL 454.0 BE42.10-P- 1000-05G
Check values for rear brake pad MODEL 454.0 (except 454.033) with CODE (30Y) Disk brakes on rear axle BE42.10-P- 1000-15F
Drum brake MODEL 454.0 except CODE (30Y) Scheibenbremse Hinterachse BE42.10-P- 1000-12D
Drum brake MODEL 450.3 /4, 451.3 /4, 452.3 /4 BE42.10-P- 1000-12C
Inspection data for rear brake floating calipers MODEL 454.0 with CODE (30Y) Scheibenbremse Hinterachse BE42.10-P- 1000-14C
RPM sensor MODEL 450.3 /4, 452.3 /4 BE42.45-P- 1000-01A
Test values for front axle floating caliper MODEL 450.3 /4, 452.3 /4, 454.0 BE42.10-P- 1000-03B
Test values for front brake disks MODEL 450.3 /4, 451.3 /4, 452.3 /4, 454.0 BE42.10-P- 1000-08E
Test values for rear brake disks MODEL 454.0 with CODE (30Y) Scheibenbremse Hinterachse BE42.10-P- 1000-09F TEST & ADJUSTMENT VALUES > CHECK VALUES FOR FRONT BRAKE PAD - BE42.10- P-1000-05E > Model 450, 451, 452 MODIFICATION NOTES Brake pad thickness, wear limit (with pad backing plate) at maintenance service Model 450.3/4
ESP control unit, component description¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 113 · Applies to: 450, 451, 452, 454 · AR: GF42.45-P-0999MCU, GF42.45-P-0001MCU, PE42.45-P-2050MCU, PE42.45-P-2000MCU, GF42.45-P-9997MCU (+1 more)
N47-5 5118MCU
Steering angle sensor, component description N49 GF42.45-P- 5107MCC BASIC KNOWLEDGE > TABLE OF CONTENTS: FUNCTIONAL DESCRIPTION, ELECTRONIC STABILITY PROGRAM (ESP) - GF42.45-P-0999MCU > MODEL 451.3/4
Electronic stability program (ESP) function
GF42.45-P-0001MCU
Electronic stability program (ESP), location of electronic components
GF42.45-P-0001- 03MCU Electrical function diagram for Electronic Stability Program (ESP)
PE42.45-P-2050MCU Wiring diagram of Electronic Stability Program (ESP)
PE42.45-P-2000MCU
Overview of system components, Electronic Stability Program (ESP)
GF42.45-P-9997MCU BASIC KNOWLEDGE > YAW RATE, LATERAL AND LONGITUDINAL ACCELERATION SENSOR, COMPONENT DESCRIPTION - GF42.45-P-4810MCU > MODEL 451.3/4 Location The yaw rate, lateral and longitudinal acceleration sensor is located on the vehicle underfloor under the left seat. Task The yaw rate, lateral and longitudinal acceleration sensor measures the rotational speed about the vertical axis. The integrated lateral acceleration sensor (AY-sensor) measures the lateral acceleration. The integrated longitudinal acceleration sensor (Ax sensor) detects longitudinal inclination. The yaw rate, lateral and longitudinal acceleration sensor passes on the information to the ESP control unit Fig 1: Identifying Yaw Rate, Lateral And Longitudinal Acceleration Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
via the Controller Area Network (data bus/CAN bus) (CAN)N47-5.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 114 · Applies to: 450, 451, 452, 454 · AR: GF42.45-P-5107MCC
BASIC KNOWLEDGE > STEERING ANGLE SENSOR, COMPONENT DESCRIPTION - GF42.45-P-5107MCC > MODEL 451.3/4 Location The steering angle sensor is located on the steering column behind the steering wheel. Task The steering angle sensor records the steering angle, the steering direction as well as the steering speed over a measuring range of 720°. This information is conveyed to the ESP control unit via the Controller Area Network (data bus/CAN bus)N47- 5) and to the power steering control unit (N68) (with code (V26) EPS power steering (FFO)). BASIC KNOWLEDGE > ESP CONTROL UNIT, COMPONENT DESCRIPTION - GF42.45-P- 5118MCU > MODEL 451.3/4 Location Fig 1: Identifying Steering Angle Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying ESP Control And Hydraulic Units Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
The display shows the current curve through the active RPM sensor during an acceleration phase.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 117 · Applies to: 450, 451, 452, 454 · AR: GF42.45-P-9997MCU
Function A change in internal resistance inside the RPM sensor is caused by the strength and direction of an external magnetic field. This change generates a square wave signal, whose frequency is dependent on the rotational speed. The amplitude height remains constant. The direction of travel is detected by a different signal representation when the wheel is running to the left or right. This signal is read directly by the ESP control unit. The width of the square wave pulse provides various additional information (e.g. direction of travel and installation position) and the distance between the square wave pulses indicates the current wheel speed. When the vehicle or the corresponding wheel is at a standstill, the RPM sensor transmits a standstill pulse every second. The external magnetic field is produced by a multipole ring. This consists of an elastomer plastic containing metallic particles. These are aligned by a special magnetization method so as to produce various magnets whose polarity at the circumference alternates from north to south. Advantages compared with a passive (inductive) RPM sensor: Sensing of vehicle speed right down to standstill. Improvement in signal quality (digital signal). Signal largely insensitive to vibrations and temperature differences. Lower weight and smaller design than induction-type pulse generator. BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS, ELECTRONIC STABILITY PROGRAM (ESP) - GF42.45-P-9997MCU > Fig 2: Displaying Current Curve Of Active RPM Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MODEL 451.3/4¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 118 · Applies to: 450, 451, 452, 454 · AR: GF42.50-P-4001MCC
Traction system hydraulic unit, component description
GF42.50-P- 4001MCC
Instrument cluster, component description A1 GF54.30-P- 6000MCU
Yaw rate, lateral and longitudinal acceleration sensor, component description B24/15 GF42.45-P- 4810MCU
Wheel RPM sensor, component description L6/1, L6/2, L6/3, L6/4 GF42.45-P- 5134MCC
ME-SFI [ME] control unit, component description N3/10 GF07.61-P- 6000MCU
ESP control unit, component description N47-5 GF42.45-P- 5118MCU
Steering angle sensor, component description N49 GF42.45-P- 5107MCC
Table of contents: Functional description, Electronic Stability Program (ESP)
GF42.45-P- 0999MCU BASIC KNOWLEDGE > TRACTION SYSTEM HYDRAULIC UNIT, COMPONENT DESCRIPTION - GF42.50-P-4001MCC > MODEL 451.3 /4 Location The hydraulic unit is located on the vehicle underfloor. Fig 1: Identifying ESP Control And Hydraulic Units Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
For control purposes, one 2/2 way valve is used on each wheel for the pressure buildup, pressure hold and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 120 · Applies to: 450, 451, 452, 454 · AR: PE42.00-P-1100MCU, PE42.45-P-2000MCU, PE42.45-P-2050MCU
pressure release functions. The high-pressure and return pumps in the hydraulic unit are required for pressure buildup and pressure release during ASR and ESP interventions and for return delivery during ABS intervention. A damper is fitted to each brake circuit to damp the delivery noise. The low pressure reservoir takes up the brake fluid during the ABS/ASR or ESP depressurization phase and delivers it to the high pressure/return flow pump. During ABS, ASR and ESP interventions, the switchover solenoid valves shut off the self-priming pump pressure circuit 1 (front axle) and self-priming pump pressure circuit 2 (rear axle) between the wheel brakes and the master brake cylinder. The brake fluid passing through the switchover solenoid valves is directed back to the master brake cylinder. Pressure limiting Switchover valves without pressure limiting valves are used on the ESP version installed. Protection against excess pressure is provided by reducing the maximum permissible current in the coils of the switchover valves (USV) to 1.24 A. WIRING DIAGRAMS > OVERVIEW OF WIRING DIAGRAMS FOR BRAKES - HYDRAULIC AND MECHANICAL SYSTEMS - PE42.00-P-1100MCU > MODEL 451 PE42.45-P- 2000MCU Wiring diagram of Electronic Stability Program (ESP) MODEL 451 PE42.45-P-2000MCU PE42.45-P- 2050MCU Electrical function diagram for Electronic Stability Program (ESP) MODEL 451 PE42.45-P-2050MCU WIRING DIAGRAMS > ELECTRONIC STABILITY PROGRAM - PE42.45-P-2000-60MCU > MODEL 451 Code Designation Coordinates A1 Instrument cluster 13L B24/15 Yaw rate, lateral and longitudinal acceleration sensor 20L L6/1 Left front RPM sensor 26L L6/1x1 RPM sensor connector 26G L6/2 Right front RPM sensor 28L L6/2x1 RPM sensor connector 27G L6/3 Left rear RPM sensor 29L L6/3x1 RPM sensor connector 29G L6/4 right rear RPM en or 31L L6/4x1 RPM sensor connector 30G N10/10 SAM control unit 4L N10/10f11 Fuse 11 2L
WIRING DIAGRAMS > WIRING DIAGRAM OF ELECTRONIC STABILITY PROGRAM (ESP) -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 124 · Applies to: 450, 451, 452, 454 · AR: PE42.45-P-2000MCU
PE42.45-P-2000MCU > MODEL 451 PE42.45-P- 2000-99MCU Wiring diagram of Electronic Stability Program (ESP)
PE42.45-P- 2000-99MCU PE42.45-P- 2000-60MCU electronic stability program
PE42.45-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 Fig 2: Electronic Stability Program (ESP) - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Center high-mounted stop lamp¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 129 · Applies to: 450, 451, 452, 454 · AR: PE42.45-P-2050MCU
E21 Center high-mounted stop lamp 13J L6/1 Left front RPM sensor 12H L6/2 Right front RPM sensor 12H L6/3 Left rear RPM sensor 12J L6/4 right rear RPM sensor 12J N3/10 ME-SFI [ME] control unit 16C N10/10 SAM control unit 3L N15/6 Automated manual transmission control unit 21D N47-5 ESP control unit 11G N49 Steering angle sensor 3D N68 Steering assist control unit 7L S9/1 Stop lamp switch 10H S11 Brake fluid indicator switch 10H S12 Parking brake indicator switch 10J U492 Valid for power steering 6H X11/4 Data link connector 16L WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR ELECTRONIC STABILITY PROGRAM (ESP) - PE42.45-P-2050MCU > MODEL 451 PE42.45-P- 2050-99MCU Electrical function diagram for Electronic stability Program (ESP)
PE42.45-P- 2050-99MCU PE42.45-P- 2050-60MCU Legend of function diagram for electrical system of Electronic Stability Program (ESP)
PE42.45-P- 2050-60MCU 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- Location and assignment of Z connector sleeves
GF00.19-P-
forwards¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 149 · Applies to: 450, 451, 452, 454 · AR: AP42.00-P-4280MCC
4.2 Saw up hand brake handle (1) in the upper area in the longitudinal direction, using a screwdriver lever up the hand brake lever (1) and remove On vehicles as of VIN WME4513312K143824 Saw up the hand brake lever (1) carefully so that the hand brake lever (5), the driver seat and front passenger seat as well as other vehicle parts are not damaged. Window glazing device, FSC 1.6gotis://K_67.0_01.0
Install
5 Slide adapter (9) onto the threaded rod of the hand brake lever (5) On vehicles as of VIN WME4513312K143824
6 Screw on BRABUS push button (4)
7 Slide on BRABUS hand brake handle (8) up to the end stop on the hand brake lever (5)
8 Tighten self-locking Inbus screws (7) on the BRABUS hand brake handle (8) evenly
9 Slide boot (6) rearwards and using an assembly wedge position under the floor covering (arrow) *110589035900 MAINTENANCE > REPLACE BRAKE FLUID - AP42.00-P-4280MCC > MODEL 451.3/4 Fig 4: Identifying Mounting Wedge (110 589 03 59 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
of brake system¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 152 · Applies to: 450, 451, 452, 454 · AR: AP42.00-P-4298MCC
Check brake system for leaks
AR42.10-P-0100- 01MCC BRAKE CYLINDER Number Designation Model 451.3/4 BA42.10-P-1001- 08C Brake bleed valve to rear axle wheel brake cylinder Nm 7 FRONT AXLE FLOATING CALIPER Number Designation Model 451.3/4 BA42.10-P-1002- 10A Brake bleeder valve to brake caliper Nm 7 MAINTENANCE > CHECK WET BOILING POINT OF BRAKE FLUID - AP42.00-P-4298MCC > MODEL 451.3/4 Checking
Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes. Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. AS42.50-Z-0001-01A Notes on repairs to brake system
AH42.00-P-0003-01A Brake fluid notes
AH42.50-P-0001-01A Fig 1: Identifying Brake Fluid Meter Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Open brake fluid reservoir¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 153 · Applies to: 450, 451, 452, 454 · AR: AP42.00-P-4280MCC
1 Open brake fluid reservoir
2 Fold up folding cover (1) on brake fluid measuring device (4) Brake fluid meter 452589002100 3 Using pipette (2) coat a few droplets of brake fluid onto the prism surface (3) and carefully fold down the folding cover (1) Pipette 452589002101 4 Direct the brake fluid measuring device (4) towards the bright light source and read off the wet boiling point of the brake fluid through the eyepiece (5) Limit of wet boiling pointat DOT4: 155°C (279°F)at DOT4+: 168°C (302°F)If necessary, subject to separate repair order:↓
Renew brake fluid. AP42.00-P-4280MCC 5 Clean brake fluid measuring device (4) with water and dry
6 Dispose of pipette (2)
7 Seal brake fluid reservoir
Fig 2: Identifying Pipette (452 589 00 21 01) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
MAINTENANCE > BRAKE SYSTEM - INSPECT FLUID LEVEL - AP42.10-P-4210MCC >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 154 · Applies to: 450, 451, 452, 454 · AR: AP42.10-P-4210MCC
MODEL 451.3/4 Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes. Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. AS42.50-Z-0001- 01A Risk of injury caused by moving parts that can pinch, crush or, in extreme cases even sever extremities. Always remove ignition key when working on windshield wiper mechanism. AS82.30-Z-0001- 01A Brake fluid notes
AH42.50-P-0001- 01A Notes on repairs to brake system
AH42.00-P-0003- 01A 1 Remove maintenance flap
2 Check fluid level The brake fluid level must
Fig 3: Identifying Brake Fluid Meter (452 589 00 21 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Brake Fluid Reservoir Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
be between the MAX and MIN¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 155 · Applies to: 450, 451, 452, 454 · AR: AP42.10-P-4251MCU
marking embossed in the brake fluid reservoir (1).If the fluid level is too low, establish and eliminate the cause. As a separate repair order. If no cause can be found, correct brake fluid level. General brake fluid Sheet 330.1 BB00.40-P-0330- 01A Brake fluids (DOT 4 plus) Sheet 331.0 BB00.40-P-0331- 00A 3 Install maintenance flap
MAINTENANCE > CHECK LINING THICKNESS OF BRAKE PADS AND CONDITION OF BRAKE DISKS - AP42.10-P-4251MCU > MODEL 451.3/4 Checking
1 Check lining thickness of brake pads (1) on front axle Check brake pads (1) in the installed condition. Observe recommended wear limit so that wear limit is not dropped below up to the next maintenance service.If necessary: ↓Replace brake pads (1) subject to separate repair
Fig 1: Identifying Brake Pads And Brake Disk Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
order.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 156 · Applies to: 450, 451, 452, 454 · AR: AP42.10-P-4253MCU
Remove/check/install front axle brake pads AR42.10-P- 1600MCU 2 Inspect brake disk (2) for scores and cracks If necessary: ↓Replace brake disk (2) subject to separate repair order.
Remove/install front axle brake disk AR42.10-P- 0230MCU MAINTENANCE > CHECK BRAKE LINING THICKNESS - AP42.10-P-4253MCU > MODEL 451.3/4 Shown on left side of vehicle Checking
1 Remove stop plug (1) from brake anchor plate of left and right drum brake
2 Check lining thickness of brake shoes The wear limit of brake shoe is to be evaluated through the inspection hole. Observe the wear limit to ensure that the wear limit is not exceeded before the next maintenance service.If necessary: ↓Remove brake drum (2) for exact
Fig 1: Identifying Plug And Brake Drum Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
determination of the lining¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 157 · Applies to: 450, 451, 452, 454 · AR: AP42.20-P-4240MCU, AR42.10-P-0165MCU
thickness of the brake shoes subject to separate repair order.
Remove/install brake drum AR42.10-P- 1010MCU
Remove/install brake shoes at rear axle AR42.10-P- 0165MCU 3 Seal inspection hole in brake anchor plate of left and right drum brake using stop plug (1)
MAINTENANCE > CHECK SETTING OF HANDBRAKE - AP42.20-P-4240MCU > MODEL 451.3/4 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 Raise vehicle with vehicle lift
Checking
2 With the handbrake released, both rear wheels must turn freely
3 Tighten the hand brake lever 4 to 5 notches and check whether the rear wheels can still be turned It must no longer be possible to turn the rear wheels, adjust the drum brake if necessary. If adjustment is no longer possible due to worn brake shoes, the brake shoes should be replaced.If necessary: ↓Adjust drum brake or replace brake shoes on rear axle subject to separate repair order.
Adjust drum brake AR42.10-P-1010- 11SM
Remove/install brake shoes at rear axle AR42.10-P-0165MCU
MAINTENANCE > CHECK AUTOMATIC HANDBRAKE ADJUSTER - AP42.20-P-4241MCU >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 158 · Applies to: 450, 451, 452, 454 · AR: AP42.20-P-4241MCU, AR42.10-P-1010MCU
MODEL 451.3/4 Removing
Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes. Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. AS42.50-Z-0001-01A Brake fluid notes
AH42.50-P-0001-01A Notes on repairs to brake system
AH42.00-P-0003-01A 1 Remove brake drum
Remove/install brake drum
AR42.10-P-1010MCU Check
2 Clean automatic adjuster (4) and check for damage and ease of movement Use commercially available brake cleanerIf necessary: ↓Replace automatic adjuster (4) subject to separate repair order.
Fig 1: Locating Brake Shoes, Dust Boot, Wheel Brake Cylinder And Automatic Adjuster Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Install, remove automatic¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 159 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0169MCU, AR42.10-P-0167MCU, AR42.10-P-0165MCU, AR42.10-P-1010MCU, AR42.00-Z-9451CA (+4 more)
brake adjuster AR42.10-P-0169MCU 3 Check ease of movement and leaktightness of wheel brake cylinder (3) as well as condition and wear of brake shoes (1) Press the dust boots (2) carefully on both sides for checking the leaktightness of the wheel brake cylinder (3). If there is the slightest sign of brake fluid escape or sluggishness of the brake pistons in the wheel brake cylinder (3) this must be replaced.If necessary: ↓Replace wheel brake cylinder (3) or brake shoes (1) subject to separate repair order.
Remove/install wheel brake cylinder AR42.10-P-0167MCU
Remove/install brake shoes at rear axle AR42.10-P-0165MCU Install
4 Install brake drum
Remove/install brake drum
AR42.10-P-1010MCU TESTING & REPAIR > TESTING AND REPAIR WORK: SMART: BRAKES - HYDRAULIC AND MECHANICAL SYSTEMS - AR42.00-Z-9451CA > MODEL 451 Adjust mechanical stop lamp switch MODEL 451.3/4 MODEL 450.3/ 4 AR42.10-P- 0041MCC Bleed brake system MODEL 451.3/4 AR42.10-P-0010MCC Bleed brake system MODEL 451.3/4 AR42.10-P- 0010MCU Install, remove automatic brake adjuster MODEL 451.3/4 AR42.10-P-0169MCC Install, remove automatic brake adjuster MODEL 451.3/4 AR42.10-P- 0169MCU Parking brake cable removal and installation MODEL 451.3/4 AR42.20-P-0545MCC Parking brake cable removal and installation MODEL 451.3/4 AR42.20-P- 0545MCU Remove/check/install front axle brake pads MODEL 451.3/4 AR42.10-P-1600MCC
Remove/check/install front axle brake pads¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 160 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0500MCC, AR42.10-P-0164MCC, AR42.10-P-1010MCC, AR42.10-P-0301MCC, AR42.10-P-0301MCE (+5 more)
MODEL 451.3/4 AR42.10-P- 1600MCU Remove/install brake carrier MODEL 451.3/4 AR42.10-P-0500MCC Remove/install brake carrier MODEL 451.3/4 AR42.10-P- 0500MCU Remove/install brake carrier plate MODEL 451.3/4 AR42.10-P-0164MCC Remove/install brake carrier plate MODEL 451.3/4 AR42.10-P- 0164MCU Remove/install brake drum MODEL 451.3/4 AR42.10-P-1010MCC Remove/install brake drum MODEL 451.3/4 AR42.10-P- 1010MCU Remove/install brake fluid reservoir MODEL 451.3## /4## 1# with CODE (LHD) Left-hand drive vehicle AR42.10-P-0301MCC Remove/install brake fluid reservoir MODEL 451.3## /4## 2# with CODE (RHD) Right- hand drive vehicle AR42.10-P-0301MCE Remove/install brake fluid reservoir MODEL 451.3/4 AR42.10-P- 0301MCU Remove/install brake hose at rear axle MODEL 451.3/4 AR42.10-P-0023MCC Remove/install brake hose at rear axle MODEL 451.3/4 AR42.10-P- 0023MCU Remove/install brake hose to front axle MODEL 451.3/4 AR42.10-P-0026MCC Remove/install brake hose to front axle MODEL 451.3/4 AR42.10-P- 0026MCU Remove/install brake line from the ESP hydraulic unit to the rear axle MODEL 451.3/4 AR42.10-P-0035MCC Remove/install brake line from the ESP hydraulic unit to the rear axle MODEL 451.3/4 AR42.10-P- 0035MCU Remove/install brake line from the master brake cylinder to the ESP hydraulic unit MODEL 451.3/4 AR42.10-P-0034MCC Remove/install brake line from the master brake cylinder to the ESP hydraulic unit MODEL 451.3/4 AR42.10-P- 0034MCU Remove/install brake lines MODEL 451.3/4 AR42.10-P-0017MCC Remove/install brake lines MODEL 451.3/4 AR42.10-P- 0017MCU Remove/install brake shoes at rear axle MODEL 451.3/4 AR42.10-P-0165MCC Remove/install brake shoes at rear axle MODEL 451.3/4 AR42.10-P- 0165MCU Remove/install electronic stability program (ESP) control unit MODEL 451.3/4 AR42.45-P-0820MCC
Remove/install electronic stability program¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 161 · Applies to: 450, 451, 452, 454 · AR: AR42.45-P-0817MCC, AR42.10-P-0070MCC, AR42.10-P-0230MCC, AR42.20-P-0500MCC, AR42.20-P-0500MCU (+5 more)
(ESP) control unit MODEL 451.3/4 AR42.45-P- 0820MCU Remove/install electronic stability program (ESP) hydraulic unit MODEL 451.3/4 AR42.45-P-0817MCC Remove/install electronic stability program (ESP) hydraulic unit MODEL 451.3/4 AR42.45-P- 0817MCU Remove/install front axle brake caliper MODEL 451.3/4 AR42.10-P-0070MCC Remove/install front axle brake caliper MODEL 451.3/4 AR42.10-P- 0070MCU Remove/install front axle brake disk MODEL 451.3/4 AR42.10-P-0230MCC Remove/install front axle brake disk MODEL 451.3/4 AR42.10-P- 0230MCU Remove/install hand brake lever MODEL 451.3/4 AR42.20-P-0500MCC Remove/install hand brake lever MODEL 451.3/4 AR42.20-P-0500MCU Remove/install left front brake line MODEL 451.3/4 AR42.10-P-0032MCC Remove/install left front brake line MODEL 451.3/4 AR42.10-P- 0032MCU Remove/install left front or right RPM sensor MODEL 451.3/4 AR42.30-P- 0712MCC Remove/install left rear brake line MODEL 451.3/4 AR42.10-P-0036MCC Remove/install left rear brake line MODEL 451.3/4 AR42.10-P- 0036MCU Remove/install mechanical stop lamp switch MODEL 451.3/4 MODEL 450.3/ 4 AR42.10-P- 0040MCC Remove/install parking brake indicator switch MODEL 451.3/4 AR42.20-P- 0501MCC Remove/install pull rod MODEL 451.3/4 AR42.20-P-0570MCC Remove/install pull rod MODEL 451.3/4 AR42.20-P- 0570MCU Remove/install rear axle speed sensor MODEL 451.3/4 AR42.30-P-0714MCC Remove/install rear axle speed sensor MODEL 451.3/4 AR42.30-P- 0714MCU Remove/install right front brake line MODEL 451.3/4 AR42.10-P-0033MCC Remove/install right front brake line MODEL 451.3/4 AR42.10-P- 0033MCU Remove/install right rear brake line MODEL 451.3/4 AR42.10-P-0037MCC Remove/install right rear brake line MODEL 451.3/4 AR42.10-P- 0037MCU Remove/install splash shield on front brake MODEL 451.3/4 AR42.10-P-0233MCC
Remove/install splash shield on front brake¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 162 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0167MCC, AR42.45-P-0841MCC, AR42.10-P-0010MCU
MODEL 451.3/4 AR42.10-P- 0233MCU Remove/install wheel brake cylinder MODEL 451.3/4 AR42.10-P-0167MCC Remove/install wheel brake cylinder MODEL 451.3/4 AR42.10-P- 0167MCU Remove/install yaw rate and lateral acceleration sensor MODEL 451.3/4 AR42.45-P-0841MCC Remove/install yaw rate and lateral acceleration sensor MODEL 451.3/4 AR42.45-P- 0841MCU TESTING & REPAIR > BLEED BRAKE SYSTEM MANUALLY - AR42.10-P-0010-04SM > During bleeding the brake fluid reservoir must be filled adequately at all times. 1. Open the right rear vent valve and bleed the brake system by pumping the brake pedal evenly and slowly. Then close the vent valve under pressure (pedal depressed). 2. Carry out the bleeding process at the left rear vent valve, right front vent valve and left front vent valve. Observe correct sequence. TESTING & REPAIR > BLEED BRAKE SYSTEM - AR42.10-P-0010MCU > MODEL 451.3/4 Remove
Risk of poisoning Only pour brake fluid into suitable and AS42.50-Z-0001- Fig 1: Locating Brake Fluid Reservoir, Brake Caliper And Wheel Brake Cylinder Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
FRONT AXLE FLOATING CALIPER¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 165 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0017MCU
Number Designation Model 451.3/4 BA42.10-P-1002- 10A Brake bleeder valve to brake caliper Nm 7 TESTING & REPAIR > MARK BRAKE LINES - AR42.10-P-0013-05MCC > Marking of detached brake lines or detached brake hoses The bolted connections of the brake lines may be opened a maximum of two times. After this the corresponding brake lines must be replaced to prevent leaks, even if no damage can be detected externally. If it is not clear whether a bolted connection has already been released more than twice, the corresponding brake line should also be replaced. In the case of repair the identification should be updated accordingly. Use suitable "yellow" or "red" bolt locking varnish, which is resistant to water, oil and gasoline, and diluted acids and alkaline solutions. After the parts have been screwed together again for the first time the union nut of the corresponding brake line should be marked with "yellow" bolt locking varnish. Clean the point to be marked beforehand. After the parts have been screwed together again for the second time the yellow bolt locking varnish should be removed and the union nut of the corresponding brake line marked with "red" bolt locking varnish. Clean the point to be marked beforehand. Brake lines or brake hoses with red marking should be replaced after loosening. If a brake line has been replaced, then the brake line in question should not be marked in color. TESTING & REPAIR > REMOVE/INSTALL BRAKE LINES - AR42.10-P-0017MCU > MODEL 451.3/4
TESTING & REPAIR > REMOVE/INSTALL BRAKE LINE FROM THE MASTER BRAKE¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 179 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0034MCU
CYLINDER TO THE ESP HYDRAULIC UNIT - AR42.10-P-0034MCU > MODEL 451.3/4 Fig 3: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 5: Identifying Socket Wrench Set (451 589 00 03 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ELECTRONIC STABILITY PROGRAM (ESP)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 182 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0035MCU
04E ELECTRONIC STABILITY PROGRAM (ESP) Number Designation Model 451.3/4 BA42.45-P-1008- 01F Bolt, ESP hydraulic unit bracket to floor panel Nm 25 TESTING & REPAIR > REMOVE/INSTALL BRAKE LINE FROM THE ESP HYDRAULIC UNIT TO THE REAR AXLE - AR42.10-P-0035MCU > MODEL 451.3/4 Fig 2: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Locating Brake Fluid Expansion Reservoir Cap Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL LEFT REAR BRAKE LINE - AR42.10-P-0036MCU¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 187 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0036MCU
MODEL 451.3/4 Fig 5: Identifying Removal Assembly (450 589 02 62 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 6: Identifying Box Wrench Bit (450 589 09 99 04) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 7: Identifying Socket Wrench Set (451 589 00 03 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
pedal (1) is clearly audible.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 194 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0041MCC
Checking
10 Connect STAR DIAGNOSIS and delete fault memory Type 450 AD00.00-P-2000- 04SM Model 451 AD00.00-P-2000- 04MCC 11 Check brake light switch signal using Star Diagnosis
12 Close Star Diagnosis Type 450 AD00.00-P-2000- 04SM Model 451 AD00.00-P-2000- 04MCC TESTING & REPAIR > ADJUST MECHANICAL STOP LAMP SWITCH - AR42.10-P-0041MCC
MODEL 451.3/4 MODEL 450.3/ 4 Remove/install
1 Remove stop lamp switch The brake light switch must be removed for adjustment. AR42.10-P- 0040MCC 2 Install in the reverse order
TESTING & REPAIR > REMOVE/INSTALL FRONT AXLE BRAKE CALIPER - AR42.10-P- 0070MCU > MODEL 451.3/4 Fig 1: Identifying Front Axle Caliper Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
several times, the complete brake system should be bled.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 197 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0164MCU, AR42.10-P-0167MCU, AR35.20-P-0302MCU
- Check all connections and screw joints for leaks.
- If necessary replenish brake fluid in the brake fluid reservoir or correct brake fluid by draining at any bleed valve.
- If the test drive is carried out after a repair to the hydraulic system of the brake system, then braking
with ESP regulation is to be carried out.
TESTING & REPAIR > REMOVE/INSTALL BRAKE CARRIER PLATE - AR42.10-P-0164MCU
MODEL 451.3/4
Remove/install
1 Remove left or right wheel brake cylinder
AR42.10-P-0167MCU 2 Compress the locking device (3) on the hand brake cable (2) with sleeve (4) and guide the hand brake cable (2) out of the brake anchor plate (1) *451589001400 3 Remove wheel bearing
AR35.20-P-0302MCU 4 Remove brake carrier plate (1)
5 Install in the reverse order
Fig 1: Compressing Locking Device On Hand Brake Cable Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
paneling¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 210 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0500MCU
21 Lower vehicle with lifting platform
22 Clip brake lines (8) of brake fluid reservoir (2) into bracket (arrow B) on firewall
23 Clip brake fluid reservoir (2) onto fresh-air intake (1)
24 Connect electrical connector (4) to brake fluid reservoir (2)
25 Install right headlamp unit
AR82.10-P- 4730MCU 26 Bleed brake system
AR42.10-P- 0010MCU TESTING & REPAIR > REMOVE/INSTALL BRAKE CARRIER - AR42.10-P-0500MCU > MODEL 451.3/4 Fig 3: Identifying Pliers (450 589 15 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
4. When all work has been completed, check the vehicle brake on the brake test stand.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 212 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-1010MCU
Differences in braking power above 20 % are not permissible. TESTING & REPAIR > REMOVE/INSTALL BRAKE DRUM - AR42.10-P-1010MCU > MODEL 451.3/4 Remove/install
1 Remove left or right rear wheel Installation: Adjust brake after assembling the rear wheel. AR40.10- P- 1100MCU Refer to: ↓Adjust drum brake AR42.10- P-1010- 11SM 2 Unscrew bolt (2)
3 Remove brake drum (1) from wheel hub (3) Check brake drum (1) for wear. BE42.10- P-1001- 12C Installation: Clean friction surface of brake shoes on the inside of the brake drum (1) and centering face (A) on the wheel hub (3) to a metallic bright finish.Grease centering face (A) on wheel hub (3) lightly with brake paste.Brake paste BR00.45- Z-1060- 06A 4 Install in the reverse order
TEST VALUES FOR DRUM BRAKE Number Designation Model 451.3/4 BE42.10-P-1001- 12C Brake drum diameter New mm 203,0 Wear limit for maintenance service mm 204,5 Fig 1: Identifying Brake Drum, Screw And Wheel Hub Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Number¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 216 · Applies to: 450, 451, 452, 454 · AR: AR42.20-P-0501MCC
Designation Model 451.3/4 BE42.10-P-1001- 08E Brake disk thickness New mm 9,7 Wear limit mm 8 FRONT AXLE FLOATING CALIPER Number Designation Model 451.3/4 BA42.10-P-1001- 10A Bolt, brake caliper to brake caliper support Nm 30 REPAIR MATERIALS Number Designation Order number BR00.45-Z-1070-06A Molykote 111 grease Q0014759V000000000 TESTING & REPAIR > REMOVE/INSTALL PARKING BRAKE INDICATOR SWITCH - AR42.20-P-0501MCC > MODEL 451.3/4 Fig 3: Identifying Vernier Caliper (450 589 01 19 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 4: Identifying Brake Piston Resetting Device (450 589 02 37 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 217 · Applies to: 450, 451, 452, 454 · AR: AR42.20-P-0545MCU
1 Adjust the seats forwards and fold down the seat backrests forwards
2 Apply parking brake
3 Remove the clips (arrows A) on the rear floor covering (5) and fold down the rear floor covering (5) forward until the catch hook (3) is accessible When folding down the floor covering ensure that this is not damaged by breaking or cracking. 4 Unlock catch hook (3) of parking brake indicator switch (S12) and remove parking brake indicator switch (S12) from hand brake lever Installation: The parking brake indicator switch (S12) must be located in its guide (arrow B) in the rear area. 5 Disconnect electrical connector (1)
6 Install in the reverse order
TESTING & REPAIR > PARKING BRAKE CABLE REMOVAL AND INSTALLATION - AR42.20-P-0545MCU > MODEL 451.3/4 Fig 1: Identifying Parking Brake Indicator Switch Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Remove/install¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 218 · Applies to: 450, 451, 452, 454 · AR: AR42.10-P-0165MCU
1 Remove left rear and right rear brake shoes
AR42.10-P-0165MCU 2 Slide the sleeve (2) over the hand brake cable (1), compress lock (arrow) on hand brake cable (1) by means of a sleeve (2) and guide hand brake cable (1) out of the brake anchor plate (3) 451589001400 3 Unhook hand brake cable (1) at the rocker of the pull rod (4), compress lock on hand brake cable (1) by means of sleeve (2) and guide hand brake cable (1) out of the support on the frame-type integral support (5) 451589001400 4 Unclip hand brake cable (1) from the brackets on the axle tube (6) and remove
5 Install in the reverse order
Fig 1: Removing/Installing Parking Brake Cable Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL PULL ROD - AR42.20-P-0570MCU >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 219 · Applies to: 450, 451, 452, 454 · AR: AR42.20-P-0570MCU
MODEL 451.3/4
Remove/install
1.1 Release rear drive module Not on model 451.391/491 AR01.00- P- 3050MCU Fig 2: Identifying Sleeve (451 589 00 14 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Removing/Installing Pull Rod (1 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 2: Removing/Installing Pull Rod (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Risk of death caused by¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 220 · Applies to: 450, 451, 452, 454 · AR: AR42.30-P-0712MCC
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 1.2 Raise vehicle with vehicle lift Model 451.391/491
2 Unhook hand brake cables (2) on the rocker (3) of the pull rod (1)
3 Remove pull rod (1) from support (4) on the frame- type integral support
4 Pull pull rod (1) out of guide sleeve (5) and remove pull rod (1) with rocker (3) and gasket (6) Completely releasing the hand brake lever releases the splines of the pull rod (1). Installation: The corrugation on pull rod (1) must point to the left side. The function of the hand brake is not assured if the pull rod (1) is incorrectly positioned. Press in the gasket (6) as far as the end stop in the guide sleeve (5).
5 Lower vehicle with vehicle lift
6 Adjust driver seat and backrest to the foremost position
7 Press the floor covering (7) in the area of the hand brake lever carefully to one side, release catch hook (8) using a suitable tool and press out guide sleeve (5) downwards Installation: The catch hook (8) on the guide sleeve (5) must point crosswise to the direction of travel.
8 Install in the reverse order
9 Carry out function test of hand brake
TESTING & REPAIR > REMOVE/INSTALL LEFT FRONT OR RIGHT RPM SENSOR - AR42.30-P-0712MCC > MODEL 451.3/4
HYDRAULIC UNIT - AR42.45-P-0817MCU >¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 225 · Applies to: 450, 451, 452, 454 · AR: AR42.45-P-0817MCU
MODEL 451.3/4
Remove/install
Risk of death when touching components on vehicles with high- voltage on-board electrical system Do not touch components and open lines of the high-voltage on-board electrical system. Persons with electronic implants (e.g. cardiac pacemakers) must never work on high-voltage on-board electrical systems. AS54.00-Z- 0001-02MEV Risk of poisoning caused by swallowing brake fluid. Risk of injury caused by brake fluid coming into contact with skin and eyes. Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. AS42.50-Z- 0001-01A Note on high-voltage battery Model 451.391/491 AH54.10-P- 0006-01MEV Note on high-voltage system Model 451.391/491 AH54.00-P- 0011-01MEV Brake fluid notes
AH42.50-P- 0001-01A Fig 1: Identifying Electronic Stability Program (ESP) Hydraulic Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
TESTING & REPAIR > REMOVE/INSTALL ELECTRONIC STABILITY PROGRAM (ESP)¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 229 · Applies to: 450, 451, 452, 454 · AR: AR42.45-P-0820MCU
CONTROL UNIT - AR42.45-P-0820MCU > MODEL 451.3/4
Remove/install
Information on preventing damage to electronic components due to electrostatic discharge
AH54.00-P- 0001-01A Fig 3: Identifying Socket Wrench Set (451 589 00 03 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA. Fig 1: Identifying Electronic Stability Program (ESP) Control Unit Components Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ESP control unit¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 231 · Applies to: 450, 451, 452, 454 · AR: AR42.45-P-0841MCU
9 ESP control unit (N47-5) carefully from the hydraulic unit (2) surfaces on the hydraulic unit (2) and on the ESP control unit (N47-5).Check gasket, replace if necessary. BA42.45-P- 1003-01F 452589039900 10 Install in the reverse order
11 Flash the ESP control unit (N47- 5) When replacing the ESP control unit (N47-5). AR54.21-P- 0012MCU ELECTRONIC STABILITY PROGRAM (ESP) Number Designation Model 451.3/4 BA42.45-P-1003- 01F Bolt, ESP [Electronic Stability Program] control unit to ESP module Nm 3 BA42.45-P-1008- 01F Bolt, ESP hydraulic unit bracket to floor panel Nm 25 TESTING & REPAIR > REMOVE/INSTALL YAW RATE AND LATERAL ACCELERATION SENSOR - AR42.45-P-0841MCU > MODEL 451.3/4 Fig 2: Identifying Set Of Torque Tools (452 589 03 99 00) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
panel¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 238 · Applies to: 450, 451, 452, 454 · AR: BE42.00-Z-9999CZ
01D panel TORQUE SPECIFICATIONS > ELECTRONIC STABILITY PROGRAM (ESP) - BA42.45-P- 1000-01F > Model 450, 451, 452 MODIFICATION NOTES 16.6.05 Bolt, intermediate bracket to floor panel Model 450.3/4 ELECTRONIC STABILITY PROGRAM (ESP) Number Designation Model 450.3/4 Model 451.3/4 Model 452.3/4 BA42.45-P-1001- 01F Nut, turn rate sensor to floor panel Nm 7 - 7 BA42.45-P-1002- 01F Bolt, intermediate bracket to floor panel Nm 20 - - BA42.45-P-1003- 01F Bolt, ESP control unit to ESP module Nm 3 3 3 BA42.45-P-1004- 01F Brake pressure sensor to ESP module Nm 18 - 18 BA42.45-P-1005- 01F Brake line to ESP hydraulic unit Nm 14 - 14 BA42.45-P-1006- 01F Nut, intermediate bracket to ESP hydraulic unit Nm 18 - 18 BA42.45-P-1007- 01F Nut, intermediate bracket to front axle carrier Nm - - 20 BA42.45-P-1008- 01F Bolt, ESP hydraulic unit bracket to floor panel Nm - 25 - TEST & ADJUSTMENT VALUES > TEST AND ADJUSTMENT VALUES: SMART: BRAKES - HYDRAULIC AND MECHANICAL SYSTEMS - BE42.00-Z-9999CZ > MODEL all antilock brake system (ABS) MODEL 450.3 /4 BE42.30-P-1000-01B Check values for front brake pad MODEL 450.3 /4, 451.3 /4, 452.3 /4 BE42.10-P-1000- 05E Check values for front brake pad MODEL 454.0 BE42.10-P-1000- 05G Check values for rear brake pad MODEL 454.0 (except 454.033) with CODE (30Y) Disk brakes on rear axle BE42.10-P-1000-15F Drum brake MODEL 454.0 except CODE (30Y) Scheibenbremse Hinterachse BE42.10-P-1000-12D
To brake the spinning wheel the brake pressure at the spinning wheel is increased via the ESP control unit.¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 246 · Applies to: 450, 451, 452, 454 · AR: PE42.45-P-2050MCU, PE42.45-P-2000MCU, GF42.50-P-4001MCC, GF54.30-P-6000MCU
ESP drive torque control circuit ASR control In order to reduce a too large drive torque and thus achieve optimum traction, a drive torque reduction takes place between the ESP control unit and the motor electronics control unit via CAN. The ESP control unit constantly checks whether the control functions can be canceled, e.g. as a result of improved road adhesion. So the drive torque specified by the driver via the accelerator pedal can be permitted again in good time. EBR control If slip occurs at the drive wheels in overrun mode, this is detected by the ESP control unit. The signal is reported to the motor electronics control unit via CAN. With this information, wheel slip is reduced by increasing drive torque and as a result the lateral stability of the vehicle is increased. This process occurs without feedback from the ESP warning lamp. ESP brake torque and drive torque control circuit ESP control If oversteering or understeering is detected, a calculated intervention by the brake system is caused by the ESP control unit at the corresponding wheel. This intervention by the brake system counteracts undesired handling characteristics. Simultaneously requests for drive torque reduction are passed on to the motor electronics control unit via CAN. Visual status indication: Information on the status of the ESP is provided by the ESP warning lamp. Actuation possibilities: ESP warning lamp flashes ESP intervention ESP warning lamp permanently on ESP is switched off ESP has a malfunction
Electronic stability program (ESP), location of electronic components
GF42.45-P-0001- 03MCU Electrical function diagram for Electronic Stability Program (ESP)
PE42.45-P-2050MCU Wiring diagram of Electronic Stability Program (ESP)
PE42.45-P-2000MCU
Traction system hydraulic unit, component description
GF42.50-P-4001MCC
Instrument cluster, component description A1 GF54.30-P-6000MCU
Yaw rate, lateral and longitudinal¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 247 · Applies to: 450, 451, 452, 454 · AR: GF42.45-P-4810MCU, GF42.45-P-5134MCC, GF07.61-P-6000MCU, GF42.45-P-5118MCU, GF42.45-P-5107MCC (+5 more)
acceleration sensor, component description B24/15 GF42.45-P-4810MCU
Wheel RPM sensor, component de cription L6/1, L6/2, L6/3, L6/4 GF42.45-P-5134MCC
ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MCU
ESP control unit, component description N47-5 GF42.45-P-5118MCU
Steering angle sensor, component description N49 GF42.45-P-5107MCC BASIC KNOWLEDGE > TABLE OF CONTENTS: FUNCTIONAL DESCRIPTION, ELECTRONIC STABILITY PROGRAM (ESP) - GF42.45-P-0999MCU > MODEL 451.3/4
Electronic stability program (ESP) function GF42.45-P-0001MCU
Electronic stability program (ESP), location of electronic components GF42.45-P-0001- 03MCU Electrical function diagram for Electronic Stability Program (ESP) PE42.45-P-2050MCU Wiring diagram of Electronic Stability Program (ESP) PE42.45-P-2000MCU
Overview of system components, Electronic Stability Program (ESP) GF42.45-P-9997MCU BASIC KNOWLEDGE > YAW RATE, LATERAL AND LONGITUDINAL ACCELERATION SENSOR, COMPONENT DESCRIPTION - GF42.45-P-4810MCU > MODEL 451.3/4 Location The yaw rate, lateral and longitudinal acceleration sensor is located on the vehicle underfloor under the left seat. Fig 1: Locating Yaw Rate, Lateral And Longitudinal Acceleration Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
Task¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 248 · Applies to: 450, 451, 452, 454 · AR: GF42.45-P-5107MCC
The yaw rate, lateral and longitudinal acceleration sensor measures the rotational speed about the vertical axis. The integrated lateral acceleration sensor (AY-sensor) measures the lateral acceleration. The integrated longitudinal acceleration sensor (Ax sensor) detects longitudinal inclination. The yaw rate, lateral and longitudinal acceleration sensor passes on the information to the ESP control unit via the Controller Area Network (data bus/CAN bus) (CAN)N47-5. BASIC KNOWLEDGE > STEERING ANGLE SENSOR, COMPONENT DESCRIPTION - GF42.45-P-5107MCC > MODEL 451.3/4 Location The steering angle sensor is located on the steering column behind the steering wheel. Task The steering angle sensor records the steering angle, the steering direction as well as the steering speed over a measuring range of 720°. This information is conveyed to the ESP control unit via the Controller Area Network (data bus/CAN bus)N47- 5) and to the power steering control unit (N68) (with code (V26) EPS power steering (FFO)). BASIC KNOWLEDGE > ESP CONTROL UNIT, COMPONENT DESCRIPTION - GF42.45-P- 5118MCU > MODEL 451.3/4 Fig 1: Locating Steering Angle Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
BASIC KNOWLEDGE > OVERVIEW OF SYSTEM COMPONENTS, ELECTRONIC STABILITY¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 252 · Applies to: 450, 451, 452, 454 · AR: GF42.45-P-9997MCU, GF42.50-P-4001MCC, GF54.30-P-6000MCU, GF42.45-P-4810MCU, GF42.45-P-5134MCC (+4 more)
PROGRAM (ESP) - GF42.45-P-9997MCU > MODEL 451.3/4 Traction system hydraulic unit, component description
GF42.50-P-4001MCC Instrument cluster, component description A1 GF54.30-P-6000MCU Yaw rate, lateral and longitudinal acceleration sensor, component description B24/15 GF42.45-P-4810MCU Wheel RPM sensor, component description L6/1, L6/2, L6/3, L6/4 GF42.45-P-5134MCC ME-SFI [ME] control unit, component description N3/10 GF07.61-P-6000MCU ESP control unit, component description N47-5 GF42.45-P-5118MCU Steering angle sensor, component description N49 GF42.45-P-5107MCC Table of contents: Functional description, Electronic Stability Program (ESP)
GF42.45-P-0999MCU BASIC KNOWLEDGE > TRACTION SYSTEM HYDRAULIC UNIT, COMPONENT DESCRIPTION - GF42.50-P-4001MCC > MODEL 451.3/4 Location The hydraulic unit is located on the vehicle underfloor. Fig 1: Locating ESP Control And Hydraulic Units Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
For control purposes, one 2/2 way valve is used on each wheel for the pressure buildup, pressure hold and¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 254 · Applies to: 450, 451, 452, 454 · AR: PE42.00-P-1100MCU, PE42.45-P-2000MCU, PE42.45-P-2050MCU
pressure release functions. The high-pressure and return pumps in the hydraulic unit are required for pressure buildup and pressure release during ASR and ESP interventions and for return delivery during ABS intervention. A damper is fitted to each brake circuit to damp the delivery noise. The low pressure reservoir takes up the brake fluid during the ABS/ASR or ESP depressurization phase and delivers it to the high pressure/return flow pump. During ABS, ASR and ESP interventions, the switchover solenoid valves shut off the self-priming pump pressure circuit 1 (front axle) and self-priming pump pressure circuit 2 (rear axle) between the wheel brakes and the master brake cylinder. The brake fluid passing through the switchover solenoid valves is directed back to the master brake cylinder. Pressure limiting Switchover valves without pressure limiting valves are used on the ESP version installed. Protection against excess pressure is provided by reducing the maximum permissible current in the coils of the switchover valves (USV) to 1.24 A. WIRING DIAGRAMS > OVERVIEW OF WIRING DIAGRAMS FOR BRAKES - HYDRAULIC AND MECHANICAL SYSTEMS - PE42.00-P-1100MCU > MODEL 451 Wiring diagram of Electronic Stability Program (ESP) MODEL 451 PE42.45-P-2000MCU Electrical function diagram for Electronic Stability Program (ESP) MODEL 451 PE42.45-P-2050MCU WIRING DIAGRAMS > ELECTRONIC STABILITY PROGRAM - PE42.45-P-2000-60MCU > MODEL 451 Code Designation Coordinates A1 Instrument cluster 13L B24/15 Yaw rate, lateral and longitudinal acceleration sensor 20L L6/1 Left front RPM sensor 26L L6/1x1 RPM sensor connector 26G L6/2 Right front RPM sensor 28L L6/2x1 RPM sensor connector 27G L6/3 Left rear RPM sensor 29L L6/3x1 RPM sensor connector 29G L6/4 right rear RPM sensor 31L L6/4x1 RPM sensor connector 30G N10/10 SAM control unit 4L N10/10f11 Fuse 11 2L
WIRING DIAGRAMS > WIRING DIAGRAM OF ELECTRONIC STABILITY PROGRAM (ESP) -¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 261 · Applies to: 450, 451, 452, 454 · AR: PE42.45-P-2000MCU, OV00.01-P-1901MCU, GF00.19-P-1000MCU, GF00.19-P-2000MCU
PE42.45-P-2000MCU > MODEL 451 Wiring diagram of Electronic Stability Program (ESP) PE42.45-P-2000-99MCU electronic stability program PE42.45-P-2000-60MCU Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Location and assignment of ground points GF00.19-P-2000MCU Fig 2: Electronic Stability Program (ESP) - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
WIRING DIAGRAMS > ELECTRICAL FUNCTION DIAGRAM FOR ELECTRONIC STABILITY¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 265 · Applies to: 450, 451, 452, 454 · AR: PE42.45-P-2050MCU, OV00.01-P-1901MCU, GF00.19-P-1000MCU
PROGRAM (ESP) - PE42.45-P-2050MCU > MODEL 451 Electrical function diagram for Electronic stability Program (ESP) PE42.45-P-2050-99MCU Legend of function diagram for electrical system of Electronic Stability Program (ESP) PE42.45-P-2050-60MCU Use of wiring diagrams OV00.01-P-1901-03MCC Search aid for all wiring diagram groups OV00.01-P-1901MCU Abbreviations for wiring diagrams OV00.01-P-1001-27MC Abbreviations of signal and circuit designations for wiring diagrams OV00.01-P-1001-28MC Location and assignment of line and connectors GF00.19-P-1000MCU Fig 2: Electronic Stability Program (ESP) - Wiring Diagram (2 Of 2) Courtesy of MERCEDES-BENZ OF NORTH AMERICA.
ESP control unit, component description¶
2007-2014 smart (450_451_452_454) - Workshop Repair Manual.pdf · p. 2089 · Applies to: 450, 451, 452, 454 · AR: GF42.45-P-5118MCU, GF42.45-P-5107MCC, GF46.35-P-7100MCU, GF46.35-P-0998MCU, PE46.35-P-2000MCU (+2 more)
N47-5 GF42.45-P-5118MCU
Steering angle sensor, component description N49 GF42.45-P-5107MCC
Electric steering control unit, component description N68 GF46.35-P-7100MCU BASIC KNOWLEDGE > TABLE OF CONTENTS FOR FUNCTION DESCRIPTION OF ELECTRIC STEERING - GF46.35-P-0998MCU > MODEL 451.3/4 with CODE (V26) Power steering, EPS (FFO)
Electric steering, function GF46.35-P-0002MCUE
Electric steering, location of components GF46.35-P-0002-01MCU Wiring diagram of electric steering PE46.35-P-2000MCU
Overview of system components, electric steering GF46.35-P-9998MCU BASIC KNOWLEDGE > ELECTRIC STEERING TORQUE SENSOR, COMPONENT DESCRIPTION - GF46.35-P-5100MCC > MODEL 451.3/4 with CODE (V26) Power steering, EPS (FFO) Location The torque sensor is located on the drag link and is integrated in the steering gear. Task By turning the steering wheel a torque is produced in control rod which is read in by the torque sensor, converted into a voltage signal and passed on to the power steering control unit (N68). Fig 1: Locating Power Steering Torque Sensor Courtesy of MERCEDES-BENZ OF NORTH AMERICA.